Disc Brake Leaf Spring Tongue Stabilization
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Solution Overview
Problem
The disc brake device experiences unstable behavior and generates braking noise due to the spring property of the leaf spring, which forms a gap between the pad-receiving surface and the base wall of the recess during braking.
Innovation Solution
The leaf spring is designed with a tongue-shaped part that extends from the rotor circumferential tip region toward the connection surface, elastically engaging with the recess side wall to bias the pad-receiving surface toward the base wall, reducing the likelihood of a gap formation and stabilizing the brake pad behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the leaf spring is designed with a tongue-shaped part that elastically engages with the recess side wall to bias the pad-receiving surface toward the base wall, then the brake pad behavior becomes stable and braking noise is reduced, but the device complexity increases due to the additional tongue-shaped structure
Solution Approach 1:
The leaf spring is segmented into distinct functional parts: a C-shaped part providing structural support and a separate tongue-shaped part providing elastic engagement. This segmentation allows each part to perform its specific function optimally - the C-shaped part maintains structural integrity while the tongue-shaped part provides the necessary elastic biasing force to stabilize the brake pad behavior and prevent braking noise.
Solution Approach 2:
The tongue-shaped part acts as an intermediary element between the leaf spring and the recess. It elastically engages with the recess side wall and transmits the biasing force to the pad-receiving surface, mediating the interaction between these components to achieve stable brake pad behavior while reducing braking noise.
2Stability of the object's composition
If the tongue-shaped part extends from the rotor circumferential tip region toward the connection surface, then the gap between pad-receiving surface and base wall is minimized, but the manufacturing precision requirements increase
Solution Approach 1:
The tongue-shaped part is designed with specific geometric parameters including its extension direction from the rotor circumferential tip region toward the connection surface, its engagement position on the recess side wall, and its biasing force characteristics. By optimizing these parameters, the design achieves effective gap minimization between the pad-receiving surface and base wall while maintaining manufacturability through well-defined geometric constraints.
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 configuration stabilizes the brake pad behavior during braking, reducing the occurrence of braking noise by minimizing the gap between the pad-receiving surface and the base wall, thus enhancing the braking performance.
Implementation Method 1
the tongue-shaped part... has a tip region elastically engaging with a side wall (an inner circumferential side wall or an outer circumferential side wall) of the recess, and biases the pad-receiving surface part toward the base wall of the recess
Data Source
AI summary
A disc brake device includes flat springs assembled in a support body and holding the brake pad back plates. The flat springs have a C-shaped part provided with: a connection surface part comprising a pad-receiving surface part; an outer circumferential surface part extending along the rotor circumferential direction from the end region of the connection surface part in the rotor radially outward direction; and an inner circumferential surface part extending along the rotor circumferential direction from the end region of the connection surface part in the rotor radially inward direction. Each flat spring also has a tongue-shaped part that: extends towards the connection surface part from the tip region of the inner circumferential surface part in the rotor circumferential direction; elastically engages an inner circumferential wall of a recess at a tip region of the tongue-shaped part; and biases the pad-receiving surface part towards a base wall of the recess.