Disc Brake Pad Retainer Bracket for Easier Leaf Spring Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing disc brakes face challenges in securing brake pads within pad recesses during assembly, particularly after replacement, due to the complexity of the dual locking function of bolts used in the spring elements, which are exposed to heat and complicate assembly.
Innovation Solution
A bracket is integrated into the retainer assembly, connected to the brake caliper, with the spring end resting against its inner side, and a positive locking element at one end of the leaf spring secures the leaf spring in position, facilitating easy and secure assembly of the pad retainer and leaf spring components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single leaf spring is arranged on the outside of the rigid retaining bracket with dual locking function, then the brake pads are securely retained, but the assembly process becomes complex and difficult under preload conditions
Solution Approach 1:
The invention divides the retaining bracket into two separate components: a rigid retaining bracket and a leaf spring. This segmentation allows each component to have specialized functions - the rigid bracket provides structural support and positioning, while the leaf spring provides elastic retention force. The separation simplifies assembly by allowing the rigid bracket to be installed first without preload, followed by the leaf spring which can be easily attached due to its flexible nature.
Solution Approach 2:
The leaf spring acts as an intermediary element between the rigid retaining bracket and the brake pads. It mediates the retention function by providing elastic force while allowing for thermal expansion and contraction. This intermediary role enables the rigid bracket to focus on structural stability while the leaf spring handles the dynamic retention requirements, simplifying the overall assembly process.
2Strength
If the leaf spring is exposed to heat from brake pads and disc, then it can maintain elastic properties, but assembly becomes difficult due to unfavorable preload conditions
Solution Approach 1:
The invention applies preliminary action by pre-shaping the leaf spring with curved sections and bends during manufacturing. These pre-formed geometric features create the necessary elastic preload and retention force without requiring additional adjustment during assembly. The leaf spring is pre-configured to exert the correct force against the brake pads and retaining bracket, eliminating the need for complex assembly adjustments under heat exposure.
Solution Approach 2:
The leaf spring's geometric parameters are specifically designed with curved sections and bends that change its mechanical properties. These parameter changes in the spring's shape create zones of high and low stress distribution, allowing the spring to maintain elastic force under thermal conditions while being easily installable. The curved geometry enables the spring to absorb thermal expansion while maintaining retention force.
3Reliability
If a fastening element is used to lock both the brake pad retainer and leaf spring, then secure attachment is achieved, but the assembly process becomes more complex
Solution Approach 1:
The fastening element is designed with multi-functionality to perform multiple tasks: it secures the leaf spring to the retaining bracket, positions the brake pads correctly, and provides adjustment capability. This single universal fastening component eliminates the need for multiple separate fasteners and adjustment mechanisms, reducing assembly complexity while maintaining secure attachment of all components.
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 design simplifies the assembly process by allowing easy insertion of the fastening element, ensuring the pad retainer and leaf spring are positioned correctly, enhancing assembly efficiency and stability.
Implementation Method 1
a leaf spring (12) that elastically rests against the side of the pad retainer (10) facing away from the brake pads (3), extends in its longitudinal direction
Implementation Method 2
a contact point arranged on a central section of the leaf spring in the form of a bend or curvature of the leaf spring with the curvature facing the brake linings
Data Source
Figure 1~2
Figure 3~5b
AI summary
The invention relates to a disc brake comprising a brake calliper (1) engaging over a brake disc (2) and brake pads (3) on both sides of the brake disc, a hold-down means (10) for the pads securing the brake pads (3) against falling out of the disc brake, which extends, in contact with the rear plates (5) of both brake pads (3), in the transverse direction in relation to same, and comprising a flat spring (12) which is spring-elastically in contact with the side of the hold-down means (10) for the pads facing away from the brake pads (3), which extends in the longitudinal direction thereof, and which is supported with both spring ends (31, 32) thereof in spring abutments (21, 22). A securing means (8) is a component of one of the spring abutments, which extends transverse to the hold-down means (10) for the pads and to the flat spring (12). In order to improve and simplify the assembly of the hold-down assembly by technical means, e.g. after exchanging the brake pads, according to the invention, a further component of the hold-down means (21) of the spring is a clip (40) which is connected to the brake calliper (1) via the securing means (8), and with which the inner side (45) of the spring end (31) facing the securing means (8) is in contact.