Brake Friction Unit With Spring-Lifted Pad Separation
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Solution Overview
Problem
Friction brakes in vehicles often experience residual drag moments due to incomplete separation of the friction pad and disc after braking, leading to increased energy consumption.
Innovation Solution
A friction unit with a column-shaped distance element guided within a guide recess of the friction pad, pre-tensioned by a spring, which lifts the friction pad from the disc by storing elastic force when the external brake force is reduced, utilizing a column shape to minimize dust entry and vibrations, and positioning the spring away from heat and debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a friction pad is used to contact the disc for braking, then braking force is generated, but residual drag moment occurs due to incomplete separation
Solution Approach 1:
The friction pad is segmented into a friction pad body and a separate distance element. The distance element acts as an independent component that maintains separation between the friction pad and disc, preventing residual contact while allowing the friction pad to contact the disc during braking for force generation.
Solution Approach 2:
The distance element serves as an intermediary component between the friction pad and the disc. It mediates the interaction by maintaining a controlled distance during non-braking conditions, ensuring complete separation and eliminating residual drag, while permitting direct contact when braking force is required.
2Loss of energy
If a spring is used to lift the friction pad from the disc, then residual brake moment is reduced, but the spring is exposed to heat and debris
Solution Approach 1:
The spring is nested within the guide recess of the friction pad assembly. This nested configuration allows the spring to perform its lifting function while being physically protected from external harmful factors such as heat and debris that are present in the braking environment.
Solution Approach 2:
The guide recess acts as an intermediary protective structure between the spring and the harsh environment. It shields the spring from direct exposure to heat and debris while still allowing the spring to function effectively in lifting the friction pad from the disc.
3Loss of energy
If a distance element is used to maintain separation, then residual drag is reduced, but dust and debris may enter the guide mechanism
Solution Approach 1:
The distance element is nested within the guide recess, creating a protected internal environment. This nested configuration minimizes the exposure of the guide mechanism to external dust and debris, reducing the risk of contamination while maintaining the separation function.
Solution Approach 2:
The guide recess acts as a protective enclosure or shell around the distance element. This shell-like structure prevents dust and debris from entering the guide mechanism while still allowing the distance element to move freely within the recess for maintaining separation.
4Loss of energy
If the friction pad is completely separated from the disc, then residual brake moment is eliminated, but the friction unit requires additional components
Solution Approach 1:
The distance element is integrated into the friction pad assembly as a unified component. The guide recess is formed as part of the friction pad structure, merging the separation function with the existing friction pad design rather than adding completely separate systems.
Solution Approach 2:
The guide recess serves multiple functions: it guides the distance element, protects the spring, and maintains the structural integrity of the friction pad assembly. This multi-functionality reduces the need for additional dedicated components, balancing separation effectiveness with design simplicity.
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
Effectively reduces residual brake moment by ensuring complete separation of the friction pad and disc, enhancing durability and reducing vibrations and dust ingress, thus improving the robustness and efficiency of the braking system.
Implementation Method 1
a spring that, with a first end, contacts the support plate and, with a second end, contacts the distance element... the elastic force spring stored in the compressed spring acts on the distance element which is in contact with the disc
Data Source
AI summary
A friction unit for a brake of a vehicle includes a support plate or backing plate, a friction pad disposed on the support plate and including a guide recess that extends between a friction surface of the friction pad and the support plate, a column shaped distance element movably guided in the guide recess of the friction pad, and a spring that, with a first end, contacts the support plate and, with a second end, contacts the distance element.