Disc Brake Expander Spring Retention Without Coupling Jamming
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Solution Overview
Problem
Existing disc brakes face issues with compromised expansion force due to jamming or disengagement of coupling means, often caused by contamination or corrosion, leading to operational reliability concerns.
Innovation Solution
The expander spring is directly connected to the retainer spring without intermediate coupling means, and a loss prevention device is integrated to ensure the expander spring remains attached to the brake even without expansion force, using holding portions and guide parts to prevent unintended detachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coupling means are used to connect the expander spring to the brake pads, then the expansion force can be transmitted, but the coupling means may jam or disengage due to contamination or corrosion, compromising operational reliability
Solution Approach 1:
The patent removes the coupling means from the system entirely. The expander spring is directly connected to the brake pads without any intermediate coupling elements. This extraction of the problematic component eliminates the risk of jamming and disengagement while simplifying the overall device structure.
Solution Approach 2:
The patent merges the expander spring directly with the brake pad assembly by eliminating the coupling means. The spring ends bear directly on the brake pads, creating an integrated connection that reduces the number of separate components and potential failure points.
2Ease of manufacture
If coupling means are used to connect the expander spring, then the expansion force transmission is possible, but the guiding of coupling means becomes complex and production is more difficult
Solution Approach 1:
The coupling means and its associated guiding structures are completely removed from the design. The expander spring connects directly to the brake pads, eliminating the need for complex guiding mechanisms and simplifying both production and assembly processes.
Solution Approach 2:
The brake pad serves multiple functions: it provides braking surface contact and simultaneously serves as the connection point for the expander spring. This multi-functionality eliminates the need for separate coupling components and their guiding structures.
3Reliability
If the expander spring is connected through coupling means, then the expansion force can be applied, but the coupling means may disengage unintentionally during operation
Solution Approach 1:
The coupling means are extracted from the system, eliminating the risk of disengagement. The direct connection between the expander spring and brake pads removes the intermediate components that could potentially fail or become disconnected during operation.
Solution Approach 2:
The design anticipates potential failure modes of coupling means by eliminating them entirely. The direct bearing connection is designed to withstand operational forces without the risk of disengagement that plagues multi-component coupling systems.
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 enhances operational reliability by preventing jamming and unintended detachment of the expander spring, ensuring consistent expansion force application and improved assembly efficiency.
Implementation Method 1
an expander spring which is specified for applying an expansion force in an effective direction between the brake pads and diverging the brake pads
Implementation Method 2
a retainer spring on each brake pad, a retainer bracket for pre-tensioning the retainer spring in relation to the respective brake pad
Data Source
AI summary
A disc brake (1) includes a brake disc (2), a brake caliper (3), two brake pads (4, 4′) that are movably guided on the brake caliper (3), a retainer spring (6, 6′) on each brake pad (4, 4′), a retainer bracket (8-8IV) for pre-tensioning the retainer springs (6, 6′) in relation to the respective brake pad (4, 4′), and an expander spring (10, 10′) that applies an expansion force between the brake pads (4, 4′) and diverging the brake pads (4, 4′). The ends of the expander spring (10, 10′) may bear in each case directly on one of the retainer springs (6, 6′). The disc brake (1) may have a loss prevention device that is operatively connected to the expander spring (10, 10′) such that the expander spring (10, 10′), in the absence of the expansion force, is held on the disc brake (1).