Disk Brake Pad Spring Stabilizing Attitude and Preventing Rust
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Solution Overview
Problem
Conventional disk brake apparatuses experience unstable pad attitudes during braking, leading to abnormal noises like brake squeal and clonk sounds due to opposing moments in forward and backward braking, and existing solutions complicate assembly and increase parts, making rust prevention challenging.
Innovation Solution
A disk brake pad spring is designed with a corrosion-resistant metal plate, featuring a U-shaped mounting portion, pressure arms, and a holding portion that elastically presses pads to stabilize their attitude and prevent rust, while being mountable after pad pins are inserted, thus maintaining assembly efficiency and reducing parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional floating caliper type disk brake apparatus is used with paired pad pins to support pads movably, then the manufacturing cost is reduced due to symmetric structure, but abnormal noises like brake squeal and clonk sounds occur due to unstable pad attitudes during braking
Solution Approach 1:
The pad spring is designed with elastic deformation capability to dynamically adapt to braking conditions. The spring body deforms elastically under braking forces to maintain stable pad attitudes during both forward and backward braking, transforming the static support structure into a dynamic one that compensates for force direction changes.
Solution Approach 2:
The pad spring acts as an intermediary element between the pad support member and the pad. It mediates the force transmission and provides continuous elastic support to stabilize pad attitude, preventing direct rigid contact that causes instability and noise during braking operations.
2Reliability
If existing solutions are implemented to stabilize pad attitudes, then brake squeal is prevented, but assembly becomes complicated and the number of parts increases
Solution Approach 1:
The pad spring integrates multiple functions into a single component: it provides elastic support for pad attitude stabilization, acts as a mounting element, and serves as a corrosion barrier. This merging of functions reduces the number of separate parts needed while maintaining effective pad stabilization.
Solution Approach 2:
The pad spring performs multiple functions simultaneously: stabilizing pad attitude through elastic deformation, preventing rust on torque transmission surfaces through corrosion resistance, and facilitating assembly through its flexible mounting capability. This multi-functionality eliminates the need for separate components for each function.
3Reliability
If existing solutions are implemented to stabilize pad attitudes, then brake squeal is prevented, but rust prevention on torque transmission surfaces becomes challenging due to increased parts
Solution Approach 1:
The pad spring body serves as a corrosion-resistant intermediary layer between the torque transmission surfaces. Its elastic and corrosion-resistant material properties prevent direct contact and rust formation on the torque transmission surfaces while still allowing effective force transmission and pad stabilization.
4Productivity
If a pad spring is designed to be mountable after pad pins are inserted, then assembly efficiency is maintained, but the structure becomes more complex
Solution Approach 1:
The pad spring's flexible and deformable structure allows it to be mounted after pad pins are inserted. The elastic properties enable the spring to accommodate the already-installed pad pins during assembly, maintaining simple assembly procedures without requiring pre-installation or complex positioning mechanisms.
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 pad spring effectively stabilizes pad attitudes, prevents brake squeal, and reduces rust on torque transmission and receiving surfaces without increasing the number of parts, ensuring efficient assembly and operation.
Implementation Method 1
a pad spring which is made of an elastic and corrosion-resistant metal plate
Implementation Method 2
made of an elastic and corrosion-resistant metal plate
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A pad spring (43) for a disk brake includes a mounting portion (44) configured to be elastically mounted onto radial outside portions of pad support members of the disk brake; a pressure portion (45a, 45b) having a pair of pressure arms configured to elastically press outer circumferential edges of circumferential-direction one-end portions of back plates of pads of the disk brake inwardly in a radial direction of a rotor of the disk brake; and a held plate section (48a, 48b) formed between torque transmission surfaces of the back plates and torque receiving surfaces of the pad support members. The pad spring is formed by bending an elastic and corrosion-resistant metal plate so as to elastically press the pads in the radial direction.