Brake Pad Return Spring Integration for Faster Caliper Assembly
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Solution Overview
Problem
Existing brake apparatuses for vehicles require extensive processing and assembly time due to complex part configurations, leading to increased costs and reduced durability, with issues such as plastic deformation of return parts, brake pad misalignment, and noise during operation.
Innovation Solution
A brake apparatus with a reduced number of parts, where the return parts function as both pad liners and elastic restoring mechanisms, coupled with the torque member, to simplify assembly, improve durability, and reduce noise by providing full spacing of brake pads from the brake disk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pad liner with return parts is mounted on a torque member, then the brake pad can be restored to its original position, but the torque member requires extensive processing and assembly time increasing cost
Solution Approach 1:
The return part is merged with the brake pad assembly, where the return part includes a return spring, return mounting part, and return coupling part that are integrated into the brake pad structure. This eliminates the need for separate pad liner mounting on the torque member, reducing assembly time while maintaining the restoration function.
Solution Approach 2:
The return part serves multiple functions: it provides elastic restoring force through the return spring, guides brake pad movement through the return coupling part, and eliminates the need for separate pad liner components. This multi-functional design reduces the number of parts and assembly steps.
2Ease of manufacture
If the torque member is processed to mount the pad liner, then the pad liner can be attached, but processing complexity and expense increase
Solution Approach 1:
The return mounting part and return coupling part are integrated into the brake pad assembly rather than being separate components requiring torque member processing. This merging eliminates complex torque member processing while maintaining secure attachment functionality.
Solution Approach 2:
The pad liner function is extracted from the torque member and integrated into the brake pad assembly itself. The return part components are taken out as separate elements that attach to the brake pad rather than requiring modification of the torque member.
3Reliability
If return parts are subject to plastic deformation from repeated operations, then the brake pad durability is reduced, but the return parts may lose their elastic restoring capability
Solution Approach 1:
The return spring is designed with specific material properties and geometric parameters (wire diameter, mean coil diameter, number of active coils) that optimize its elastic capability. The elastic induction part with notches or grooves is designed to control deformation patterns, preventing plastic deformation while maintaining elastic restoring force over repeated operations.
4Stability of the object's composition
If there is a gap between the brake pad and pad liner, then the brake pad may incline to one side, but noise occurs during operation
Solution Approach 1:
The return part is extracted as a separate integrated component with guide functionality, eliminating the need for a separate pad liner. The return coupling part provides guidance that prevents brake pad inclination while the return spring provides cushioning that reduces operational noise.
Solution Approach 2:
The return coupling part acts as an intermediary between the brake pad and torque member, providing guidance and preventing direct contact that would cause noise and misalignment. The return spring serves as a mediator that absorbs shocks and maintains proper spacing.
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 reduces part costs and assembly time by integrating return parts as pad liners, enhances durability by minimizing plastic deformation, and eliminates noise issues by ensuring proper alignment and spacing of brake pads.
Implementation Method 1
a return spring connected to the return mounting part and returns the one of the pair of brake pads to its original position by the elastic restoring force thereof
Implementation Method 2
an elastic induction part to induce elastic deformation is disposed in the return spring
Implementation Method 3
an elastic support part connected to the return mounting part, the elastic support part contacts the torque member, and supports the one of the pair of brake pads by pushing the one of the pair of brake pads by the elastic restoring force thereof
Data Source
AI summary
A brake apparatus for a vehicle according to the present disclosure includes a torque member configured to surround a brake disk, a pair of brake pads disposed in the torque member in a way to face each other, and a plurality of return parts mounted on the pair of brake pads, respectively, coupled with the torque member, and configured to guide movements of the brake pads and return the brake pads to their original positions by elastic restoring forces thereof.