Disc Brake Clip Geometry for Low-Force Pad Retention
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Solution Overview
Problem
Existing brake clips for disc brake assemblies require high installation forces, leading to potential under or over installation and poor performance due to tilting, which results in undesirable noise and vibration issues.
Innovation Solution
A brake clip design featuring a U-shaped section with retention tangs and an abutment leg, optionally incorporating a retraction spring, to reduce installation force by engaging with the anchor bracket's channel and providing a mechanism for secure mounting with lower loading requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional brake clip with tangs is used to retain the brake pad, then the brake pad is securely retained in the channel, but a high installation force is required to engage the tangs with the anchor bracket surface
Solution Approach 1:
The installation tang is formed with a curved leading end that matches the curvature of the channel surface. This curved geometry allows the tang to smoothly engage with the channel during installation, reducing the peak installation force required while maintaining secure retention. The curved leading end acts as a stress distributor, preventing concentration of forces that would require higher installation loads.
Solution Approach 2:
The patent modifies the geometric parameters of the installation tang, specifically creating a curved leading end with a radius of curvature that corresponds to the channel surface. This parameter change transforms the engagement mechanism from a sharp-edge insertion to a gradual curved surface contact, reducing the force required for installation while maintaining the retention function.
2Reliability
If a high installation force is applied to engage the brake clip tangs, then the brake pad is securely retained, but the brake clip may become tilted and result in under or over installation
Solution Approach 1:
The curved leading end of the installation tang guides the brake clip into proper alignment with the channel during installation. The curvature provides a self-aligning mechanism that ensures the tang engages centrally in the channel, preventing tilting and ensuring precise installation position without requiring high forces.
Solution Approach 2:
The curved leading end of the installation tang acts as an intermediary element between the installation tool and the channel. This curved mediator distributes the installation force evenly and guides the brake clip into correct positioning, preventing direct transmission of high forces that could cause tilting or imprecise installation.
3Reliability
If the brake clip is under or over installed due to high installation force, then the brake pad may be retained, but the brake clip performs poorly and causes noise and vibration
Solution Approach 1:
The curved leading end ensures precise central alignment of the installation tang in the channel, preventing under or over installation. This precise positioning eliminates gaps or excessive compression that would cause the brake clip to tilt during operation, thereby preventing the noise and vibration associated with poor installation.
Solution Approach 2:
The patent replaces the traditional sharp-edge mechanical engagement with a curved surface engagement system. This substitution changes the mechanics of installation from force-dependent sharp edge insertion to geometry-dependent curved surface mating, ensuring precise positioning that eliminates the conditions leading to noise and vibration.
Data Source
AI summary
A disc brake assembly includes a brake clip having a U-shaped section, at least one retention tang, and an abutment leg. The U-shaped section has a base leg and opposing upper and lower legs extending from the base leg. The upper leg has an inner face facing the lower leg. The at least one tang extends away from the U-shaped section and inner face. The abutment leg extends from the lower leg and has a midpoint between a top edge and a bottom edge. The midpoint is not planar with the top and bottom edges.