Disc Brake Caliper Pad Spring Geometry for Residual Torque Reduction
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Solution Overview
Problem
Existing disc brake systems face issues with incomplete detachment of brake pads from the disc due to insufficient axial elastic force, leading to residual braking torque, non-uniform pad wear, and sensitivity to geometric and frictional variations, especially as pads wear over time.
Innovation Solution
A spring design with a transverse elongated plate and specific geometric ratios and inclinations of its stretches ensures a consistent and uniform elastic force across different pad positions and wear conditions, providing a robust separation of pads from the brake disc by accumulating elastic deformation energy and applying both axial and radial forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional springs are used, then the structure is simple, but the separation function is not ensured during the entire life cycle of the pad
Solution Approach 1:
The patent modifies the spring application angle parameter within the range of 15° to 45°, which fundamentally changes the force distribution characteristics. This parameter change ensures that the axial elastic force consistently overcomes frictional resistance throughout the entire pad wear cycle, maintaining reliable pad separation and eliminating residual braking torque across the complete service life of the brake pads.
2Force
If the axial elastic force is increased, then pad separation is improved, but the sensitivity to geometric variabilities and friction increases
Solution Approach 1:
The patent selects a specific application angle range of 15° to 45° that optimizes the balance between axial force generation and sensitivity to variations. This parameter choice ensures sufficient axial elastic force for complete pad separation while reducing the system's sensitivity to geometric tolerances and friction variations, thereby improving overall reliability and consistency throughout the pad life cycle.
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 ensures reliable and uniform pad separation from the brake disc across the pad's life cycle, reducing residual braking torque and sensitivity to geometric and frictional variations, while maintaining stable positioning and easy insertion.
Implementation Method 1
a spring design with a transverse elongated plate and specific geometric ratios and inclinations of its stretches ensures a consistent and uniform elastic force across different pad positions and wear conditions, providing a robust separation of pads from the brake disc by accumulating elastic deformation energy
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
A spring (22) for friction pads (11) which can be associated with a caliper (2) of a disc brake (1) to bias the friction pads (11) elastically away from a brake disc (3) comprises a central stretch (26) and two opposite transverse stretches (27), extending from the central stretch (26) in two opposite transverse directions and each forming a supporting stretch (29), a resting stretch (30) and a wing stretch (31) extending between the supporting stretch (29) and the resting stretch (30), wherein the supporting stretches (29) lie on the same supporting plane (32) and the wing stretch (31) comprises: • - an ascending wing stretch (33) extending from the supporting stretch (29) away from the supporting plane (32) towards an upper side (34) of the spring (22) and away from a longitudinal median plane (28) to an upper apical point (35), • - a descending wing stretch (36) extending from the upper apical point (35) further away from the longitudinal median plane (28) and towards a lower side (37) of the spring (22) to a folding line (38) which connects the wing stretch (31) to the resting stretch (30).