Brake Caliper Piston Bush Structure for Low Residual Drag
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Solution Overview
Problem
The increasing diversity in vehicle parameters and stringent emission requirements lead to higher development costs and complexities in manufacturing automobile brake calipers, as traditional designs struggle to balance hydraulic performance and drag moment, especially with varying cylinder diameters.
Innovation Solution
An anti-drag structure for automobile brake calipers featuring a brake caliper body with a piston bush and step ring grooves, utilizing a rubber seal ring and phenolic resin PF ring for elastic deformation and hydraulic stability, combined with a high-strength aluminum alloy and anodic oxidation for improved wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional brake caliper designs are used with different cylinder diameters for different vehicle parameters, then the brake performance can be matched to different vehicles, but the manufacturing complexity increases and production costs rise
Solution Approach 1:
The brake caliper is divided into modular components: a standardized caliper body and interchangeable piston assemblies (piston + seal ring + dust boot). The piston assembly can be replaced as a unit to accommodate different cylinder diameters and brake performance requirements, while the main caliper body remains unchanged. This segmentation allows different vehicle parameters to be satisfied through component interchange rather than redesigning the entire caliper.
Solution Approach 2:
The caliper body is designed with universal features that can accommodate multiple piston diameters through the standardized mounting structure and piston assembly interface. The same caliper body can serve multiple vehicle models and brake specifications by simply changing the piston assembly, achieving multi-functionality and reducing manufacturing complexity.
2Device complexity
If traditional seal ring designs are used under high hydraulic pressure conditions, then the brake caliper structure is simple, but the residual drag moment increases and emission requirements are not met
Solution Approach 1:
The seal ring material parameters are changed by selecting rubber compounds with specific elasticity and pressure-resistant properties. The dust boot material parameters are optimized to provide appropriate friction characteristics. These parameter changes allow the seal system to maintain low drag moment under high hydraulic pressure (exceeding 3 Mpa) while keeping the overall caliper structure relatively simple.
Solution Approach 2:
The brake claw uses composite material construction combining metal structure with rubber or polymer coatings. This composite approach reduces friction and drag moment while maintaining structural strength, allowing the caliper to meet emission requirements without significantly increasing structural complexity.
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 enhances the generality and reduces production costs by accommodating different cylinder diameters, decreases residual drag moment, and lowers fuel consumption, while improving brake performance and safety.
Implementation Method 1
uses the rubber seal ring that is made of rubber and can elastically deform under pressure
Implementation Method 2
the phenolic resin PF ring is linearly compressed and elastically deforms in a stepped mode
Implementation Method 3
the phenolic resin PF ring is linearly compressed and elastically deforms in a stepped mode
Implementation Method 4
the brake caliper body is an aluminum alloy part, and the outer surface of the brake caliper body is attached with an anodic oxidation layer
Data Source
AI summary
The present invention relates to an anti-drag structure of automobile brake calipers, comprising a brake caliper body which is provided with a cylinder bore and a brake claw arranged along the axis of the cylinder bore in an extending mode; and a cylindrical piston bush is pressed in the cylinder bore by interference fit, a step ring groove is formed in the inner wall of the piston bush and composed of a major diameter ring groove and a minor diameter ring groove which have rectangular sections. The present invention can improve the generality of the brake caliper body through the arrangement of the piston bush and improve the standardization of production manufacturing of brake calipers, and can reduce the residual drag moment of the brake caliper and the fuel consumption with the rubber seal ring and the phenolic resin PF ring to achieve the purpose of emission reduction.