Brake Caliper Piston Recess Design for Weight Reduction

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Solution Overview

Problem

Existing piston designs for brake calipers are heavy and difficult to produce due to the need for material thickening to create a conical surface for mechanical actuation, which complicates the production process and increases weight.

Innovation Solution

A piston design featuring a recess on the outer surface of the piston head, allowing the conical surface to be formed without material accumulation, with a complementary projection on the inner surface, enabling force flow and shape-induced stiffening, and optionally a separate thin-walled cup for the conical surface, reducing dead volume and improving hydraulic rigidity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If material thickening is used to create the conical surface for mechanical actuation, then the conical surface can be formed, but the piston weight increases and production becomes more difficult

Engineering Contradiction:

Improveproduction simplicityVSAvoidpiston weight

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

Instead of adding material to create the conical surface (thickening), the invention removes material by forming a recess in the piston head. This inversion approach creates the conical surface for mechanical actuation without increasing weight, and in fact reduces it compared to traditional thickening methods

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The invention changes the geometric parameters of the piston head by creating a recess with specific dimensions and shape. This allows the conical surface to be formed through material removal rather than addition, optimizing both weight and manufacturability while maintaining the necessary mechanical actuation functionality

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If material thickening is used to create the conical surface, then the conical surface can be formed, but the production process becomes more complex

Engineering Contradiction:

Improveproduction simplicityVSAvoidproduction process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The invention inverts the traditional approach by forming a recess instead of thickening material. This simplifies the production process as the recess can be created in a single forming operation without requiring additional material or complex assembly steps

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The recess is designed with specific geometric segmentation that allows it to be formed independently and integrated into the piston head structure. This modular approach simplifies manufacturing by allowing the recess to be created as a distinct feature rather than requiring complex overall redesign

Inventive Principle:

Principle #1Segmentation

3Weight of moving object

If a recess is formed in the piston head to create the conical surface, then weight is reduced and production is simplified, but the force flow may be affected

Engineering Contradiction:

Improvepiston weightVSAvoidforce flow

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The recess is strategically positioned and shaped to concentrate material in specific areas where strength is needed for force flow, while removing material only where it is not critical. This local optimization maintains necessary structural integrity while achieving weight reduction

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The recess incorporates curved and rounded geometric features that help distribute stress more evenly throughout the piston head structure. The curved transitions in the recess design prevent stress concentration points that would otherwise compromise force flow and structural strength

Inventive Principle:

Principle #14Spheroidality (Curvature)

Data Source

PatentUS8869677B2Piston for a brake caliper of a disc brake

Publication Date: 2014.10.28 CONTINENTAL TEVES AG & CO OHG

AI summary

A piston for a brake caliper of a disc brake constructed as a pot which is open at one end, having a longitudinal axis, a wall, and a piston head. The piston is supported in a cylinder of the brake caliper such that it can be moved along the longitudinal direction, and it can be placed against a brake pad in the region of the piston head by an axial contact surface. When the piston is subjected to pressure by a hydraulic fluid, the piston moves in the cylinder and presses the brake pad against a brake disc. A projection having a conical surface is provided on an inner surface of the piston head. A recess is provided, which is substantially at the same distance from the longitudinal axis as the projection on the inner surface of the piston head, on an outer surface of the piston head.