Brake Device Piston Protection via Segmentation
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Solution Overview
Problem
Conventional brake devices face issues such as increased volume and weight, high manufacturing costs, and potential damage to the piston due to deformation and external forces, which affect performance and reliability.
Innovation Solution
A brake device design featuring a pad propulsion part with a conversion assembly that converts rotational motion into linear motion, where the piston is located outside the cylinder part, and a seal system with grooves and a boot to reduce contact and improve return characteristics, weight, and surface pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the piston is accommodated inside the caliper body, then the piston is protected from external damage, but the volume and weight of the device increase
Solution Approach 1:
The caliper body is divided into a fixed part and a movable part. The piston is accommodated in the movable part that can move relative to the fixed part, allowing the piston to be protected during non-operational states while enabling compact overall design.
Solution Approach 2:
The piston accommodation space is created through dimensional design where the movable part can translate along the braking force direction, providing protection in one dimension while maintaining compactness in other dimensions.
2Reliability
If the piston is accommodated inside the caliper body, then the piston is protected from external damage, but the manufacturing cost increases
Solution Approach 1:
The caliper body is segmented into fixed and movable parts that can be manufactured separately using standard casting or machining processes, then assembled together. This reduces manufacturing complexity and cost compared to creating a single complex housing.
Solution Approach 2:
The movable part serves multiple functions: it accommodates the piston, provides protection when retracted, and enables the braking action when extended. This multi-functionality reduces the need for additional protective components, lowering overall manufacturing cost.
3Stability of the object's composition
If the caliper body is deformed due to long-term use, then the piston may receive external force, but the piston moving direction is constrained by the caliper body space
Solution Approach 1:
The movable part can dynamically adjust its position along the braking force direction. When the caliper body deforms, the movable part can shift to accommodate the deformation while maintaining proper piston alignment, preventing external forces from damaging the piston.
Solution Approach 2:
The movable part acts as an intermediary between the fixed caliper body and the piston. It absorbs and compensates for deformations in the fixed part, protecting the piston from receiving harmful external forces while maintaining the constrained movement necessary for braking operation.
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 design reduces the risk of piston damage, enhances return properties, improves surface pressure on the brake pad, and decreases the weight and manufacturing cost of the brake device.
Implementation Method 1
The conversion assembly may include a bolt screw rotating around an axis, a moving nut coupled to a helix of the bolt screw, wherein the moving nut moves in a direction of the cylinder part by rotation of the bolt screw.
Data Source
AI summary
A brake device includes a brake pad, a pad propulsion part connected to the brake pad and configured to move the brake pad linearly, and a caliper body including a cylinder part on which the pad propulsion parti is accommodated. The pad propulsion part includes a conversion assembly converting rotation motion into linear motion, and a piston connected to one end of the conversion assembly, the conversion assembly is accommodated inside the cylinder part, and the piston is located outside the cylinder part.