Brake Caliper Fluid Channel Layout for Heat and Stress Relief
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Solution Overview
Problem
Conventional disc brake calipers face issues with increased complexity, weight, and manufacturing costs due to the susceptibility of cross-over fluid channels to damage and high stresses, leading to brake failure from vaporization of brake fluid.
Innovation Solution
A brake caliper design featuring a channel that connects hydraulic circuits at different longitudinal positions, located in areas less susceptible to stress and heat, with optional cooling ducts to enhance heat transfer and reduce vaporization risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cross-over channel is incorporated in or in close proximity to the bridging portions, then fluid communication between piston chambers is achieved, but the caliper body size, weight and complexity increase to mitigate stress and heat effects
Solution Approach 1:
The cross-over channel is extracted from the high-stress bridging portions and relocated to a different longitudinal position within the caliper body where stress and heat exposure are reduced. This separation allows the channel to function reliably without requiring the caliper body to be oversized or overly complex to protect the channel from vaporization conditions.
2Reliability
If the cross-over channel is incorporated in or in close proximity to the bridging portions, then fluid communication between piston chambers is achieved, but manufacturing and assembly costs increase
Solution Approach 1:
The cross-over channel is extracted from the high-stress bridging portions and relocated to a different longitudinal position within the caliper body where stress and heat exposure are reduced. This separation allows the channel to function reliably without requiring the caliper body to be oversized or overly complex to protect the channel from vaporization conditions.
3Quantity of substance
If the channel is located in high-stress bridging portions, then compact design is achieved, but brake fluid vaporization and brake failure occur
Solution Approach 1:
The cross-over channel is extracted from the high-stress bridging portions and relocated to a different longitudinal position within the caliper body where stress and heat exposure are reduced. This separation allows the channel to function reliably without requiring the caliper body to be oversized or overly complex to protect the channel from vaporization conditions.
Solution Approach 2:
The patent introduces an intermediary cooling duct system that mediates between the high-stress bridging portions and the cross-over channel. The cooling duct delivers cooling air to reduce temperatures in the channel region, preventing brake fluid vaporization even when the channel is positioned in areas subject to thermal exposure.
4Reliability
If external cross-over pipe is used to join piston chamber channels, then fluid communication is achieved, but susceptibility to damage and leaks increases
Solution Approach 1:
The cross-over channel is merged with the caliper body structure itself, forming an integral part of the caliper rather than being a separate external component. This integration eliminates the need for external pipes and their associated fittings, thereby removing susceptibility to external damage and leaks while maintaining reliable fluid communication between piston chambers.
Solution Approach 2:
The caliper body is designed to serve multiple functions: it provides structural support, houses the piston chambers, and incorporates the cross-over channel for fluid communication. This multi-functionality eliminates the need for separate external piping components, reducing the number of potential failure points.
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
The design improves stiffness, reduces weight, and enhances resistance to failure while maintaining cost-effectiveness by positioning the fluid channel away from high-stress areas and incorporating cooling to prevent brake fluid vaporization.
Implementation Method 1
a cooling duct may be provided adjacent or over or surrounding the region in which the channel is located, e.g. to further enhance the benefits of the invention. Some known caliper designs include cooling ducts located in this general region to transfer cooling air across the void between spaced limbs and directed towards the outboard piston and cylinder assemblies
Data Source
Figure 1~3
Figure 4~6
Figure 7~8
AI summary
A brake caliper (1) including a caliper body (2) with a pair of spaced limbs(3), a pair of end bridging members (4) each joining together a respective end of each limb(3) and an intermediate bridging portion (5) between the bridging members (4) and joining together a respective intermediate portion of each limb(3).Each limb (3) includes a hydraulic circuit (30) including fluidly connected hydraulic cylinders (31a, 31b, 31c) within which respective pistons (6a, 6b, 6c) are received. The hydraulic circuits (30) are fluidly connected together by a fluid channel (7). Part of the fluid channel (7) is formed in the intermediate bridging portion (5) and extends diagonally across the space between the limbs (3) and between the bridging members(4).