Disc Brake Caliper Body Layout for Easier Bleeding and Machining
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Solution Overview
Problem
The existing caliper body designs for vehicle disc brakes face challenges in processability and air extractability due to misalignment of connection and communication holes, leading to increased machining effort and air accumulation, which degrades the performance of the brake system.
Innovation Solution
A caliper body design where the connection hole and communication hole are aligned on the same straight line, with slanted air extraction sections in the recesses of the cylinder holes, and a deep bottom cylinder hole for the second brake system, improving processability and air extractability by allowing simultaneous boring of holes and preventing air accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the connection hole is opened in the peripheral wall of the cylinder hole, then the bleeder screw can be attached, but the cylinder hole is affected when the bleeder screw is screwed in
Solution Approach 1:
The connection hole is nested within the recess formed at the bottom of the cylinder hole, creating a hierarchical structure where the connection hole is positioned inside the recess rather than on the peripheral wall. This nesting arrangement allows the bleeder screw to be attached without affecting the cylinder hole integrity, as the recess provides a dedicated space for the connection hole and bleeder screw assembly.
2Reliability
If cylindrical recesses are formed in the bottoms of the cylinder holes and the connection hole is opened in the recesses, then the cylinder hole is not affected when the bleeder screw is screwed in, but machining takes effort because the positions in which the connection hole and the communication hole are formed deviate in a disc inward-outward direction
Solution Approach 1:
The connection hole and communication hole are merged into the same radial line, allowing both holes to be machined simultaneously or in sequence along the same path. This merging of hole positions eliminates the need for complex positioning and deviated machining operations, significantly reducing machining effort while maintaining cylinder hole protection through the recess structure.
Solution Approach 2:
The holes are arranged in the radial direction (disc inward-outward direction) rather than in different axial positions, changing the dimensional arrangement from axial separation to radial alignment. This dimensional change allows both holes to be accessed and machined from the same direction, simplifying the manufacturing process.
3Device complexity
If the recesses are formed in a cylindrical shape, then the structure is simple, but air easily accumulates on the upper surfaces of the recesses, degrading air extractability
Solution Approach 1:
The recess is designed with an asymmetric cross-sectional shape rather than a simple cylindrical shape. The recess has a wider opening at the top and narrows toward the bottom, creating an asymmetric profile that prevents air accumulation. This asymmetric geometry allows air to escape more easily while maintaining structural simplicity, resolving the contradiction between structural simplicity and air extractability.
Data Source
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AI summary
The present invention is a caliper body for a vehicle disc brake with improved processability and improved air extractability. Multiple cylinder holes 6d, 6e, 6f are disposed side by side in the disc circumference direction on a working section 6a of a caliper body 6. Recesses 6k and 6m are formed in the bottoms of the cylinder holes 6d and 6f, and the recesses 6k and 6m are in communication with each other via a communication hole 16. In the recess 6m of the cylinder hole 6f that is disposed in the uppermost part when the caliper body 6 is installed in a vehicle, a connection hole 17a that opens to the outer surface of the caliper body 6 is formed on the same line as the communication hole 16. For the recesses 6k and 6m, the communication hole 16 or the connection hole 17a connects at a position that becomes the upper end when the caliper body 6 is installed in a vehicle, and slanted air extraction sections 6t and 6u that slant toward the upper end are formed.