Disc Brake Pad Support Structure for Even Wear and Torque Transfer
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Solution Overview
Problem
Disc brakes with a single piston are prone to uneven pad wear and flexing, leading to premature replacement and difficulties in adjusting the actuation mechanism, while dual piston brakes face challenges in material efficiency and edge damage during braking operations.
Innovation Solution
A disc brake design featuring a brake pad support arrangement that transmits torque loads to a brake carrier via a keyed relationship, allowing for a thin backplate and minimizing edge damage, with a spreader plate that distributes load and prevents piston rotation for efficient wear adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single piston is used to actuate the brake pad, then the device complexity is reduced, but uneven pad wear and flexing occur leading to premature replacement
Solution Approach 1:
A spreader plate is introduced as an intermediary component between the piston and the brake pad. This spreader plate distributes the actuation force uniformly across the pad width, preventing flexing and pivoting that cause uneven wear. The spreader plate acts as a mediator that transforms the concentrated piston force into a distributed load across the entire pad surface.
Solution Approach 2:
The piston head geometry is modified with an enlarged diameter that exceeds the brake pad width. This parameter change allows the piston to apply force across the entire pad width directly, eliminating the need for a spreader plate in some configurations and preventing uneven wear through increased contact area.
2Strength
If a thicker backplate is used to prevent flexing, then the pad resistance to flexing is improved, but material usage increases and edge damage risk remains
Solution Approach 1:
The spreader plate serves as a structural intermediary that carries the braking induced torque load from the pad to the carrier. This allows the use of thinner backplates since the spreader plate provides the necessary structural support and load path, eliminating the need for excessive backplate thickness to prevent flexing.
Solution Approach 2:
The load transmission function is segmented between the brake pad, spreader plate, and carrier. The spreader plate specifically handles the torque load transmission, allowing the pad backplate to be optimized for its primary function of friction contact rather than structural support, enabling thinner backplate design.
3Device complexity
If the brake pad directly contacts the brake carrier, then the load transmission path is simplified, but edge damage occurs due to limited surface area
Solution Approach 1:
The spreader plate is positioned between the brake pad and carrier to mediate the load transmission. It provides a larger surface area for torque load transfer, distributing the forces across the spreader plate edges rather than concentrating them on the pad backplate edges, thereby preventing edge damage to both the pad and carrier.
4Adaptability or versatility
If two parts of the piston are threadably engaged for adjustment, then the actuation mechanism adjustability is improved, but it becomes difficult to restrain one part while the other rotates
Solution Approach 1:
The adjustment mechanism merges the threading function with the spreader plate structure. The threaded element is integrated into the spreader plate, which is itself restrained by the carrier geometry. This combination allows adjustment operation while the spreader plate's structural integration with the carrier provides the necessary restraint during rotation.
Data Source
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AI summary
A disc brake comprising a caliper including an actuation mechanism to transmit an actuating force to a brake pad; a brake carrier to transmit a braking induced torque load from at least one brake pad to a vehicle axle or the like; wherein the actuation mechanism comprises a brake pad support arrangement configured to mount a brake pad thereon and to transmit the majority of the braking induced torque load generated by the brake pad to the brake carrier in use.