Brake Caliper Piston Driver With PTFE Bearing Face

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Solution Overview

Problem

The existing electromechanical disc brake systems have a complex structure and high manufacturing costs due to the use of ball thrust bearings and additional anti-friction washers, which are costly and complex to produce.

Innovation Solution

Eliminating the ball thrust bearing and applying a fluoropolymer anti-friction coating directly on the bearing face of the drive member reduces the number of components and manufacturing costs, using a one-piece stirrup with a central hole coated on both sides for reduced friction and improved performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ball thrust bearings and additional anti-friction washers are used, then friction is reduced and operational reliability is improved, but manufacturing cost and device complexity increase

Engineering Contradiction:
Improveoperational reliabilityVSAvoiddevice complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the anti-friction function into the existing ball thrust bearing by coating its surfaces with PTFE, eliminating the need for separate anti-friction washers. This merging reduces component count and assembly complexity while maintaining the low-friction operational reliability that both components previously provided separately.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent applies a PTFE coating to the ball thrust bearing surfaces, creating a low-cost, easily applied anti-friction layer that replaces expensive specialized washers. The coating provides durable anti-friction properties at minimal cost, effectively substituting for more complex and expensive anti-friction components.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

2Object-generated harmful factors

If ball thrust bearings and anti-friction washers are used, then friction is reduced, but manufacturing cost increases

Engineering Contradiction:
ImprovefrictionVSAvoidmanufacturing cost
Core Design Contradiction:
Object-generated harmful factorsVSEase of manufacture

Solution Approach 1:

The patent uses PTFE coating, a cost-effective material that can be applied directly to the ball thrust bearing surfaces through standard coating processes. This eliminates the need for expensive specialized anti-friction washers while maintaining low friction, significantly reducing manufacturing costs.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

By integrating the anti-friction function into the existing ball thrust bearing through coating, the patent eliminates separate anti-friction washers and their associated manufacturing and assembly costs, reducing overall manufacturing complexity and expense while maintaining friction reduction.

Inventive Principle:
Principle #5Merging (Combining)

3Object-generated harmful factors

If multiple separate anti-friction components are used, then friction is reduced, but the number of components and assembly complexity increase

Engineering Contradiction:
ImprovefrictionVSAvoidnumber of components
Core Design Contradiction:
Object-generated harmful factorsVSQuantity of substance

Solution Approach 1:

The patent merges the anti-friction function into the ball thrust bearing itself by coating its surfaces with PTFE, eliminating the need for separate anti-friction washers. This reduces the total number of components while maintaining the friction reduction achieved by having multiple anti-friction elements.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The ball thrust bearing is given multiple functions: it provides both the mechanical support and friction reduction previously requiring separate components. The PTFE-coated bearing surfaces perform the anti-friction function that would otherwise require dedicated washers, making the bearing a multi-functional component.

Inventive Principle:
Principle #6Universality (Multi-functionality)

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 solution reduces manufacturing costs by eliminating expensive ball thrust bearings and washers, while maintaining low friction through the use of a fluoropolymer coating, enhancing the operational efficiency and longevity of the brake system.

Implementation Method 1

applying a fluoropolymer anti-friction coating directly on the bearing face of the drive member reduces the number of components and manufacturing costs, using a one-piece stirrup with a central hole coated on both sides for reduced friction

Methodology Applied
Scientific EffectAnti-friction coating (fluoropolymer/PTFE): Polytetrafluoroethylene (PTFE)

Data Source

PatentEP3551905B1Driver for electromechanical brake caliper piston, comprising a non-friction face
Publication Date: 2022.03.30 HITACHI ASTEMO FRANCE
  • EP3551905B1 patent drawingFigure 1~2

AI summary

The invention relates to an electromechanical brake (1) caliper (2) comprising a caliper body (3) comprising a housing (7) containing a piston (8) and a member (11) for driving a mechanism (9) for moving said piston (8). The driving member (11) comprises a threaded body (17) and a head (21) comprising a face (23) supported on a bottom (22) of the housing (7), said supported face (23) being provided with a non-friction coating.