Brake Pad Spring Assembly for Low Residual Torque and Even Wear
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Solution Overview
Problem
Existing brake caliper systems experience residual braking torque, misalignment of brake pads, and uneven wear due to existing spring solutions that either reduce contact area, limit cooling capacity, or require additional space, necessitating a solution that minimizes residual torque and promotes even wear while avoiding permanent coupling with the piston.
Innovation Solution
A pad-and-spring assembly that includes an elastic device with a supporting plate and a free surface with through openings, allowing elastic biasing to move the brake pad away from the disc when braking ceases, avoiding direct coupling with the piston and maintaining parallel alignment, thus minimizing residual torque and ensuring even wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If existing spring solutions are used to bias the brake pad away from the disc, then residual braking torque is reduced, but the brake pad alignment and even wear are compromised
Solution Approach 1:
The elastic device is segmented into multiple arms (at least two arms) that are distributed around the brake pad. Each arm independently applies elastic biasing force, ensuring uniform distribution of forces and maintaining proper brake pad alignment while minimizing residual torque. The arms are positioned at different locations to provide balanced support.
Solution Approach 2:
The elastic device provides localized elastic biasing forces at specific points around the brake pad through its multiple arms. Each arm contacts the brake pad at a specific location, creating localized force application points that collectively ensure uniform wear and proper alignment while minimizing overall residual torque.
2Loss of energy
If springs are positioned to bias the brake pad axially, then residual torque is minimized, but the contact area between spring and pad is reduced
Solution Approach 1:
The elastic device transitions from traditional axial spring positioning to a multi-dimensional arrangement with arms extending in radial directions around the brake pad. This dimensional change allows the elastic biasing force to be applied from multiple angles and locations, increasing the effective contact area while maintaining axial biasing effectiveness to minimize residual torque.
3Force
If traditional spring arrangements are used, then elastic biasing is achieved, but additional space is required in the caliper body
Solution Approach 1:
The elastic device is nested within the existing caliper body structure, with arms that extend into the space between the brake pad and the caliper housing. The device utilizes existing caliper body features and spaces, nesting the elastic elements within the constrained volume rather than requiring additional external space.
Solution Approach 2:
The elastic device utilizes the radial dimension around the brake pad rather than only axial space. By arranging arms in a radial configuration around the pad, the device effectively uses the circumferential space within the caliper body, reducing the axial space requirement and fitting within the constrained caliper volume.
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 effectively reduces residual braking torque, prevents misalignment, and maintains the cooling capacity of the brake system by applying an elastic bias to move the brake pad away from the disc, promoting even wear and reducing maintenance needs.
Implementation Method 1
at least one elastic device (5) adapted to apply an elastic biasing action directed in axial direction (X-X) to said brake pad (2) to move it away from an associable brake disc
Data Source
AI summary
A pad-and-spring assembly has a supporting plate supporting friction material. The supporting plate has a disc facing surface, a plate back, and facing thrust structure. The friction material has a radially inner edge, and a radially outer edge, radially opposite to the radially inner edge, and defining the outer radial dimension level of the friction material with its tangential extension on the disc facing surface. The disc facing surface has a free surface located radially inside with respect to the tangential extension of the radially outer edge of the friction and having a through opening edge delimiting a through opening. An elastic device of the assembly has a body having at least one connecting portion, connecting to the body of the brake caliper and a supporting portion, axially crossing the through opening to apply elastic biasing action directly in axial direction to the through opening edge.