Caliper Spring Design for Disc Brake Pad Knocking
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Solution Overview
Problem
Existing disc brake caliper springs fail to prevent pad knocking against the caliper body, especially during changes in vehicle motion, such as shifting from forward to reverse gear, and require specific geometry modifications to existing brake designs.
Innovation Solution
A spring with a sheared and bent laminar body is interposed between the pad's support plate edge and the caliper body, featuring hooking and tab portions that exert tangential influence to maintain the pad compressed and prevent knocking, without altering the overall dimensions of the pads or caliper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional spring is used in the caliper, then the pad can be maintained compressed between springs, but knocking and vibrations occur during changes in vehicle motion
Solution Approach 1:
The spring is designed with a dynamic laminar body that can flex and adapt its shape during operation. The bent laminar structure allows the spring to dynamically respond to changes in vehicle motion and pad position, maintaining continuous contact and damping vibrations effectively during direction changes
Solution Approach 2:
The spring utilizes elastic deformation of the laminar body to change its physical parameters dynamically. The material and geometry are selected so that the spring can undergo controlled elastic bending, changing its shape and contact points with the pad to maintain damping effectiveness under varying operational conditions
2Object-affected harmful factors
If a spring with specific geometry is designed to prevent pad knocking, then knocking is reduced, but the brake design requires complete re-designing
Solution Approach 1:
The spring is segmented into distinct functional portions: a base portion for mounting, a bent laminar body for damping, and a free end for pad contact. This segmentation allows each portion to be optimized independently while maintaining compatibility with existing caliper and pad designs, avoiding complete re-design
Solution Approach 2:
The spring acts as an intermediary element between the existing caliper structure and the pad. It mediates the interaction by providing the necessary damping function without requiring modifications to the caliper body or pad design, thus avoiding complete re-design of the brake system
3Object-affected harmful factors
If the spring is arranged to influence the pad in tangential direction, then tangential motion is dampened, but the spring geometry becomes complex
Solution Approach 1:
The spring employs a bent laminar body with curved geometry rather than straight lines. The curvature of the laminar body allows it to flex effectively in the tangential direction, dampening vibrations while the curved shape is achieved through simple bending of a laminar material, balancing geometric complexity with manufacturing simplicity
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 dampens tangential motion, reduces vibrations and noise, and improves braking comfort without requiring design or machining changes, allowing for easy application to existing calipers, enhancing performance and fluid movement during direction changes.
Implementation Method 1
a bent laminar body (3) which extends along a line of development arranged substantially in tangential direction T-T... capable of allowing attaining the aforementioned needs... effectively dampens tangential motion, reduces vibrations and noise
Data Source
AI summary
A spring of a caliper of a brake disc is capable of avoiding knocking of the pad against the rests of the caliper body and suitable to be arranged astride a disc of a brake disc. The spring includes a sheared and bent laminar body and is mounted on a caliper between an edge of a support plate of a pad, and at least one wall of a caliper body. The laminar body includes a tab portion bent as a spring, a first hooking portion having at least one C-shaped portion to be arranged astride the plate edge, and a second hooking portion resting on a radially outer portion of the plate edge.