Integrated Brake Spring Assembly Reducing Residual Torque
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Solution Overview
Problem
Existing brake caliper spring assemblies face challenges in reducing residual torque, vibration, and noise while being adaptable to various disc brake applications without increasing production costs or affecting vehicle performance, due to issues like friction between spring components and the need for customized designs for each application.
Innovation Solution
A pad-holding spring and pad return spring assembly made from different semi-finished products, where the pad return spring is preloaded in the radial direction to maximize axial force and stability, avoiding friction contact and allowing for easy modification and standardization, with the pad return spring being customizable by diameter for specific applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the pad return spring and pad-holding spring are made from separate shaped and bent pieces of sheet metal and assembled afterward, then the pad return springs can be customized according to application requirements, but the use of axial disc springs raises issues of space and weight gain that negatively affect vehicle performance
Solution Approach 1:
The patent merges the pad return spring and pad-holding spring into a single integrated component made from one piece of sheet metal. This eliminates the need for separate assembly, reduces the overall weight of the spring assembly, and removes the friction contact that occurs between separate components during operation.
Solution Approach 2:
The integrated spring assembly performs multiple functions simultaneously: it acts as both the pad return spring (biasing the pad away from the disc) and the pad-holding spring (holding the pad in the correct position). This multi-functionality reduces the number of parts needed and simplifies the overall brake caliper assembly.
2Ease of manufacture
If the pad return spring slides on a portion of the pad-holding spring during brake pad movements, then the springs can be assembled from separate pieces, but this sliding generates friction that negatively affects braking efficiency, service life, and reliability
Solution Approach 1:
By combining the pad return spring and pad-holding spring into a single integrated component, the patent eliminates the sliding interface between separate parts. This removes the source of friction entirely, improving reliability, braking efficiency, and service life while maintaining ease of manufacture through one-piece construction.
3Reliability
If a one-piece spring assembly is used for each different disc brake application, then friction between components is eliminated, but production costs increase as different spring assemblies are required for each application
Solution Approach 1:
The patent maintains the integrated one-piece design that eliminates friction, but applies parameter changes by modifying the dimensions, curvature, and geometry of the single spring assembly to suit different disc brake applications. This allows a single basic design to be adapted across multiple applications without requiring completely different spring assemblies, thereby controlling production costs while maintaining reliability.
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 effectively reduces residual torque, extends the service life of the springs, minimizes maintenance, and maintains high braking efficiency by eliminating frictional contact and allowing for uniform pad-holding springs across applications, while reducing the overall dimensions and weight of the assembly.
Implementation Method 1
a pad-holding spring configured to be arranged between at least one guiding ear of a brake pad and a support to bias said brake pad in radial and circumferential directions
Implementation Method 2
a pad return spring configured to bias said brake pad in axial direction away from a brake disc
Data Source
AI summary
A pad-holding and pad return spring assembly has a pad-holding spring arranged between a guiding ear of a brake pad and a support, and a pad return spring. The pad-holding spring has a C-shaped section having a central portion adapted to be inserted into a recess of the support and to accommodate the guiding ear. The pad return spring has an anchoring portion connected to the C-shaped section extending in axial direction in a first orientation opposite to a brake disc, and an elastic return arm connected to the anchoring portion and having an elastic return arm end for engaging the brake pad. The elastic return arm develops along an elastic return arm longitudinal direction oriented in the axial direction with a second orientation concordant with the brake disc, is elastically movable between an advanced position and a resting position and in operation is spaced from the pad-holding spring and the anchoring portion.