Caliper Adaptor for Disc Brake Radial Position Adaptation
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Solution Overview
Problem
The varying outer radii of disc brake rotors in human-powered vehicles require multiple caliper designs, increasing manufacturing costs and complexity.
Innovation Solution
A caliper adaptor with a frame coupling portion and multiple coupling portions that can be coupled to different radial positions of disc brake calipers, allowing for a common structure to be used across various caliper bodies, simplifying the coupling process and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple disc brake caliper designs are used for different rotor outer radii, then the disc brake system can accommodate various rotor sizes, but the manufacturing cost and complexity increase
Solution Approach 1:
The caliper adaptor is designed as a universal mounting component that can accommodate multiple disc brake caliper models with different outer radii. By providing a standardized interface between the caliper and vehicle body, a single adaptor design serves multiple functions across different caliper variants, reducing the need for multiple specialized mounting solutions
Solution Approach 2:
The caliper adaptor acts as an intermediary component between the disc brake caliper and the vehicle body. This mediator allows different caliper types to be mounted to the same vehicle body location by providing a standardized mounting interface, thereby reducing the complexity of designing multiple direct mounting solutions
2Adaptability or versatility
If multiple disc brake caliper designs are used for different rotor outer radii, then the disc brake system can accommodate various rotor sizes, but the manufacturing cost increases
Solution Approach 1:
The caliper adaptor serves as a universal mounting solution that can be used across multiple disc brake caliper models and vehicle body types. This multi-functionality allows manufacturers to produce a single standardized adaptor design in large volumes, achieving economies of scale that reduce per-unit manufacturing costs compared to producing multiple specialized caliper designs
3Ease of manufacture
If a single caliper design is used for different radial positions, then manufacturing cost is reduced, but the coupling structure becomes more complex
Solution Approach 1:
The mounting system is segmented into two distinct functional components: a standardized caliper adaptor that handles the coupling to the vehicle body, and the caliper itself that maintains a simple, consistent design. This segmentation allows the caliper to remain simple for manufacturing purposes while the adaptor absorbs the complexity of accommodating different radial positions
Data Source
AI summary
A caliper adaptor comprises a frame coupling portion, a first coupling portion, and a second coupling portion. The first coupling portion is configured to be coupled to a first caliper body of the disc brake caliper in a first state where the first caliper body is in a first radial position relative to the rotational axis. The first coupling portion extends in the axial direction in the first state. The second coupling portion is configured to be coupled to a second caliper body in a second state where the second caliper body is in a second radial position relative to the rotational axis. The second radial position is different from the first radial position. The second coupling portion extends in the axial direction in the second state.