Disc Brake Caliper Spring Angle for Uniform Pad Separation
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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, uneven 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, providing sufficient axial bias to maintain pad separation from the disc, reducing residual braking torque and improving wear uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the axial elastic force is increased to ensure complete pad detachment, then pad separation is improved, but the frictional resistance from radial force increases, opposing the axial thrust
Solution Approach 1:
By modifying the application angle parameter to the range of 15°-45°, the patent optimizes the force vector distribution. This change increases the axial force component for reliable detachment while simultaneously reducing the radial force component that generates frictional resistance, thus resolving the contradiction between detachment reliability and friction reduction.
2Device complexity
If the application angle of the elastic force is less than 15°, then the spring configuration is simple, but the axial elastic force varies according to pad wear state, making constraint conditions uncertain
Solution Approach 1:
The patent specifies an application angle range of 15°-45° that maintains a consistent relationship between axial and radial force components throughout pad wear. This parameter optimization ensures that the axial elastic force remains sufficient for detachment while the radial force maintains adequate vibration reduction, making the constraint conditions predictable and consistent across the pad's entire service life.
3Device complexity
If the expansion spring uses a small application angle, then the structure is compact, but residual braking torque occurs due to incomplete pad separation from the disc
Solution Approach 1:
By optimizing the application angle to 15°-45°, the patent ensures sufficient axial elastic force to completely separate the pads from the brake disc, eliminating residual braking torque. The spring remains compact while achieving reliable pad detachment throughout the pad's wear 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 effectively maintains pad separation from the disc across the pad's life cycle, reducing residual braking torque and sensitivity to geometric and frictional variations, ensuring consistent and uniform wear patterns.
Implementation Method 1
a spring for elastically retaining and positioning the pads in a disc brake caliper
Implementation Method 2
the elastic force having an application angle with respect to the plane of the pad that is greater than or equal to 15° and less than or equal to 45°
Data Source
AI summary
A spring for friction pads which can be associated with a caliper of a disc brake to bias the friction pads elastically away from a brake disc may have a central stretch and two opposite transverse stretches, extending from the central stretch in two opposite transverse directions and each forming a supporting stretch, a resting stretch and a wing stretch extending between the supporting stretch and the resting stretch. The supporting stretches lie on the same supporting plane and the wing stretch may have an ascending wing stretch and a descending wing stretch. The spring may also have one or more fixing stretches connected to the central stretch and forming at least two opposite fixing stretches for elastic snap fixing to corresponding fixing seats of the caliper.