Fixed-Caliper Disk Brake Bow Spring for Rattle-Free Pad Clearance
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Solution Overview
Problem
Existing motor-vehicle fixed-caliper partially lined disk brakes face challenges in maintaining a rattle-free and maintenance-friendly design, with prior solutions often requiring complex spring systems and additional fixings that complicate production and service.
Innovation Solution
A compact, sheet-steel bow spring design with U-shaped spring legs and a central yoke portion is used, allowing for a flexible and space-saving clearance spring system that is elastically clamped between friction lining backing plates, eliminating the need for additional fixings and providing identical restoring spring force on both sides of the brake disk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a complex spring system with additional fixings is used, then the brake system can maintain structural stability, but the production complexity and device complexity increase
Solution Approach 1:
The patent combines the spring element and the fixing function into a single integrated component. The U-shaped spring legs directly engage with the brake disk and housing structures, eliminating the need for separate fixings or mounting hardware. This merging of functions reduces the number of parts and simplifies production while maintaining structural stability.
Solution Approach 2:
The clearance spring serves multiple functions simultaneously: it provides the restoring force for the friction lining, acts as a positioning element, and serves as its own fixing mechanism through the elastic engagement of its U-shaped legs. This multi-functionality eliminates the need for additional specialized components.
2Stability of the object's composition
If additional fixings and complex spring systems are used, then the brake system can maintain structural stability, but the maintenance friendliness and serviceability deteriorate
Solution Approach 1:
By integrating the fixing function into the spring structure itself through the U-shaped legs, the design eliminates separate fixing components that would require disassembly and reassembly during maintenance. The spring component is self-contained and can be installed or replaced as a single unit.
Solution Approach 2:
The spring is designed as a modular component with distinct functional zones (yoke portion, U-shaped legs, engagement points) that allows for standardized manufacturing and easy replacement. The segmentation enables the spring to be handled and installed as a discrete unit without affecting other brake system components.
3Device complexity
If a compact sheet-steel bow spring design is used, then the device complexity and production complexity are reduced, but the restoring spring force may be insufficient compared to complex spring systems
Solution Approach 1:
The patent optimizes the spring's geometric parameters (leg thickness, leg length, U-shaped curvature radius, yoke portion dimensions) to achieve the required restoring force. By carefully selecting these parameters within the compact sheet-steel design, the spring generates sufficient elastic force despite its simplified structure.
Solution Approach 2:
The spring is made from sheet steel with optimized material properties (strength, elasticity, thickness) to ensure that the compact design generates adequate restoring force. The material selection and thickness optimization compensate for the simpler geometry, maintaining the required force output.
4Volume of moving object
If a compact design with parallel spring legs is used, then the space requirements are reduced, but the clearance function and noise reduction capability may be compromised
Solution Approach 1:
The U-shaped curved legs of the spring provide elastic compliance that allows the friction lining to maintain proper clearance from the brake disk. The curvature enables the spring to absorb vibrations and reduce noise while occupying minimal space, as the elastic deformation occurs within the compact U-shaped geometry rather than requiring extended linear space.
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 maintenance friendliness, reduces production complexity, and provides a compact, high-performance brake system with reduced noise and improved serviceability, while maintaining performance without additional installation space requirements.
Implementation Method 1
elastic spring legs which are bent away plastically from the yoke portion substantially in a U shape... the spring legs are clamped in elastically resiliently between the friction lining backing plates
Data Source
AI summary
A motor-vehicle fixed-caliper partially lined disk brake with pin mounting for backing plates of disk brake linings, comprising a one-piece clearance spring with two spring legs which are elastically clamped in between the backing plates on a bearing portion which is free of friction material.