Opposed-Piston Disc Brake Pad Spring for Noise and Yield Control
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Solution Overview
Problem
Conventional disc brakes face challenges in maintaining uniform performance and preventing abnormal sounds during braking and non-braking due to complex bending processes, which can lead to distortion and reduced yield in mass production.
Innovation Solution
An opposed piston type disc brake design featuring a disk-shaped disc rotor, a caliper with pistons, and a pad spring with a base and locking portions that stabilize brake pads, reducing the number of bending processes and ensuring uniform performance by pressing the pads in both axial and radial directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the acting point portion is extended from the main frame to press the brake pad, then the brake pad pressing performance is improved, but the number of bending processes increases and manufacturing complexity worsens
Solution Approach 1:
The pad spring is divided into multiple functional sections: a base portion, an acting point portion extending from the base, and a power point portion. This segmentation allows each section to perform its specific function independently while simplifying the overall manufacturing process by reducing the number of bending operations needed compared to extending from the main frame.
2Reliability
If multiple bending processes are performed on the pad clip, then the brake pad support and pressing performance is improved, but the manufacturing yield is degraded due to distortion
Solution Approach 1:
The pad spring is designed with pre-formed geometric shapes (such as arc-shaped or bent configurations) in its base and connecting portions that are created during initial forming processes. This preliminary action reduces the need for multiple subsequent bending operations, thereby minimizing distortion and improving manufacturing yield while maintaining the necessary support and pressing functions.
3Ease of manufacture
If the pad clip structure is simplified for easy manufacturing, then the manufacturing process is improved, but the ability to suppress abnormal sounds and vibrations worsens
Solution Approach 1:
The pad spring incorporates specific local structural features such as arc-shaped portions, bending sections, and engagement portions that are strategically positioned to suppress vibrations and abnormal sounds. These local quality enhancements are integrated into an otherwise simplified structure, allowing easy manufacturing while maintaining noise and vibration suppression capabilities through carefully designed geometric features.
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 effectively stabilizes brake pad orientation, reduces abnormal sounds, and simplifies manufacturing, increasing yield and reducing costs by minimizing distortion and the complexity of bending processes.
Implementation Method 1
a power point portion that acts a force to the acting point portion by utilizing principle of leverage and the elastic force of the material
Implementation Method 2
a power point portion that acts a force to the acting point portion by utilizing principle of leverage
Data Source
AI summary
In this disc brake, a pair of brake pads has recesses in the outer peripheral surfaces thereof. A pad spring has a first pressing section extending axially and provided to a base, the first pressing section pressing, toward the trailing side, a first section to be pressed which is provided on the trailing-side side surface of side surfaces which form the recess of a brake pad—and which are raised outward in the radial direction of a rotor. Also, the pad spring has a second pressing section extending axially and provided to the base, the second pressing section—pressing radially inward on the bottom surface of the recess of each of the pair of brake pads, the bottom surface being a second section to be pressed which is provided on an outer peripheral section.