Brake Caliper Nut Holder Structure for Variable Piston Sizes
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Solution Overview
Problem
The existing brake apparatus for vehicles faces challenges in accommodating varying piston sizes due to size and thickness changes in brake discs, leading to continuous manufacturing costs and inefficiencies in using a single nut unit across different specifications.
Innovation Solution
A brake apparatus design featuring a screw bar, nut unit, and piston unit, where the nut holder is threadedly coupled with the screw bar and includes a contact module section that expands its interval to accommodate varying piston sizes, allowing the nut to push the piston unit effectively, enabling the use of a single nut unit across various piston specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a new specification of nut is fabricated for each variation in piston size and brake disc thickness, then the brake apparatus can accommodate different specifications, but manufacturing costs increase continuously
Solution Approach 1:
The nut unit is designed with a universal structure that can accommodate multiple piston specifications through adjustable components. The contact module section can be adjusted or removed to adapt to different piston sizes and brake disc thicknesses, allowing a single nut unit design to serve multiple functions across different brake caliper specifications without requiring continuous fabrication of new nut specifications.
Solution Approach 2:
The nut holder is designed with movable and adjustable components, particularly the contact module section that can be positioned dynamically to match different piston specifications. This dynamic adjustability allows the same nut unit to adapt to varying piston sizes and brake disc thicknesses, eliminating the need for multiple fixed-specification nut designs.
2Ease of manufacture
If the nut unit is designed to be compact and simple, then manufacturing is easier, but it may not accommodate varying piston sizes effectively
Solution Approach 1:
The nut unit is segmented into distinct functional components: the nut holder, the contact module section, and the piston interaction elements. This segmentation allows the basic nut structure to remain simple and easy to manufacture, while the adjustable contact module can be separately configured to accommodate different piston specifications. The modular segmentation maintains manufacturing simplicity while enabling adaptability.
3Reliability
If the contact module sections are always in contact with the piston unit, then piston movement is controlled, but the interval cannot be expanded to accommodate size variations
Solution Approach 1:
The contact module sections are designed with dynamic positioning capability, allowing them to move between a contact state (for piston movement control) and a retracted state (for accommodating size variations). The interval between contact module sections can be expanded when needed to match different piston dimensions, while maintaining reliable contact when piston control is required, providing both reliability and adaptability.
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 allows for easy adaptation to different piston sizes, reducing manufacturing costs and ensuring efficient operation across various brake caliper specifications by using a common nut unit, facilitating smooth movement and contact with the piston unit.
Implementation Method 1
an electronic parking brake (EPB) of an automobile converts the rotational force of a driving motor into a linear motion using a screw and nut mechanism, thereby pushing a piston
Implementation Method 2
a nut holder which is threadedly coupled with the screw bar, is movable on the nut and is moved toward a pad member by rotation of the screw bar
Implementation Method 3
As the pushed piston presses a brake pad, which is a friction material, against a wheel disc, a braking force is generated
Data Source
AI summary
A brake apparatus for a vehicle includes a screw bar positioned inside a caliper body, and rotated by receiving power of a driving motor; a nut unit including a nut which surrounds the screw bar, and a nut holder which is threadedly coupled with the screw bar, is movable on the nut and is moved toward a pad member by rotation of the screw bar; and a piston unit surrounding the nut unit, and pressing the pad member, wherein the nut holder is brought into contact with the piston unit while being moved toward the pad member, and moves the nut such that the nut pushes the piston unit.