Brake Caliper Bridge Rib Structure for High Rigidity and Cooling
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Solution Overview
Problem
Existing disc brake calipers face challenges in achieving high structural rigidity while minimizing weight and size, leading to increased deformation and pedal travel, which affects braking responsiveness and vehicle performance, especially in racing vehicles.
Innovation Solution
A caliper body design featuring a central bridge with bridge ribs and reinforcing elements, forming trenches and through-windows for improved rigidity and ventilation, allowing for a lightweight and rigid structure with reduced deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the caliper body is made with a monolithic structure comprising two elongated elements connected by bridges, then structural rigidity is improved, but weight and size increase
Solution Approach 1:
The caliper body is divided into multiple elongated elements (first and second elongated elements) connected by bridges, creating a segmented structure that reduces material usage and weight while maintaining structural rigidity through the bridge connections
Solution Approach 2:
Reinforcing elements are strategically placed in specific locations within the caliper body, such as in the bridges and at critical stress points, to provide localized strength enhancement without requiring the entire structure to be heavier
2Strength
If the caliper body is made with a monolithic structure comprising two elongated elements connected by bridges, then structural rigidity is improved, but the caliper size increases
Solution Approach 1:
The caliper body is divided into multiple elongated elements (first and second elongated elements) connected by bridges, creating a segmented structure that reduces material usage and weight while maintaining structural rigidity through the bridge connections
Solution Approach 2:
The design utilizes three-dimensional spatial arrangement of the elongated elements and bridges, optimizing the configuration in multiple dimensions to achieve high rigidity within a compact volume
3Strength
If the caliper body is made with a monolithic structure comprising two elongated elements connected by bridges, then structural rigidity is improved, but deformation and pedal travel increase
Solution Approach 1:
Reinforcing elements are strategically placed in specific locations within the caliper body, such as in the bridges and at critical stress points, to provide localized strength enhancement without requiring the entire structure to be heavier
Solution Approach 2:
The caliper body incorporates reinforcing elements that may be made of different materials or have different structural properties than the main caliper body material, creating a composite structure that optimizes both rigidity and deformation characteristics
Data Source
AI summary
A caliper body has a first elongated vehicle-side element, a second elongated wheel-side element, a central caliper bridge connecting the first elongated vehicle-side element to the second elongated wheel-side element and having a first bridge end portion, a central bridge portion extending between the first elongated vehicle-side element and the second elongated wheel-side element, and a second bridge end portion. The first and second bridge end portions respectively connect the central bridge portion to the first elongated vehicle-side element and the second elongated wheel-side element. The central caliper bridge has a pair of bridge ribs forming a trench therebetween and extending seamlessly running along the first bridge end portion, forming a pair of first end rib portions, the central bridge portion, forming a pair of central rib portions, and the second bridge end portion, forming a pair of second end rib portions. The first and second end rib portions respectively form a pair of first and second end elbows.