Disc Brake Caliper Body Structure for High Rigidity at Lower Weight
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Solution Overview
Problem
Existing disc brake caliper bodies face challenges in achieving high structural rigidity while minimizing weight and dimensions, which is crucial for both racing and sports vehicles, as well as being adaptable for multiple applications without increasing complexity or weight, leading to unsatisfactory performance and increased production costs.
Innovation Solution
A simplified caliper body design with symmetrically arranged connecting housings and central bridges that reduce radial thickness and incorporate reinforcement elements, allowing for high performance across various applications with reduced production costs and adaptable geometry for different wheel positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the caliper body is made extremely rigid to maintain acceptable deformation values during braking, then braking performance and structural stability are improved, but the dimensions and weight of the caliper body increase
Solution Approach 1:
The caliper body is divided into two separate semi-calipers (first and second semi-calipers) that are joined together. Each semi-caliper contains one elongated element, and they are connected through connecting elements (bolts, screws, or integrated connections) at the bridges. This segmentation allows each half to be optimized independently while achieving the required structural rigidity when assembled, reducing the overall weight compared to a single monobloc design with equivalent stiffness.
Solution Approach 2:
The caliper body utilizes composite construction by joining two semi-calipers made of lightweight materials (such as aluminum or aluminum alloys) through mechanical fastening or integrated connections. This composite approach enables the achievement of high structural rigidity through the combined structure while maintaining lower weight compared to a solid monobloc design, as the joining elements can be optimized for both strength and weight reduction.
2Stability of the object's composition
If the caliper body dimensions are increased to improve structural rigidity, then deformation during braking is reduced, but the caliper becomes larger and heavier
Solution Approach 1:
By segmenting the caliper into two separate semi-calipers connected by bridges and connecting elements, the design achieves structural stability through the distributed connection points and optimized geometry of each half. This segmentation allows for a more efficient use of material, reducing the overall volume required to achieve the same braking stability compared to a solid monobloc design, as the connecting elements create a stable structure without requiring excessive material in any single location.
3Ease of manufacture
If a monobloc caliper body design is used to simplify construction, then manufacturing is easier, but weight and dimensions increase
Solution Approach 1:
The caliper is designed as two separate semi-calipers that can be manufactured independently using standard manufacturing processes for each half. This segmentation allows each semi-caliper to be produced with optimized geometry and material usage, reducing the weight of each component. The final assembly through connecting elements maintains structural integrity while enabling weight reduction compared to a monobloc design, and the modular approach can actually simplify certain manufacturing aspects by allowing independent optimization of each half.
4Strength
If reinforcement elements are added to increase structural rigidity, then braking performance is improved, but device complexity and production costs increase
Solution Approach 1:
The segmentation of the caliper into two semi-calipers with connecting elements creates inherent structural reinforcement at the connection points (bridges). These connecting elements serve as reinforcement structures that provide the necessary rigidity without requiring additional separate reinforcement components. The design achieves enhanced structural strength through the segmented architecture itself, reducing device complexity compared to adding separate reinforcement elements to a monobloc design.
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 solution enables high braking performance with reduced weight and dimensions, facilitating multiple applications and lower production costs, making high-performance braking accessible to a broader market segment while maintaining structural integrity and adaptability.
Implementation Method 1
a brake fluid pressure which through a pipe is applied to the brake fluid present in the hydraulic circuit placed inside the caliper body to reach the cylinders where the pressure is applied onto the bottom surface of the pistons, whereby forcing them to be close against the pads
Implementation Method 2
The pressure action of the brake fluid is also applied on the bottom wall of the cylinder, whereby causing a reaction in the caliper body which deforms it away of the disc surfaces
Implementation Method 3
the pads, which in turn abut against the braking surfaces of the disc to apply the braking action on the vehicle
Data Source
AI summary
A caliper body has a first elongated element facing a first braking surface. The first elongated element has first and second ends. The caliper body has a second elongated element facing a second braking surface. The first elongated element has first and second ends of second elongated element. The first ends of first and second elongated elements face each other. The second ends of first and second elongated elements face each other. The first ends of first and second elongated elements are connected by a first end bridge. The second ends of first and second elongated elements are connected by a second end bridge. The first and second elongated elements are connected by a central bridge. The first or second elongated element has two connecting housings for connection to a support for the caliper body in a vehicle.