Electronic Disc Brake Parallel Spring Piston Return

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Solution Overview

Problem

Conventional electronic disc brakes face issues with limited piston return distance due to the design of sealing members, leading to increased brake drag and wear, and poor initial brake feeling due to excessive roll-back from compression springs.

Innovation Solution

The electronic disc brake incorporates a low-pressure spring and a high-pressure spring arranged in parallel, along with an adjuster mechanism to maintain a constant gap between the disc and friction pads, preventing drag and ensuring proper brake function by forming a gap between the springs in the longitudinal direction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If a single compression spring is used to return the piston, then the piston can be moved backward, but the return distance is excessive causing poor initial brake feeling

Engineering Contradiction:

Improvepiston return distanceVSAvoidinitial brake feeling

Core Design Contradiction:

Length of moving objectVSEase of operation

Solution Approach 1:

The single compression spring is divided into two separate compression springs (first compression spring and second compression spring) arranged in parallel. This segmentation allows each spring to contribute differently to the piston return force, enabling precise control over the return distance and eliminating excessive roll-back that degrades brake feeling.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

By using two compression springs with different characteristics instead of one spring, the system can adjust the force-displacement parameters to achieve the desired piston return distance. The first compression spring provides initial return force while the second compression spring provides additional support, allowing optimization of the return distance to prevent poor brake feeling.

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If the sealing member is designed with limited deformation width, then the structure is simple, but the piston return distance is short causing brake drag

Engineering Contradiction:

Improvesealing member structureVSAvoidpiston return distance

Core Design Contradiction:

Device complexityVSLength of moving object

Solution Approach 1:

The two compression springs act as intermediary elements between the sealing member's elastic recovery and the piston return motion. They amplify and extend the piston return distance by providing additional mechanical advantage, allowing the piston to travel farther back without requiring a more complex sealing member structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system uses the dynamic compression and expansion of two springs to extend the piston return distance. As the sealing member recovers its shape, it compresses the first spring, which then transfers force to compress the second spring, creating a staged dynamic response that extends the overall return distance beyond what the sealing member alone could achieve.

Inventive Principle:

Principle #15Dynamics

3Device complexity

If friction pads are not sufficiently separated from the disc, then the structure is simple, but wear of friction pads increases due to drag

Engineering Contradiction:

Improvebrake structureVSAvoidfriction pad wear

Core Design Contradiction:

Device complexityVSLoss of substance

Solution Approach 1:

The braking system is segmented into two independent spring mechanisms working in parallel, providing staged force application. This ensures that the friction pads are reliably separated from the disc after braking, preventing drag-induced wear without requiring additional complex mechanisms.

Inventive Principle:

Principle #1Segmentation

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 enhances piston return distance, reduces brake drag, and improves initial brake feeling by maintaining a consistent gap between the disc and friction pads, preventing unnecessary wear and noise.

Implementation Method 1

a low-pressure spring and a high-pressure spring arranged in parallel in the spring case to apply elastic force to the push rod

Methodology Applied

Scientific EffectElastic force: Elasticity

Implementation Method 2

the piston 22 to be moved back to an original position thereof by resilience of the sealing member 30, by which the sealing member 30 recovers an original shape thereof

Methodology Applied

Scientific EffectResilience: Elasticity

Data Source

PatentUS9347508B2Electronic disc brake

Publication Date: 2016.05.24 HL MANDO CORP

AI summary

Disclosed is an electronic disc brake. The electronic disc brake includes a caliper housing at which a piston is installed, a carrier coupled with the caliper housing, a pair of pad plates installed at the carrier to be slidable toward a disc, an adjuster to prevent the pad plates from moving away from the disc and maintain the pad plates at a certain distance from the disc, a push rod screw-coupled to the adjuster, a spindle unit coupled to the push rod and installed at a cylinder of the caliper housing, a spring case forming an accommodation space between the cylinder and the push rod, a low-pressure spring and a high-pressure spring arranged in parallel in the spring case, and a support plate slidably installed in the cylinder so that a gap is formed between the low-pressure spring and the high-pressure spring in the longitudinal direction.