Disc Brake Caliper Bridge Layout for Higher Rigidity at Lower Weight
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Solution Overview
Problem
Existing caliper bodies for disc brakes face a trade-off between structural rigidity and weight, with current solutions failing to maximize rigidity while minimizing bulk and weight, particularly in racing vehicles where responsiveness and lightness are critical.
Innovation Solution
The caliper body design features inverted U-shaped bridges with tangential connections and strategically placed windows to distribute stress, reducing weight while maintaining structural integrity and minimizing deformation during braking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the caliper body is made extremely rigid to minimize deformation during braking, then braking responsiveness is improved, but the weight and bulk of the caliper body increases
Solution Approach 1:
The caliper body is divided into multiple separate components (first caliper body portion, second caliper body portion, connecting element) rather than being a single monolithic structure. This segmentation allows each part to be optimized independently for strength-to-weight ratio, achieving sufficient rigidity while reducing overall weight compared to a solid monoblock design.
Solution Approach 2:
The connecting element uses a different material or structural composition than the main caliper body portions. This composite approach allows the connecting element to provide necessary structural linkage while being designed with lower density or optimized geometry to reduce weight, thereby achieving the desired balance between rigidity and weight reduction.
2Weight of moving object
If the caliper body bulk is reduced to minimize unsuspended mass, then vehicle performance is improved, but the structural rigidity and resistance to deformation decreases
Solution Approach 1:
By segmenting the caliper body into separate portions connected by a connecting element, the design removes unnecessary material from the overall structure. Each segment can be minimized in size while maintaining its functional requirements, and the connecting element is designed to provide the minimum necessary structural linkage, achieving bulk reduction while preserving essential rigidity.
Solution Approach 2:
The connecting element is designed with localized structural features that provide rigidity only where needed for structural integrity, rather than uniformly thickening the entire caliper body. This allows weight and bulk reduction in non-critical areas while maintaining sufficient rigidity in load-bearing regions through optimized local geometry and material distribution.
3Strength
If reinforcement elements are added to increase structural rigidity, then deformation is reduced, but the weight and complexity of the caliper body increases
Solution Approach 1:
The segmentation of the caliper body into separate portions and a connecting element inherently provides structural reinforcement at the connection points without requiring additional reinforcement elements. The modular structure allows for strategic placement of connection points that naturally reinforce the structure where loads are transmitted, achieving rigidity enhancement while avoiding the added complexity of separate reinforcement components.
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 design achieves a significant weight reduction of 5-8% with increased rigidity of 2-4% to 8-9% compared to traditional designs, providing enhanced braking responsiveness and reduced pedal stroke, suitable for high-performance vehicles.
Implementation Method 1
the pressure is exerted on the surface of the bottom of the pistons forcing them to clamp against the pads, which in turn abut against the braking surfaces of the disc
Implementation Method 2
Friction pads are foreseen arranged between each elongated element of the caliper and the braking surfaces of the brake disc
Data Source
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AI summary
A caliper body (1) for a disc brake, suitable for being arranged astride of a disc (40) for a disc brake; said caliper body comprising: a mounting - side elongated portion (2) equipped with at least one mounting portion said body also comprises a non mounting - side elongated portion (3) each elongated portion (2, 3) houses or forms at least two cylinders (15) said elongated portions (2, 3) being connected together by a first end bridge (4) that connects the two disc entry- side tangential ends (21, 23), said elongated portions (2, 3) are connected by a second end bridge (5) that connects the two disc exit- side tangential ends (22, 24); said caliper body (1) also comprising three central bridges (6, 7, 100, 101, 102) connecting the two elongated portions (2, 3) in their regions arranged between the two end bridges (4, 5); each of said central bridges (6, 7, 100, 101, 102) is connecting to said elongated portions at the side of said at least two cylinders (15) forming at least four through -windows in said calipter body (1).