Cold-Worked Brake Piston for Multipurpose Applications
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Summary
Problems
Existing brake pistons for service brakes are not suitable for repurposed use in parking brake calipers due to independent centers of gravity and development aims, lacking an interface for parking brake mechanisms, and conventional working methods result in high effort and disproportionate reduction in wall thickness, limiting shaping freedom.
Innovation solutions
A cold-worked brake piston with a partially thickened cylindrical piston wall portion, achieved through adaptive plastic deformation and strain-hardening, allowing for free wall thickness configuration and increased load-bearing capacity, suitable for both service and parking brake applications, using non-cutting methods like extrusion and internal roller-burnishing.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If conventional working methods (deep drawing, ironing) are used to manufacture brake pistons, then the piston wall thickness is reduced, but the load-bearing capacity and structural integrity are compromised
Why choose this principle:
The patent applies local plastic deformation through controlled material flow to increase wall thickness in specific regions. By changing the physical state and flow characteristics of the material during cold working, the process achieves local thickening (s2) without requiring additional material, thereby improving load-bearing capacity in critical areas while maintaining manufacturing efficiency
Principle concept:
If conventional working methods (deep drawing, ironing) are used to manufacture brake pistons, then the piston wall thickness is reduced, but the load-bearing capacity and structural integrity are compromised
Why choose this principle:
The invention creates non-uniform wall thickness distribution with locally thickened regions (s2 > s1) where stress concentrations occur. This local quality enhancement allows the piston to have adequate strength at critical locations (piston wall, interface regions) while maintaining lighter overall weight and simpler manufacturing compared to uniformly thick-walled designs
Application Domain
Data Source
AI summary:
A cold-worked brake piston with a partially thickened cylindrical piston wall portion, achieved through adaptive plastic deformation and strain-hardening, allowing for free wall thickness configuration and increased load-bearing capacity, suitable for both service and parking brake applications, using non-cutting methods like extrusion and internal roller-burnishing.
Abstract
The invention relates to a brake piston 1 for a brake caliper 9 of a disk brake, which is produced using working processes from a metallic material, in particular from a flat metal sheet, and is formed in one piece as a unilaterally open pot with a piston longitudinal axis A, with a piston wall 2 and with a piston head 3. There is a need for robust and light as well as alternatively constructed, efficiently producible and well guided brake pistons. The object is achieved firstly in principle on the basis of a cup-shapedly worked brake piston blank 19 , in that at least one locally defined, i.e. partially cold-upset or partially ironed, cylindrical piston wall portion is present with a partially deformed piston wall 2 which is configured in adaptively modified manner by plastic material deformation by means of material redistribution (flow) including strain-hardening of its piston wall thickness of s1−x.