Disc Brake Return Spring Mounting to Prevent Pad Drag
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Solution Overview
Problem
Existing disc brake systems face issues with premature wear and residual braking due to insufficient repulsion of brake pads from the disc, leading to continuous rubbing and increased noise, dust emission, and energy consumption.
Innovation Solution
An axial elastic return spring is interposed between the brake pad and the fixed support, featuring an elastic deformation portion, a carrier portion, and a pad portion. The carrier portion includes a support part and a connection part with connection folds that press on an anchoring part to prevent lifting, facilitating mounting and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the disc does not repel the brake pads with sufficient force, then the brake pads cannot return to their inactive position, but this causes continuous rubbing, noise, dust emission, and heating
Solution Approach 1:
An elastic return spring is introduced as an intermediary element between the brake pad and the fixed support. The spring provides the necessary repulsive force to return the brake pad to its inactive position when the piston is not pressing, eliminating continuous rubbing and associated harmful effects like noise, dust emission, and heating.
Solution Approach 2:
The elastic properties of the return spring are designed to provide sufficient repulsive force under specific conditions. The spring's elastic deformation characteristics allow it to exert the necessary force to move the brake pad from active to inactive position, changing the force parameter dynamically based on brake pad position.
2Reliability
If a complex fastening system is used for the return spring, then reliability is improved, but manufacturing cost and mounting complexity increase
Solution Approach 1:
The return spring is divided into distinct functional portions: a carrier portion with connection folds for fastening to the fixed support, and a pad portion for attachment to the brake pad. This segmentation allows each portion to be optimized independently and simplifies the overall mounting process.
Solution Approach 2:
The connection folds are designed to be deformable, allowing the return spring to be dynamically installed by deforming the folds during mounting and then allowing them to spring back into their functional configuration. This dynamic mounting approach eliminates complex fastening operations while ensuring reliable connection.
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 axial elastic return spring effectively moves the brake pad away from the disc when the piston is not pressing, reducing residual braking duration and intensity while simplifying the mounting process, lowering manufacturing costs, and improving reliability and performance.
Implementation Method 1
an elastic deformation portion, arranged to produce an elastic reaction force during pressing of said pad in the active position so as to return said brake pad to the inactive position
Implementation Method 2
a connection part comprising at least one connection fold arranged and configured to press on an anchoring part carried by a transverse face of the fixed support and to cooperate with said anchoring part to prevent lifting of said connection part
Data Source
AI summary
An elastic return spring for axially returning a brake pad of an automotive disc brake from an active position to an inactive position, the spring being intended to be interposed between the brake pad and a fixed support, with an elastic deformation portion, a carrier portion arranged to be fastened to the fixed support of the disc brake, and a pad portion. The carrier portion includes a support part and a connection part which including at least one connection fold arranged and configured to bear on an anchoring part of the fixed support and to cooperate with said anchoring part to avoid any lifting of the connection part.