Brake Caliper Thrust Structure for Heat Dissipation and Rigidity
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Solution Overview
Problem
Conventional brake calipers face challenges in maintaining structural rigidity while effectively managing heat accumulation during braking, leading to potential overheating and reduced performance, especially in high-performance applications where heat evacuation is complex and weight reduction is crucial.
Innovation Solution
The introduction of a brake caliper thrust device with increased heat exchange surfaces and ventilation features, such as heat dissipation elements and air passage openings, to enhance thermal resistance and reduce working temperatures without compromising structural integrity or increasing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the caliper body is made with a single casting to reduce the number of parts, then the structural rigidity is improved, but the heat exchange surface area is reduced leading to poor heat evacuation
Solution Approach 1:
The caliper body is divided into multiple separate casting pieces (first caliper body piece, second caliper body piece, etc.) that are assembled together. This segmentation allows each piece to be optimized for both structural strength and heat exchange surface area, with protruding portions and recesses creating extended surfaces for thermal management while maintaining overall rigidity through the assembled structure.
2Temperature
If the caliper body is designed with extensive ventilation openings to improve heat evacuation, then the heat exchange performance is improved, but the structural rigidity is reduced
Solution Approach 1:
Ventilation openings and heat exchange features are strategically placed in specific local regions of the caliper body where they provide maximum thermal benefit with minimum structural compromise. The protruding portions and recesses create localized heat exchange surfaces in areas optimized for thermal management, while maintaining structural integrity in load-bearing regions.
3Weight of moving object
If the caliper body is made from lightweight material to reduce unsprung mass, then the weight is reduced, but the heat resistance and structural strength are compromised
Solution Approach 1:
The caliper body utilizes composite construction with multiple material properties distributed throughout the structure. Different portions of the caliper body can be made from materials optimized for specific functions - lightweight materials in non-critical areas and heat-resistant, high-strength materials in regions requiring thermal and mechanical performance, achieving a balance between weight reduction and heat resistance.
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 solution improves heat exchange performance, reduces caliper body temperature, and increases thermal resistance, thereby preventing overheating and maintaining structural rigidity, while allowing for efficient heat evacuation and reduced weight.
Implementation Method 1
at least one heat dissipation element (10) protruding into said internal cavity (6) adapted to increase the extension of said at least one internal surface (8) to evacuate the heat accumulated by said at least one wall (9, 31) of the thrust device (1)
Implementation Method 2
evacuate the heat accumulated by said at least one wall (9, 31) of the thrust device (1)
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A brake caliper thrust device (1) for a disc brake comprising a thrust device body (4), adapted to be translated inside a guide device (5); said thrust device body (4) defining an internal cavity (6) at least partially open and facing towards the object to be pushed, for example a brake pad (7) associable with the thrust device (1); said internal cavity (6) being delimited by at least one internal surface (8) defined by at least one wall (9, 31) of the thrust device (1); wherein, from said at least one wall (9, 31) of the thrust device (1), at least one heat dissipation element (10) protrudes into said internal cavity (6), adapted to increase the extension of said at least one internal surface (8) to evacuate the heat accumulated by said at least one wall (9, 31) of the thrust device (1).