Opposed-Piston Brake Caliper Side Bridge Structure for Rigidity and Weight
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Solution Overview
Problem
Existing opposed piston type disc brake devices face challenges in achieving both sufficient rigidity and weight reduction, which are essential for improving fuel efficiency and traveling performance.
Innovation Solution
The caliper design includes an inner body, an outer body, and side bridges with specific structural features such as concave portions, first beam portions, and second beam portions, which enhance rigidity while allowing for weight reduction through optimized material distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the side bridges are made with sufficient material and solid structure to ensure rigidity, then the braking force stability is improved, but the weight of the caliper increases
Solution Approach 1:
The side bridges incorporate a porous inner core portion with controlled porosity (30-70%) that provides structural rigidity while significantly reducing material usage and weight. The porous structure maintains necessary mechanical strength through its geometric configuration while allowing weight reduction compared to solid structures.
Solution Approach 2:
The side bridges use a composite structure combining an outer shell portion (solid or near-solid material) with an inner core portion (porous material). This composite approach allows the outer shell to provide structural integrity and mounting attachment points while the porous inner core contributes to rigidity with minimal weight, achieving both strength and weight reduction goals.
2Stability of the object's composition
If solid side bridges are used to ensure rigidity, then braking force stability is maintained, but fuel efficiency and traveling performance deteriorate due to increased weight
Solution Approach 1:
The porous inner core portion reduces caliper weight while maintaining sufficient rigidity through optimized porosity (30-70%). This weight reduction directly improves fuel efficiency and traveling performance, while the porous structure's geometric design ensures braking force stability is maintained during operation.
Solution Approach 2:
The composite structure of outer shell + porous inner core achieves optimal balance between rigidity and weight. The outer shell provides structural framework and mounting points, while the porous core reduces weight for improved fuel efficiency, yet maintains enough rigidity to ensure stable braking force transmission.
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 design effectively maintains the necessary rigidity to ensure a desired braking force while achieving weight reduction, thereby improving the overall performance and efficiency of the disc brake system.
Implementation Method 1
the inner core portion is formed in a porous structure in which a large number of holes are formed three-dimensionally in the inner core portion
Implementation Method 2
a caliper comprising: a pair of side bridges disposed so as to cover a rotor
Implementation Method 3
when rigidity of the side bridges connecting the inner body and the outer body in the axial direction is not sufficient, the inner body and the outer body may be elastically deformed in directions away from each other
Data Source
AI summary
There is provided a caliper for an opposed piston type disc brake including: an inner body including a pair of attachment boss portions; an outer body; and a pair of side bridges connecting, in the axial direction, end portions of the inner body on both outer sides in the circumferential direction and end portions of the outer body on both outer sides in the circumferential direction. At least one of the pair of side bridges includes a concave portion extending in the axial direction and opening to an outer surface of the side bridge, and a first beam portion and a second beam portion disposed so as to sandwich the concave portion from both sides, end portions of the respective first beam portion and the second beam portion on the inner side in the axial direction being connected to the attachment boss portions.