Caliper Hardware Clip with Integral Spring Separator
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Solution Overview
Problem
Existing disc brake caliper hardware fails to ensure even alignment and prevent brake pad drag, as central return springs provide uneven forces and complicate manufacturing, while alternative designs are complex and prone to wear.
Innovation Solution
A caliper hardware clip with outwardly extending spring elements at both ends of the brake pads, acting as a separator to maintain even spacing and prevent pad drag, manufactured as a single piece to simplify production and avoid central obstructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a central return spring is mounted between the two brake pads to assist with returning the brake pads to a rest position, then the brake pads are helped to return to rest position, but the spring provides an uneven return and retention force on the brake pads causing misalignment and drag
Solution Approach 1:
The invention divides the brake pad retention system into two separate hardware clips, with each clip positioned at one end of each brake pad. Each hardware clip includes an independent spring element that acts on only one brake pad, providing localized and even return force. This segmentation eliminates the misalignment problem caused by a single central spring acting on both pads simultaneously.
Solution Approach 2:
The hardware clip serves as an intermediary component between the brake pad and the caliper assembly. The clip includes a frame with recesses that receive the brake pad ends, and spring elements that apply controlled force through the recesses. This intermediary structure ensures even force distribution and proper alignment while facilitating smooth operation.
2Ease of operation
If holes are drilled in each of the backing plates to receive the return spring, then the spring can be mounted to assist pad return, but drilling adds cost and delay to manufacturing
Solution Approach 1:
The invention extracts the spring mounting function from the brake pad backing plate itself. Instead of drilling holes in the backing plates to receive springs, the spring elements are mounted in the hardware clips which then receive the brake pads. This eliminates the need for additional holes in the backing plates, reducing manufacturing steps, cost, and time.
Solution Approach 2:
The hardware clip design integrates the spring mounting function into the clip structure itself. The spring elements are retained by the frame structure of the hardware clip, which then interfaces with the brake pad through recesses. This self-contained design eliminates the need for modifications to the brake pad backing plate.
3Ease of operation
If separate pieces with constraining sections and protruding pieces are used to retain the spring, then the spring can be positioned, but the design complicates manufacturing and reduces reliability as parts can separate
Solution Approach 1:
The invention merges the spring retention function with the hardware clip frame structure. The spring elements are positioned and retained by integral features of the frame, such as recesses or pockets formed in the clip itself. This unified design eliminates separate retention pieces, reducing the number of parts and eliminating potential separation points, thereby improving reliability while simplifying manufacturing.
4Ease of operation
If arms with overlapping portion or lip are used to pull the brake pads outward, then pad return is achieved, but the design is complex to manufacture requiring several bends and may lack rigidity due to the overlapping portion
Solution Approach 1:
Instead of using arms that pull the brake pads outward through overlapping portions and lips, the invention inverts the approach by using spring elements in hardware clips that push the brake pads outward. This inverted mechanism achieves the same functional result (pad return) but with a simpler, more rigid structure that is easier to manufacture without requiring multiple bends or overlapping sections.
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 ensures even and repeatable outward force on brake pads, preventing drag and reducing manufacturing complexity, while eliminating the need for central springs, thus enhancing brake performance and manufacturing efficiency.
Implementation Method 1
a first spring element extending from the frame towards the first brake pad and a second spring element extending from the frame towards the second brake pad
Data Source
AI summary
A caliper hardware clip including a frame having a top edge, a bottom edge, and a front surface, a first recess formed in the front surface to receive an end of a first brake pad, a second recess formed in the front surface to receive an end of a second brake pad, a separator integrally formed with the frame, the separator including a bridge portion extending forward from a central portion of the top edge of the frame, a first spring arm extending down and left from a left side of the bridge portion along the front surface of the frame, and a second spring arm extending down and right from a right side of the bridge portion along the front surface of the frame.