Brake Caliper Mounting Bracket for Higher Rigidity
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Solution Overview
Problem
Existing brake caliper mounting assemblies in vehicles face issues with flexing and uneven brake forces due to the lack of adequate rigidity in the steering knuckle-brake caliper connection, leading to uneven brake wear and reduced braking precision.
Innovation Solution
The proposed brake caliper mounting assembly secures the steering knuckle on both inward and outward sides of its lugs using a caliper bracket and support brackets, with strategically designed thicknesses and through-holes to reduce flexing and increase rigidity, allowing the brake caliper to be positioned closer to the rotor for better pad engagement and heat distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a caliper bracket is used to space the brake caliper further away from the steering knuckle, then the brake kit can be installed with bigger discs/rotors and calipers, but the rigidity of the steering knuckle-brake caliper connection is reduced causing flexing and uneven brake forces
Solution Approach 1:
The caliper bracket is divided into multiple segments: a main body portion, a first support bracket extending from it, and a second support bracket extending from it. This segmentation allows each part to perform a specific function - the main body provides structural support while the extended support brackets create additional attachment points to the steering knuckle, thereby distributing loads and maintaining connection rigidity even with larger brake components
Solution Approach 2:
The support brackets extend in multiple directions (first support bracket in one direction, second support bracket in another direction) from the main body, creating a three-dimensional bracing structure. This multi-dimensional arrangement provides enhanced structural stability and resistance to flexing compared to a simple single-direction bracket, allowing larger brake calipers to be mounted while maintaining connection rigidity
2Adaptability or versatility
If the brake caliper is positioned further from the steering knuckle using a caliper bracket, then bigger brake components can be installed, but uneven brake forces and brake wear occur due to flexing
Solution Approach 1:
The caliper bracket is divided into multiple segments: a main body portion, a first support bracket extending from it, and a second support bracket extending from it. This segmentation allows each part to perform a specific function - the main body provides structural support while the extended support brackets create additional attachment points to the steering knuckle, thereby distributing loads and maintaining connection rigidity even with larger brake components
Solution Approach 2:
The support brackets extend in multiple directions (first support bracket in one direction, second support bracket in another direction) from the main body, creating a three-dimensional bracing structure. This multi-dimensional arrangement provides enhanced structural stability and resistance to flexing compared to a simple single-direction bracket, allowing larger brake calipers to be mounted while maintaining connection rigidity
Data Source
AI summary
Disclosed herein are embodiments of a brake caliper mounting assembly. The assembly can include a caliper bracket and support brackets which secure a brake caliper and a steering knuckle. The caliper bracket can include a top portion which secures a first arm of the brake caliper to a first lug of the steering knuckle along outward sides thereof, a bottom portion which secures a second arm of the brake caliper to a second lug of the steering knuckle along outwards sides thereof, and a stem extending between the top and bottom portions. The assembly can further include a first support bracket which secures the first arm of the brake caliper to the first lug of the steering knuckle along inward sides thereof and a second support bracket which secures the second arm of the brake caliper to the second lug of the steering knuckle along inward sides thereof.