Brake Caliper Assembly with Segmented Support Structure
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Solution Overview
Problem
Existing disc brake systems for terrestrial vehicles face challenges in combining the characteristics of fixed and floating caliper systems, including heat dispersion, ease of dismantling, and torsional stress management, while maintaining high braking force and resistance to impacts.
Innovation Solution
A brake caliper assembly with a support structure that includes a connecting arm and strut element, allowing for flexible positioning and dimensions, improved heat dispersion, and simplified wheel dismantling without removing the caliper, while minimizing torsional stresses through a neutral axis force discharge and modular design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a fixed caliper system is used, then high braking force and resistance to impacts are achieved, but heat dispersion capacity is insufficient and the system is rigidly attached to the chassis
Solution Approach 1:
The caliper is divided into two independent halves (first half and second half) that can move relative to each other along the neutral axis. This segmentation allows each half to independently dissipate heat while maintaining the overall structural strength needed for high braking force.
Solution Approach 2:
A strut element acts as an intermediary component connecting the first and second caliper halves, allowing them to move independently while maintaining connection. This mediator enables heat dispersion through relative motion while preserving the structural integrity for high braking force.
2Temperature
If a floating caliper system is used, then heat dispersion is improved and the caliper can move to compensate for wear, but braking force and resistance to impacts are reduced
Solution Approach 1:
The caliper design combines features of both fixed and floating caliper systems into a single universal structure. The two halves can move relative to each other like a floating caliper for heat dispersion, while the overall rigid attachment to the fork provides the stability and braking force characteristics of a fixed caliper.
3Device complexity
If traditional caliper systems are used, then the caliper structure is complex and requires removal for wheel dismantling, but the invention simplifies the structure and allows easy wheel removal
Solution Approach 1:
The caliper is segmented into two independently movable halves connected by a strut element, creating a simpler modular structure. This segmentation allows the wheel to be removed without detaching the entire caliper assembly from the fork, as the caliper halves can remain in place while the wheel is detached from the hub.
4Strength
If a rigid caliper attachment is used, then resistance to impacts is improved, but torsional stresses on the caliper during braking increase
Solution Approach 1:
The caliper transitions from a completely rigid structure to a semi-dynamic structure where the two halves can move relative to each other along the neutral axis. This dynamic capability allows the caliper to absorb torsional stresses through controlled movement while maintaining overall rigidity for impact resistance.
Solution Approach 2:
The caliper halves are positioned asymmetrically with respect to the neutral axis, allowing differential movement that specifically addresses torsional stresses during braking while maintaining symmetric braking force application on the disc.
Data Source
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AI summary
A brake caliper assembly and an associated support structure comprises an external casing, a pair of brake pads connected and capable of being actuated by actuating means in order to impart braking force on the disc and comprising respective support elements and a layer of friction material. The support structure comprises a connecting arm that connects the caliper to the fork and a strut element capable of being subjected to compression or traction that extends between the support elements and a fixing portion provided on the fork and is connected to the support elements by means of a connecting element separate and independent from the external casing.