Brake Pad Return Spring Structure for Uniform Pad Retraction
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Solution Overview
Problem
Conventional brake calipers face issues with uneven return force distribution to brake pads, leading to incomplete return operations, increased friction, and braking noise, and have complex structures that complicate assembly and increase manufacturing costs.
Innovation Solution
A return spring with a main plate, sliding portion, load supporting portion, and returning portion, connected to a brake pad, providing uniform return force and load support while minimizing friction through surface contact and elastic properties, and eliminating the need for a pad liner to simplify the brake caliper structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional spring member is installed above the brake pad to provide return force, then the upper portion of the brake pad can return smoothly, but the lower portion cannot receive sufficient return force and fails to return properly
Solution Approach 1:
The return spring is repositioned from the upper portion to the lower portion of the brake pad, changing the spatial dimension of force application. This allows the return force to be applied at the point where it is most needed (the lower portion), enabling uniform return force distribution across the entire brake pad and ensuring proper return operation.
2Device complexity
If a pad liner is integrated with a spring to provide return force, then the structure is compact, but the deformation from brake pad movement causes insufficient return force
Solution Approach 1:
The return spring is designed as a separate component from the brake pad, rather than being integrated into it. This segmentation allows the spring to maintain its elastic properties and provide sufficient return force independently, while still being connected to the brake pad to guide its movement along the guide groove.
Solution Approach 2:
The return spring acts as an intermediary component between the brake pad and the guide groove. It provides the necessary return force to the brake pad while the brake pad moves along the guide groove, mediating between the movement constraint and the force requirement.
3Reliability
If multiple components (pad liner, spring member, pad support pin) are used in the brake caliper, then the return force and support functions are provided, but the assembly complexity and manufacturing cost increase
Solution Approach 1:
The return spring is designed to perform multiple functions simultaneously: it provides return force to the brake pad, supports the brake pad load, and guides the brake pad movement along the guide groove. By merging these functions into a single component, the number of parts is reduced, simplifying the brake caliper structure and reducing assembly complexity.
Solution Approach 2:
The return spring is designed as a multi-functional component that can provide both return force and load support, and guide brake pad movement. This universal design eliminates the need for separate components for each function, reducing the overall complexity of the brake caliper system.
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 ensures reliable brake pad return, reduces drag and noise, simplifies the brake caliper structure, enhances assembly efficiency, and decreases manufacturing costs by providing a single component that supports both return force and load, while improving brake pad operation efficiency and reducing weight.
Implementation Method 1
a returning portion (130) connected to the main plate (110) and providing a return force resulted from elasticity of the returning portion (130) when the brake pad (200) moves
Implementation Method 2
a load supporting portion (140) connected to the main plate (110) and elastically supporting a load of the brake pad (200)
Data Source
AI summary
The present disclosure relates to a return spring for a brake caliper, a brake pad equipped with the return spring, and a brake caliper equipped with the brake pad. The return spring includes a main plate formed as a flat plate, a returning portion connected to the main plate and providing a return force resulted from elasticity of the returning portion when the brake pad moves, a load supporting portion connected to the main plate and elastically supporting a load of the brake pad, and a sliding portion connected to the main plate and rubbing against an inner surface of the guide groove when the brake pad moves.