Disc Brake Pad Spring Assembly for Caliper Deformation Compensation
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Solution Overview
Problem
Existing floating disc brake calipers face deformation issues due to axial and tangential force imbalances, leading to self-locking effects and uneven wear on brake pads, which existing solutions do not fully address, especially concerning the alignment and retention of outer pads.
Innovation Solution
A pad and spring assembly for floating calipers, where springs are integrated into the caliper body to bias pads in both axial and radial directions, ensuring accurate alignment and compensation for structural deformation, with a method for easy installation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the caliper body is made lightweight with a single-sided bracket, then weight and dimensions are reduced, but deformation under braking action increases
Solution Approach 1:
The patent applies asymmetry by positioning the bracket and piston on only one side of the caliper body, creating an asymmetric structure that reduces weight while introducing force imbalance. This is compensated by deliberately misaligning the pads relative to each other to counteract the deformation caused by the asymmetric force distribution.
Solution Approach 2:
The patent implements preliminary anti-action by pre-misaligning the pads in the opposite direction of the expected deformation. The outer pad is positioned ahead of the inner pad in the direction of rotation, creating a preliminary counter-moment that compensates for the self-locking effect and uneven wear that would otherwise occur under braking loads.
2Ease of operation
If guiding pins are used to allow caliper sliding, then ease of operation is improved, but minimum clearances cause force imbalance
Solution Approach 1:
The guiding pins act as intermediaries between the caliper body and bracket, enabling smooth sliding motion. However, they introduce minimum clearances that contribute to force imbalance, which is then compensated by the pad misalignment strategy to restore braking force balance.
3Force
If pads are arranged in misaligned position, then braking action balance is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies local quality by introducing intentional non-uniformity in pad positioning. Rather than requiring all components to be perfectly symmetric and aligned, the solution accepts asymmetric pad arrangement as a deliberate design feature to compensate for the asymmetric caliper structure and operating conditions.
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
This solution enhances braking accuracy and performance by maintaining pad alignment, reducing wear, and allowing for lighter, more compact brake systems while minimizing the need for additional support structures.
Implementation Method 1
a spring (30) connected to said support plate (13) and adapted to be inserted in a seat (34) formed in the body of the caliper (101) at said pocket (19), said spring (30) being adapted to bias said pad (10) in the axial direction (X-X)
Implementation Method 2
said spring (30) being adapted to bias the pad (10) with respect to the caliper (101) also in radial direction (R-R)
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
An assembly (1) for a disc brake caliper (100), in which, when said caliper (101) is arranged astride a disc (3) of a disc brake (100) having a defined rotation axis (C), said assembly (1) defines an axial direction (X-X) parallel to said rotation axis (C), a radial direction (R-R) orthogonal to said axial direction (X-X) and a tangential or circumferential direction (T-T) orthogonal to both the axial direction (X-X) and the radial direction (R-R), said assembly (1) comprises: - a first pad (10) comprising a friction material (12), defining a friction surface, and a support plate (13) which supports said friction material (12) and is adapted to release the braking action onto the caliper (101) of the disc brake (100), in which - said support plate (13) comprises at least one lateral projection (14) which extends in a direction substantially coplanar to the plate (13) and is placed at an end of the support plate (13), and in which said at least one lateral projection (14) is adapted to be accommodated in a pocket (19) obtained in the body of the caliper (101); - said assembly (1) further comprising at least one spring (30), in which said spring (30) is connected to said lateral projection (14) of said support plate (13), and in which - said spring (30) being adapted to be accommodated in a seat (34) obtained in the body of the caliper (101) at said pocket (19), and in which - said spring (30) is adapted to be inserted in said seat (34) to be fastened in an undercut manner against said undercut surface (34) to bias said pad (10) in the axial direction (X-X).