Multi-Part Brake Caliper Hollow Section for Wear and Noise Reduction

Solution Overview

Problem

Existing brake calipers experience uneven wear and noise due to elastic deformation during braking, and their one-piece metallic design restricts design improvements for better deformation characteristics and production costs.

Innovation Solution

A multi-part brake caliper design where the first part is a metal-casted piston side and the second part is a sheet metal finger side with a hollow section, allowing for independent production and optimization of deformation characteristics through different materials and manufacturing methods, and secured by mechanical connection or welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a one-piece metallic brake caliper is used, then structural strength is ensured, but elastic deformation during braking causes uneven wear and noise

Engineering Contradiction:

Improvestructural strengthVSAvoiduneven wear and noise

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The brake caliper is divided into multiple separate parts (first part, second part, third part) that are connected through connecting elements. This segmentation allows each part to deform independently during braking, reducing uneven wear and noise while maintaining overall structural strength through the connecting elements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The brake caliper uses composite construction with different materials for different parts. The first part is made of metal casting, the second part of sheet metal, and connecting elements may be plastic or metal. This composite approach optimizes deformation characteristics for each component while ensuring overall strength.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If a one-piece metallic brake caliper is used, then manufacturing simplicity is maintained, but design flexibility for optimizing deformation characteristics is restricted

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoiddesign flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The brake caliper is divided into multiple separate parts (first part, second part, third part) that are connected through connecting elements. This segmentation allows each part to deform independently during braking, reducing uneven wear and noise while maintaining overall structural strength through the connecting elements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The brake caliper uses composite construction with different materials for different parts. The first part is made of metal casting, the second part of sheet metal, and connecting elements may be plastic or metal. This composite approach optimizes deformation characteristics for each component while ensuring overall strength.

Inventive Principle:

Principle #40Composite materials

3Weight of moving object

If the brake caliper is designed as separate parts, then deformation characteristics can be optimized and weight reduced, but device complexity increases

Engineering Contradiction:

Improvecaliper weightVSAvoidcaliper structure complexity

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The brake caliper is divided into multiple separate parts (first part, second part, third part) that are connected through connecting elements. This segmentation allows each part to deform independently during braking, reducing uneven wear and noise while maintaining overall structural strength through the connecting elements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The second part is made of sheet metal which provides flexibility and weight reduction. The sheet metal construction allows the caliper to absorb deformation energy while maintaining a lightweight structure compared to solid metal casting.

Inventive Principle:

Principle #30Flexible shells and thin films

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 multi-part design reduces weight, optimizes deformation characteristics, and minimizes uneven wear and noise by dissipating deformation energy, while allowing for design flexibility and cost reduction.

Implementation Method 1

The brake caliper may thus elastically deform or, put differently, elastically deflect

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS20230417297A1Multi-part brake caliper having at least one hollow section

Publication Date: 2023.12.28 HL MANDO CORP

AI summary

The invention concerns a multi-part brake caliper for a vehicle disc brake, the brake caliper comprising:a first part comprising a portion that is arrangeable at a first side face of a brake disc of the vehicle disc brake and that is configured to receive a brake piston;a second part that is formed separately from the first part and comprises a finger portion that is arrangeable at a second side face of the brake disc;wherein the first part is a metal casted part and the second part comprises sheet metal and wherein the second part further comprises at least one at least partially enclosed hollow section.