Angled Brake Carrier Mounting Plane for Caliper Space
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Solution Overview
Problem
Existing brake carriers for disc brakes face challenges in optimizing installation space and weight due to geometric constraints and strength requirements, particularly when accommodating components like brake cylinders, leading to space conflicts and inefficient material usage.
Innovation Solution
The brake carrier is designed with contact surfaces rotated by an angle relative to a horizontal plane, with the brake carrier itself serving as the variant-driving component, allowing for angular offset without altering the axle body geometry, and incorporating geometric elements like thickened webs, toroidal contours, and reinforcing ribs to reduce mechanical stresses and save material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the brake carrier is designed with traditional axial or parallel mounting to the vehicle axle, then the installation space for the brake caliper is occupied, but the guide elements cannot be spaced further apart resulting in less stable and higher-friction guidance
Solution Approach 1:
The patent applies dimensionality change by rotating the mounting plane of the brake carrier from an axial/parallel orientation to a radial orientation relative to the vehicle wheel axle. This angular repositioning in a different dimensional orientation creates new installation space for the brake caliper while allowing guide elements to be spaced further apart, thereby improving guidance stability and reducing friction.
2Weight of moving object
If the brake carrier is made lighter to reduce weight, then material usage is reduced, but the strength requirements for the brake carrier may not be met
Solution Approach 1:
The patent applies local quality by implementing geometric elements such as thickened webs, torus-shaped contour features, and bracket-like thickenings with reinforcing ribs at specific locations where mechanical stresses occur. These localized reinforcements maintain the necessary strength and stress distribution in critical areas while allowing the overall brake carrier to use less material and reduce weight.
3Area of stationary object
If the contact surfaces of the brake carrier are positioned in a horizontal plane, then the brake carrier geometry is simple, but the installation space for adjacent components is limited and brake cylinder space conflicts arise
Solution Approach 1:
The patent applies asymmetry by rotating the contact surfaces of the brake carrier from a horizontal plane to a radial plane at a defined angle relative to the vehicle axle. This asymmetric angular positioning creates additional installation space for adjacent components such as the brake cylinder, eliminating space conflicts while the overall structural symmetry is maintained through corresponding features on opposite sides.
4Area of stationary object
If the axle body is modified to create installation space for brake cylinder, then the installation space problem is solved, but the axle body is subject to geometrically disadvantageous modifications increasing cost
Solution Approach 1:
The patent applies the extraction principle by removing the need for axle body modifications and instead creating the required installation space through the brake carrier's own angular geometry. The radial mounting plane of the brake carrier inherently provides the necessary space for the brake cylinder and other adjacent components, eliminating costly geometric modifications to the axle body while maintaining all functional requirements.
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
A brake carrier (2) for a disc brake (1) of a vehicle, comprising: a. a frame-like disc surround (8) for gripping an edge of a brake disc (4) of the disc brake (1), which has two mutually parallel hub swings (10a, 10b) and two frame parts (11a, 11b) connecting these hub swings (10a, 10b), b. mutually spaced bearing surfaces (20, 21) which are designed to bear against an axle flange (5) in a mounting plane (A) of the axle flange (5) in a mounted state, c. mounting holes (19) in the bearing surfaces (20, 21) through which the brake carrier (2) can be screwed to the axle flange (5) of an axle body of the vehicle, is characterized in that d. the support surfaces (20, 21) lie in a common plane which is rotated by an angle (α) relative to a horizontal, vehicle-related plane (E).