Brake Piston Footing Design for Uniform Force Distribution
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Solution Overview
Problem
Increasing the braking force in disk brake systems for larger and heavier vehicles is challenging due to issues with uneven wear and operational problems caused by increasing the number of pistons or piston diameter, and high pressure leading to brake pad distortion.
Innovation Solution
A piston design with an extended footing that contacts the brake pad, featuring a load-bearing column and spindle nut configuration to distribute force effectively, preventing relative rotation and ensuring alignment with the brake pad, thus enhancing braking force without distorting the pad.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the number of brake pistons is increased to achieve greater braking force, then the braking force is improved, but the device complexity and risk of uneven wear increase
Solution Approach 1:
The patent merges multiple piston functions into a single piston by providing an extended footing that contacts multiple brake pads simultaneously. This allows one piston to perform the work of multiple pistons, increasing braking force while reducing the number of piston components needed in the system.
Solution Approach 2:
The patent extends the piston footing in a dimensional direction perpendicular to the central axis, allowing the single piston to contact brake pads at multiple locations. This dimensional extension enables one piston to achieve the braking force of multiple pistons without increasing component count.
2Force
If the piston diameter is increased to achieve greater braking force, then the braking force is improved, but the piston width is limited by the brake pad width
Solution Approach 1:
Instead of increasing piston diameter (one dimension), the patent extends the footing in a different dimensional direction - perpendicular to the central axis and parallel to the brake pad surface. This allows the piston to achieve greater braking force without being constrained by brake pad width limitations.
Solution Approach 2:
The patent provides different dimensional characteristics at different parts of the piston - the body maintains a compact diameter while the footing extends in length to contact multiple brake pad locations. This local quality differentiation allows the piston to overcome width limitations while still generating sufficient braking force.
3Force
If high hydraulic pressure is applied to increase braking force, then the braking force is improved, but the brake pad becomes distorted
Solution Approach 1:
The extended footing merges multiple contact points into a single piston structure, allowing the brake force to be distributed across multiple brake pad locations simultaneously. This distribution reduces localized stress concentration that would otherwise cause pad distortion under high pressure.
Solution Approach 2:
The patent changes the geometric parameters of the piston footing - extending its length and adjusting its width - to create a larger contact area with the brake pads. This parameter change allows the same hydraulic pressure to produce greater braking force without exceeding the pressure threshold that causes pad distortion.
4Force
If the piston diameter is increased to achieve greater braking force, then the braking force is improved, but the risk of uneven wear and operational problems increases
Solution Approach 1:
The extended footing merges multiple contact locations into a single integrated structure, ensuring uniform force application across all brake pad contact points. This unified approach prevents the uneven wear and operational problems that arise when multiple separate pistons are used.
Data Source
AI summary
A brake piston is described. The brake piston is configured for use in a disk brake system, the piston comprising: a body having an outside width perpendicular to a central axis; a footing disposed at a distal end of the piston; wherein the footing is configured to exert force on a brake pad during actuation of the disk brake system; the footing having a face configured to contact the brake pad, the face having a length and a width, wherein the length is longer than the outside width of the body, and the length is greater than the width.