Disc Brake Pad Spring Integrated Guide Plate Design
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Solution Overview
Problem
The existing disc brake pad springs have separate abutting and guide portions, increasing material width and complicating processing, which affects yield and cost.
Innovation Solution
A disc brake design that incorporates a pad spring with a guide plate and biasing members, including a folded region that serves as both a guide and abutting portion, improving yield and reducing costs by integrating functions and simplifying processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate abutting portion and guide portion are provided in the pad spring, then the pad spring can perform both abutting and guiding functions, but the material width increases and processing becomes complicated
Solution Approach 1:
The patent merges the abutting portion and guide portion into a single integrated structure. The guide plate has a surface that abuts on the mounting ear portion, and includes a folded region protruding axially from this surface. The folded region is folded in a direction toward the outside of the disc and includes an abutting portion for the second biasing member. This integration eliminates the need for separate components, reducing material width and simplifying processing while maintaining both abutting and guiding functions.
Solution Approach 2:
The guide plate is designed to perform multiple functions simultaneously. It provides a surface for abutting on the mounting ear portion, includes a folded region that guides the mounting ear portion, and incorporates an abutting portion for the second biasing member. This multi-functional design allows a single component to replace what would traditionally require separate parts, improving yield and reducing cost.
2Reliability
If separate abutting portion and guide portion are provided in the pad spring, then both functions are achieved, but the processing complexity increases
Solution Approach 1:
The patent combines the abutting portion and guide portion into a single integrated guide plate structure. The guide plate has a surface that abuts on the mounting ear portion and includes a folded region that is folded in a direction toward the outside of the disc. The folded region includes an abutting portion for the second biasing member. This merging reduces the number of separate parts and simplifies processing operations.
3Reliability
If separate abutting portion and guide portion are provided in the pad spring, then both functions are ensured, but the material width increases
Solution Approach 1:
The patent merges the abutting portion and guide portion into a single integrated guide plate structure. The guide plate has a surface that abuts on the mounting ear portion and includes a folded region that is folded in a direction toward the outside of the disc. The folded region includes an abutting portion for the second biasing member. This merging reduces the number of separate parts and simplifies processing operations.
Solution Approach 2:
The guide plate utilizes three-dimensional folding to create the abutting portion. The folded region protrudes in the axial direction of the disc from the surface that abuts on the mounting ear portion, and is folded in a direction toward the outside of the disc. This dimensional approach allows the abutting function to be integrated into the guide plate without increasing its planar footprint, thereby reducing material width.
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 integrated design enhances the pad spring's yield and reduces the disc brake's cost by simplifying processing and assembly, while ensuring reliable operation and safety.
Implementation Method 1
a first biasing member configured to press the mounting ear portion of the pad toward outside of the disc
Implementation Method 2
a second biasing member that is provided at the pad to bias the pad in a direction away from the disc
Data Source
AI summary
A disc brake includes a caliper; a pad pressed against a disc by a movable portion of the caliper and including a mounting ear portion provided to be protruded in a longitudinal direction of the pad; a pad spring including a guide plate configured to guide the mounting ear portion, and a first biasing member configured to press the mounting ear portion of the pad toward outside of the disc; and a second biasing member provided at the pad to bias the pad in a direction away from the disc. The guide plate of the pad spring has a surface that abuts on the mounting ear portion of the pad pressed by the first biasing member. The pad spring includes a folded region protruded in an axial direction of the disc from the surface abutting on the mounting ear portion of the pad, and folded in a direction toward the outside of the disc and away from the mounting ear portion. The folded region includes an abutting portion which the second biasing member provided at the pad abuts on.