Deformable Brake Piston Cap for Uniform Pressure Plate Loading
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Solution Overview
Problem
Existing piston cap designs in wheel brake systems concentrate stress on the pressure plate during compression, leading to wear and damage, particularly due to non-uniform force distribution, which can result in premature failure and reduced operational life.
Innovation Solution
A piston cap with a cap face that deforms to distribute compression forces more evenly across the pressure plate, featuring a convex surface that reduces curvature upon contact, thereby reducing stress concentrations and preventing buckling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a rigid piston cap is used to transmit compression force, then the compression force is transmitted efficiently, but stress concentrations occur on the pressure plate leading to wear and damage
Solution Approach 1:
The piston cap incorporates a convex spherical surface that deforms under compression to distribute force evenly across the pressure plate, eliminating stress concentrations while maintaining efficient power transmission
2Stability of the object's composition
If a rigid piston cap is used to maintain structural stability, then the piston cap remains stable during operation, but the cap face cannot adapt to the pressure plate surface leading to non-uniform force distribution
Solution Approach 1:
The piston cap transitions from a static rigid structure to a dynamic deformable structure that adapts its shape during compression, allowing the cap face to conform to the pressure plate surface for uniform force distribution while maintaining overall structural stability
3Object-affected harmful factors
If a deformable piston cap is used to distribute force evenly, then stress concentrations are reduced, but the piston cap may buckle under high compression loads
Solution Approach 1:
The convex spherical surface geometry provides inherent buckling resistance through its curved structure, which naturally distributes compressive loads throughout the entire cap body, preventing localized instability while maintaining force distribution benefits
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 deformation of the piston cap ensures a more uniform stress profile on the pressure plate, reducing wear and damage, and extending the operational life of brake system components by distributing forces more effectively.
Implementation Method 1
The cap face is configured to deflect upon compression against the pressure plate, such that the cap face distributes the compression force more evenly on the contact surface of the pressure plate
Data Source
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AI summary
In some examples, a brake system includes a piston configured to cause a compression of a disc stack. The piston includes a piston body configured to compress a cap face of a piston cap against a pressure plate to cause the compression of the disc stack. The cap face may define a convex surface. The piston cap may be configured such that the convex surface reduces it curvature when the cap face is compressed against the pressure plate. In examples, the piston cap is configured to elastically deform to cause the cap face to reduce the curvature when the cap face is compressed against the pressure plate.