Brake Pad Mounting Spring Segmentation for Noise Reduction
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Solution Overview
Problem
The existing brake pad mounting systems in disk brake yokes often produce noise during braking due to the impact of the brake pad ears with their housing, which is not adequately dampened by conventional springs, and require both sliding and spring action, leading to geometric inconsistencies and noise generation.
Innovation Solution
A mounting device with specifically designed springs that include a first bearing limb, a curved sliding limb, and connecting limbs to separate them, along with a slide plate system and resilient hinges, which allows for improved sliding of the brake pad ears and reduces noise by distributing forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a conventional spring is used to dampen the impact of the brake pad ears with the housing, then the noise is reduced, but the sliding function and spring action cannot be simultaneously achieved, leading to geometric inconsistencies and noise generation
Solution Approach 1:
The spring is divided into multiple limbs (first bearing limb, second sliding limb, third limb, fourth limb) where each limb performs a specific function. The bearing limbs provide spring action for impact dampening, while the sliding limbs provide smooth sliding surfaces, separating the sliding function from the spring action function to eliminate geometric inconsistencies and noise.
Solution Approach 2:
The second sliding limb is designed with a curved shape and convex surface that contacts the housing. This curved geometry enables smooth sliding motion during braking while maintaining spring action, eliminating the geometric inconsistencies that cause noise in conventional linear spring designs.
2Reliability
If the spring is calibrated to accommodate the mass and speed of the brake pad, then the damping effect is optimized, but the sliding effect and spring action cannot be combined on a single part
Solution Approach 1:
The spring structure is segmented into bearing limbs for damping and sliding limbs for smooth operation. This segmentation allows the spring to be calibrated for optimal damping effect while simultaneously providing a dedicated sliding surface for ease of operation during brake activation.
Solution Approach 2:
The spring assembly performs multiple functions: the bearing limbs provide impact dampening and spring action, while the sliding limbs provide smooth sliding motion. This multi-functionality allows a single spring component to achieve both optimized damping and ease of sliding operation.
3Ease of operation
If the sliding system is deformed due to geometric inconsistencies and spring action, then the brake pad can be displaced axially, but noise is generated during braking
Solution Approach 1:
The curved sliding limb with convex surface provides a geometry that accommodates axial displacement while maintaining smooth contact with the housing. This curved geometry eliminates the geometric inconsistencies that would otherwise cause noise during braking operations.
Solution Approach 2:
The spring design changes the geometric parameters from linear to curved, allowing the sliding surface to adapt to the deformation caused by spring action. This parameter change enables axial displacement while preventing the generation of noise during braking.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces or eliminates noise during braking by enhancing the sliding mechanism of the brake pad ears, ensuring smooth operation and minimizing noise, even under low braking pressures.
Implementation Method 1
This damping effect is obtained by deformation of the spring
Implementation Method 2
a second sliding limb in contact with the lower face of the housing of the yoke. This limb has a curved shape. It is located parallel to a plane perpendicular to the plane of the ear and it has a convex surface intended to slide on said lower face of the housing of the yoke
Data Source
AI summary
A mounting system for a brake pad in the housings of a disk brake yoke in which the brake pad comprises at its ends two mounting ears (10), each ear being mounted in a housing of a disk brake yoke. The mounting system comprises for each pad ear, a spring (5) of linear or lamella shape, intended to bear, on the one hand, below a lower face (12) of the ear and, on the other hand, on the lower face of the housing of the yoke so as to separate the lower face (12) of the ear from the lower face of the housing.