Brake Pad Assembly Spring With Concave Support for Noise Reduction
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Solution Overview
Problem
Existing brake pad assemblies in disc brakes experience noise and vibration issues due to direct contact between the brake pad carrier plate and the brake caliper, leading to 'clunking noises' during braking.
Innovation Solution
A spring design with a concave curved first leg and two separate contact legs for the brake caliper, along with a clamp and connecting legs, is used to decouple the brake pad carrier plate from the brake caliper, distributing contact over two areas and reducing vibration and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a spring with convex contact surface is used to separate the brake pad carrier plate from the brake caliper, then direct contact between metal parts is prevented, but the contact surface stability is poor and vibration/twisting occurs
Solution Approach 1:
The patent applies curvature principle by changing the contact surface shape from convex to concave. The concave curved contact surface (specifically the first leg with concave curvature) provides better stability and reduces vibration compared to convex surfaces. This curvature modification allows the spring to maintain stable contact with the brake caliper while effectively preventing metal-to-metal contact and associated noise.
2Object-affected harmful factors
If a single contact area is used between the spring and brake caliper, then the structure is simple, but the vibration and noise reduction effect is insufficient
Solution Approach 1:
The patent applies segmentation principle by dividing the contact function into multiple separate contact legs (first leg, second leg, third leg) that contact the brake caliper at different locations. This multi-point contact configuration distributes the contact forces, improves vibration damping, and enhances noise reduction effectiveness while maintaining reasonable structural complexity.
3Stability of the object's composition
If the spring directly connects the brake pad carrier plate and brake caliper, then the connection is stable, but noise and vibration are transmitted between metal parts
Solution Approach 1:
The spring itself acts as an intermediary element between the brake pad carrier plate and the brake caliper. By using the spring's elastic properties and its strategically designed contact legs, the patent prevents direct metal-to-metal contact while maintaining stable connection. The spring absorbs and dampens vibrations, blocking noise transmission between the rigid metal components.
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 spring design effectively reduces brake noise and vibration by decoupling the metal parts, enhancing NVH properties and providing a stable connection between the brake pad carrier plate and the caliper, resulting in a better driving experience.
Implementation Method 1
A spring design with a concave curved first leg and two separate contact legs for the brake caliper, along with a clamp and connecting legs, is used to decouple the brake pad carrier plate from the brake caliper, distributing contact over two areas and reducing vibration and noise.
Implementation Method 2
the spring comprises a clamp for fastening the spring to the form-locking element and a support part for supporting and sliding on a brake caliper or a brake caliper housing. In this context, the support part of the spring has a first leg which is designed to face the brake caliper and which has a concavely curved shape
Data Source
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AI summary
Spring 102 for a brake pad assembly 101 of a brake device 100, in particular a disc brake, wherein the spring 102 is configured to be pushed onto a positive locking element 103 of a brake pad backing plate 104, the spring 102 comprising a clamp 105 for fastening the spring 102 to the positive locking element 103 and a support part 106 for supporting and sliding on a brake caliper 107, wherein the support part 106 of the spring 102 has a first leg 13 which is configured to face the brake caliper 107 and which has a concave curved shape, wherein, when the brake pad backing plate 104 and the spring 102 are installed inside the brake caliper 107, the first leg 13 forms a connecting section between a second leg 12 and a third leg 14. which are designed to come into contact with the brake caliper 107 in a supporting and sliding manner, - the clamp 105 of the spring 102 a fourth leg 1,The invention comprises a fifth leg 5 and a sixth leg 8, which are designed and arranged such that, when the brake pad backing plate 104 and the spring 102 are installed inside the brake caliper 107, they face the brake pad backing plate 104, and the spring 102 further comprises a connecting leg 16 which integrally connects the clamp 105 to the support part 106 of the spring 102. The invention also relates to a brake pad assembly 101 and a brake device 100.