Disc Brake Pad Clip Geometry for Clonk and Drag Torque
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Solution Overview
Problem
Existing disc brake apparatuses generate a clonk sound due to mismatched moments acting on the pads during forward and backward braking, and they also suffer from increased drag torque due to gaps between the sandwiched plate portions and the torque-receiving surface.
Innovation Solution
A pad clip made of a metal plate is designed to be attached between coupling portions of a disc brake apparatus, featuring a main body portion, pressing portions, and sandwiched plate portions. The sandwiched plate portions are positioned between the torque-receiving surface and the pad, with their interference with the torque-receiving surface set to be larger than the interference of the fixing portions, ensuring continuous contact regardless of bending deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the sandwiched plate portions are positioned between the torque-receiving surface and the pad, then the drag torque is reduced, but gaps may form between the sandwiched plate portions and the torque-receiving surface due to bending deformation
Solution Approach 1:
The patent changes the geometric parameters of the sandwiched plate portions by providing cutout portions that extend in the radial direction. This modifies the flexibility and deformation characteristics of the sandwiched plate portions, allowing them to maintain continuous contact with the torque-receiving surface while still reducing drag torque through controlled interference fit.
Solution Approach 2:
The sandwiched plate portions are segmented by providing cutout portions that extend radially, dividing the plate into sections. This segmentation allows different parts of the sandwiched plate to deform independently, maintaining contact with the torque-receiving surface while accommodating bending deformation of the main body portion.
2Stability of the object's composition
If the pad clip structure is added to prevent clonk sound, then the braking stability is improved, but the device complexity increases
Solution Approach 1:
The pad clip is designed to perform multiple functions simultaneously: it prevents clonk sound by maintaining consistent moment directions during braking, reduces drag torque through the sandwiched plate portions, and accommodates deformation through the cutout portions. This multi-functionality reduces the need for additional separate components.
Solution Approach 2:
The patent merges the functions of preventing clonk sound and reducing drag torque into a single pad clip component. The main body portion with fixing portions addresses the clonk sound issue, while the integrated sandwiched plate portions with cutout portions address the drag torque issue, combining multiple solutions into one unified structure.
3Reliability
If the interference of sandwiched plate portions with torque-receiving surface is increased, then gaps are prevented, but the manufacturing precision requirements increase
Solution Approach 1:
The patent provides cutout portions in the sandwiched plate portions that extend in the radial direction, which changes the flexibility and deformation characteristics. This allows the design to accommodate a range of manufacturing tolerances while maintaining sufficient interference to prevent gaps, reducing the stringency of manufacturing precision requirements.
Solution Approach 2:
The sandwiched plate portions are designed to be flexible rather than rigid, allowing them to deform and adapt to variations in manufacturing precision. The cutout portions enable the plate to dynamically adjust its shape to maintain contact with the torque-receiving surface, compensating for manufacturing tolerances.
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 pad clip effectively prevents the generation of gaps between the sandwiched plate portions and the torque-receiving surface, thereby reducing the drag torque of the pads and eliminating the clonk sound by ensuring consistent moment directions during braking.
Implementation Method 1
regardless of bending deformation generated in the main body portion based on elastic deformation of the pressing portion
Data Source
AI summary
A pad clip in which a circumferential dimension from a first contact portion in contact with a side surface of a coupling portion, which is disposed on the other side in the circumferential direction, on the one side in the circumferential direction in a fixing portion disposed on the other side to a side surface of a sandwiched plate portion on the one side is available to be set independently of a circumferential dimension from a first contact portion to a second contact portion in contact with the side surface of the coupling portion, which is disposed on the one side, on the other side in the fixing portion disposed on the one side. The side surface of the sandwiched plate portion is in surface contact with a torque-receiving surface regardless of bending deformation generated in a main body portion based on elastic deformation of a pressing portion.