Piston Brake Caliper Rotor Web Deflection
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Solution Overview
Problem
Conventional disk brake systems with opposed pistons and deflectable rotors face challenges in efficiently distributing braking force across both sides of the rotor, leading to inconsistent friction and braking performance, especially when one piston is activated, causing uneven wear and potential brake drag or reduced responsiveness.
Innovation Solution
The disk brake system incorporates a first and second brake piston with a nut and spindle mechanism that extends to push the first brake pad against the rotor, deflecting the rotor's web to engage the second brake pad, ensuring balanced friction and force distribution during operation, and includes a pad adjustor with springs to maintain optimal gap settings between pads and pistons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If one piston is activated in a conventional disk brake system, then braking force is applied to one side of the rotor, but uneven wear and brake drag occur due to inconsistent friction distribution
Solution Approach 1:
The brake system is segmented into two independent piston assemblies, each capable of independent activation. This allows the braking force to be distributed across both sides of the rotor through separate piston-brake pad units, ensuring balanced friction application and eliminating the uneven wear and drag problems associated with single-piston activation.
2Reliability
If opposed pistons are used to distribute braking force, then friction distribution improves, but device complexity increases due to additional components
Solution Approach 1:
The caliper assembly merges the piston, brake pad, and mounting bracket into an integrated opposed-piston unit. This combination reduces the number of separate components and simplifies the overall caliper structure while maintaining the balanced friction distribution benefits of having pistons on both sides of the rotor.
3Productivity
If the rotor is made deflectable at the web to move contact surfaces, then braking force distribution improves, but manufacturing precision requirements increase
Solution Approach 1:
The rotor web is designed with specific geometric parameters and material properties that enable controlled deflection under braking load. By optimizing the web thickness, curvature, and material modulus, the system achieves the desired contact surface movement and force distribution without requiring extremely tight manufacturing tolerances, thus balancing performance with manufacturability.
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 configuration enhances braking efficiency by ensuring balanced force distribution across both sides of the rotor, reducing wear and maintaining responsiveness, while the pad adjustor compensates for wear, preventing brake drag and maintaining optimal brake performance.
Implementation Method 1
the disk brake system can press brake pads against opposite contact surfaces of a brake rotor in order to increase friction to cause a braking effect
Implementation Method 2
upon operation of the brake system in a first operation mode, the first brake piston moves the second contact surface toward the second brake piston by deflection of the rotor at the web
Implementation Method 3
a nut in communication with an interior of the first brake piston; and a spindle in threaded communication with the nut; wherein upon rotation of the spindle, a thread position of the spindle changes in relation to the nut, extending the nut so as to push the first piston toward the second piston
Implementation Method 4
a pad adjustor with springs to maintain optimal gap settings between pads and pistons
Data Source
AI summary
Brake systems and methods of their operation are disclosed, including a brake system comprising: a rotor comprising: a hub configured for attachment to a vehicle; and a first and a second contact surfaces; and a web connecting the first and second contact surfaces to the hub; a first and a second brake pad located adjacent to the respective first and second contact surfaces of the brake rotor, wherein the first and the second brake pads are configured to press on the respective first and second contact surfaces during operation of the brake system; a first brake piston configured to push the first brake pad against the first contact surface of the rotor during operation of the brake system; wherein upon operation of the brake system in a first operation mode, the first piston moves the second contact surface toward the second piston by deflection of the rotor at the web.