Disc Brake Pad Spring Angle Control for Residual Torque Reduction
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Solution Overview
Problem
Existing disc brake expansion springs fail to reliably detach brake pads from the disc due to insufficient axial elastic force, leading to residual braking torque, non-uniform wear, and sensitivity to geometric and frictional variations, especially as pads wear over time.
Innovation Solution
A spring design with a specific configuration featuring a bent elongated plate forming a fixing stretch, a resting stretch, and an arch-shaped return stretch, which applies a strong axial elastic force to maintain pad separation from the disc while minimizing radial force, reducing sensitivity to geometric and frictional variations, and accommodating pad wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the axial elastic force is insufficient to overcome frictional resistance, then residual braking torque occurs and pad detachment is incomplete, but increasing the spring force may increase radial force and friction
Solution Approach 1:
The patent modifies the application angle parameter to optimize the force vector decomposition, achieving sufficient axial elastic force to overcome frictional resistance without excessive radial force generation. The angle range of 15°-45° provides an optimal balance that ensures reliable pad detachment while minimizing harmful frictional effects at the support pin interfaces.
2Reliability
If the application angle of the elastic force varies with pad wear, then the constraint conditions of the pads become uncertain and sensitive to geometric variability, but maintaining a fixed angle is difficult as pads wear
Solution Approach 1:
The patent employs a dynamic spring configuration where the application angle can vary within the 15°-45° range to adapt to pad wear. The spring's geometric design allows it to maintain optimal force application throughout the pad's life cycle, automatically adjusting to compensate for wear-induced position changes and ensuring stable constraint conditions without requiring manual intervention.
Solution Approach 2:
The patent utilizes parameter changes in the spring's application angle to accommodate pad wear. By designing the spring to operate within a specific angle range (15°-45°) that can dynamically adjust, the system maintains reliable pad detachment and constraint conditions throughout the entire pad life cycle, reducing sensitivity to geometric variability and wear.
3Reliability
If the spring applies strong axial force to ensure pad detachment, then residual braking torque is reduced, but the radial force increases friction at support interfaces
Solution Approach 1:
The patent optimizes the application angle parameter within the range of 15°-45° to achieve the ideal force distribution. This angular parameter optimization ensures that the spring generates sufficient axial elastic force for reliable pad separation while simultaneously limiting the radial elastic force component, thereby minimizing friction at the support pin interfaces and eliminating residual braking torque.
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 effectively reduces residual braking torque, ensures consistent pad positioning, and enhances wear uniformity by providing a robust elastic constraint system that maintains pad detachment throughout the pad's life cycle, reducing sensitivity to geometric and frictional factors.
Implementation Method 1
a spring for pads (11) having an elongated plate bent so as to form a fixing stretch (24), a resting stretch (25) and an arch-shaped return stretch (26)
Implementation Method 2
the radial elastic force generates a frictional resistance which opposes the axial thrust of the spring and thus the mutual distancing of the pads in the resting interfaces between the pads and the caliper
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A spring (22) for friction pads (11) which can be associated with a caliper (2) of a disc brake (1) for pushing the friction pads (11) away from a brake disc (3), wherein the spring (22) comprises a fixing stretch (24), a resting stretch (25), opposite to the fixing stretch (24), and a return stretch (26) formed between the fixing stretch (24) and the resting stretch (25), wherein the return stretch (26) extends from a narrowing region (29), in form of widened loop with respect to the narrowing region (29), to an upper apical region (28) of the spring (22), wherein the fixing stretch (24) forms a fixing seat (30) at the caliper (2) and the resting stretch (25) forms a plate-shaped contact portion (32), a plate-shaped intermediate portion (34), extending between the narrowing region (29) and the contact portion (32), and a bending edge (35) formed between the contact portion (32) and the intermediate portion (34).