Caliper Brake Pad Spring Assembly With Three-Zone Retention
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Solution Overview
Problem
Existing disc brake springs require multiple components and complex assembly processes, and their connection to the caliper body is prone to dislodging under external stress, affecting the functionality and durability of the braking system.
Innovation Solution
A band-shaped spring design with geometric modifications that ensures a secure and durable connection to the caliper body without central connection bridges, using three constraint zones to maintain the spring's position and balance despite external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple connection appendages are used to connect springs to the caliper body, then the connection reliability is improved, but the assembly time and device complexity increase
Solution Approach 1:
The patent merges multiple connection appendages into a single integrated connection element that connects the spring to the caliper body at multiple points simultaneously. This reduces the number of separate components and assembly steps while maintaining the connection reliability that would require multiple separate appendages.
Solution Approach 2:
The connection element is designed to perform multiple functions: it connects the spring to the caliper body, provides structural support, and maintains proper positioning. This multi-functional design eliminates the need for separate connection appendages, reducing assembly time while maintaining reliability.
2Reliability
If multiple connection appendages are used to connect springs to the caliper body, then the connection reliability is improved, but the device complexity increases
Solution Approach 1:
The patent merges multiple connection appendages into a single integrated connection element that connects the spring to the caliper body at multiple points simultaneously. This reduces the number of separate components and assembly steps while maintaining the connection reliability that would require multiple separate appendages.
3Device complexity
If a single connection appendage is used to simplify the spring structure, then the device complexity is reduced, but the connection reliability deteriorates due to dislodging under external stress
Solution Approach 1:
The connection element is designed to engage with the caliper body at multiple spatial locations and orientations, creating a multi-dimensional connection that resists dislodging forces from various directions. This dimensional approach allows a single element to provide the reliability of multiple separate appendages.
4Ease of manufacture
If central connection bridges are used in the caliper body, then the spring connection is simplified, but the manufacturing complexity and assembly time increase
Solution Approach 1:
The patent extracts the connection function from the central connection bridge concept and implements it through side connection bridges that are already present in the caliper body. This eliminates the need for additional central connection bridges while maintaining simple spring connection.
5Ease of manufacture
If the spring anchoring portions are connected to casting-made connection bridges, then the manufacturing is simplified, but the connection reliability deteriorates under high external stresses
Solution Approach 1:
The connection element incorporates curved or angled engagement surfaces that distribute stress more effectively across the connection points. This geometric design allows the casting-made connection bridges to withstand high external stresses without compromising reliability.
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 maintains optimal positioning and functionality by minimizing sliding forces while maximizing friction forces, ensuring consistent performance and reducing assembly time.
Implementation Method 1
a spring (1) for a caliper body (8), shaped to be arranged straddling a brake disc (2) to apply an elastic action on at least one brake pad (3) to bias it away from said brake disc (2)
Implementation Method 2
The spring design maintains optimal positioning and functionality by minimizing sliding forces while maximizing friction forces
Data Source
AI summary
A spring for a caliper body where the spring may be shaped to be arranged straddling a brake disc for applying an elastic action on at least one brake pad to bias it away from said brake disc. The spring may have a first thrust portion and a second thrust portion adapted to apply an elastic action on at least one brake pad, biasing the brake pad at least away from the brake disc. The spring may also have a first coupling portion adapted to couple the spring with a first side bridge. The spring may also have a second coupling portion adapted to couple the spring with the second side bridge on a tangentially opposite part with respect to the first coupling portion. The spring may also have a backing portion. The spring may also have at least one concave spring portion.