Disc Brake Caliper End Cap With Hidden Tool Engagement
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Solution Overview
Problem
Disc brake calipers for human-powered vehicles often have visible tool engagement structures, which detract from their appearance and make them less aesthetically appealing, while also potentially compromising the cleanliness and consistency of the hydraulic chamber.
Innovation Solution
A disc brake caliper design featuring a single main body with a hydraulic cylinder bore and an end cap that closes the hydraulic chamber, where the end cap has a continuous even exterior surface, eliminating visible tool engagement structures and allowing for a seamless appearance through surface treatments like anodic oxide coating or paint layers, and incorporating a sealing bolt with fluid bores for efficient fluid passage and strong braking power.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If tool engagement structures are provided on the end cap for forming the hydraulic chamber, then the hydraulic chamber can be formed, but the appearance becomes dirty and unattractive with visible seams and tool marks
Solution Approach 1:
The end cap is divided into a body portion and a separate closing portion that is inserted into the body portion. The closing portion forms the hydraulic chamber when inserted, eliminating the need for tool engagement structures on the external surface. This segmentation allows the hydraulic chamber to be formed internally without compromising the clean external appearance.
2Shape
If the end cap has a continuous even exterior surface for clean appearance, then aesthetics improve, but the hydraulic chamber must be formed differently
Solution Approach 1:
The closing portion is nested within the body portion of the end cap. The closing portion is inserted into a cavity in the body portion, and its outer surface forms the hydraulic chamber. This nesting arrangement allows the exterior surface to remain continuous and even while still providing the necessary hydraulic chamber formation through the internal geometry of the nested 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
The design provides a clean and attractive appearance, enhances braking power by utilizing a pair of hydraulic chambers, and ensures secure fluid retention, while maintaining a low profile and easy mounting to human-powered vehicles.
Implementation Method 1
the surface treatment includes an anodic oxide coating
Implementation Method 2
the surface treatment includes a paint layer that covers an external seam line
Implementation Method 3
a second hydraulic fluid passage in fluid communication with the first hydraulic fluid passage via the first and second fluid bores of the sealing bolt
Data Source
AI summary
A disc brake caliper is basically provided with a single main body and an end cap. The single main body includes a hydraulic cylinder bore partially defining a hydraulic chamber having a cylinder axis and an end bore disposed along the cylinder axis. The end cap is coupled to the single main body in the end bore so as to close the hydraulic chamber. The end cap has an exterior surface that is free of a tool engagement structure.