Disc Brake Pad Spring Layout for Compact Rattle Suppression
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Solution Overview
Problem
Conventional vehicular disk brakes face challenges in downsizing and lightening the caliper body while effectively suppressing friction pad rattling, as the attachment of pad springs requires a predetermined clearance and increased thickness for rigidity, leading to potential size and weight issues.
Innovation Solution
A vehicular disc brake design where turn-in side and turn-out side pad springs are attached to the bridge portion of the caliper body, allowing the friction pads to be biased radially inward and outward, eliminating the need for clearance between the bridge and pads, and featuring torque reception stepped portions to support ear pieces, thus enabling a compact and lightweight caliper body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pad spring is attached to the middle portion of the bridge portion to suppress friction pad rattling, then rattling suppression is achieved, but a predetermined clearance must be provided between the bridge portion and friction pads, increasing the caliper body size
Solution Approach 1:
The pad spring attachment position is moved from the middle portion (circumferential direction) to the end portions (radial direction) of the bridge portion. This dimensional change allows the spring to act on the friction pads from a different spatial location, eliminating the need for clearance between the bridge portion and friction pads while maintaining rattling suppression functionality.
Solution Approach 2:
The single pad spring in the middle portion is divided into two separate pad springs positioned at the end portions of the bridge portion. This segmentation allows each spring to independently suppress rattling at different locations, achieving effective vibration control without requiring additional clearance space.
2Strength
If the middle portion of the bridge portion is formed thick to ensure rigidity for pad spring attachment, then structural rigidity is improved, but the caliper body weight increases
Solution Approach 1:
The pad spring attachment is relocated from the middle portion to the end portions of the bridge portion. This allows the bridge portion to maintain adequate rigidity through its overall structure rather than requiring localized thickening, thereby reducing unnecessary material and weight.
Solution Approach 2:
Instead of uniformly thickening the middle portion, the design allows for localized thickness variations only where structurally necessary. The end portions are optimized for spring attachment while the overall bridge portion maintains sufficient rigidity through its geometry and material distribution, avoiding excessive weight.
3Force
If ear pieces are provided on friction pads for torque reception, then torque transmission is improved, but the friction pad structure becomes more complex
Solution Approach 1:
The ear pieces for torque reception are integrated directly into the friction pad structure as protrusions or extensions of the pad body, rather than being separate components. This merging of functions reduces the number of discrete parts while maintaining effective torque transmission from the friction pad to the caliper body.
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
This design allows for a compact and lightweight caliper body without increasing size or weight, while effectively suppressing friction pad rattling through the use of symmetrically formed friction pads and strategically positioned pad springs, improving assemblability and reducing costs.
Implementation Method 1
a turn-in side resilient portion biasing the friction pads to a disc radial inner side and the disc turn-out side, and a turn-out side resilient portion biasing the friction pads to the disc radial inner side
Data Source
AI summary
This vehicular disc brake in which a pad spring can be preferably attached while a caliper body is downsized and lightened, is provided with: a turn-in side pad spring provided with a turn-in side resilient portion a that is attached on a disc turn-in side relative to a friction pad accommodating portion of a bridge portion and that biases a friction pad to a disc radial inner side and a disc turn-out side, and a turn-in side retainer portion laid on a turn-in side torque reception stepped portion m; and a turn-out side pad spring provided with a turn-out side resilient portion that is attached on a disc turn-out side relative to the friction pad accommodating portion of the bridge portion 3c and that biases the friction pad to the disc radial inner side, and a turn-out side retainer portion laid on a turn-out side torque reception stepped portion.