Brake Caliper Body Structure for Four-Pad Load Distribution
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Solution Overview
Problem
Existing disc brake caliper designs face challenges in achieving high braking action with limited brake disc diameters, while maintaining a lightweight and rigid caliper body with minimal deformations, and ensuring ease of adjustment and accuracy, especially in sports vehicles where large calipers are undesirable due to weight and size constraints.
Innovation Solution
A four-pad configuration with a three-point fastening system, including a slotted fastener, allows for optimized weight-rigidity ratio and improved coupling between the pad and disc, reducing deformation and enhancing braking performance by distributing contact pressure uniformly across a larger area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the caliper body is made very rigid to cover a large arc of disc, then deformation is reduced, but the caliper body becomes bulky and heavy
Solution Approach 1:
The caliper body is divided into two separate half-calipers (first and second half-calipers) that are positioned on opposite sides of the brake disc. Each half-caliper is lighter and less rigid than a single monoblock caliper, but together they provide the necessary stability and braking force distribution across a large arc of the disc.
Solution Approach 2:
The patent applies different structural characteristics to different parts of the caliper system. The half-calipers have localized reinforcement where needed for rigidity while maintaining overall lightweight construction, allowing each component to have optimal properties for its specific function and position.
2Power
If two brake calipers are used on a single brake disc to increase friction surface, then braking performance is improved, but management and synchronization complexity increases
Solution Approach 1:
The patent combines two separate half-caliper systems into a single integrated brake assembly that straddles the brake disc. The first and second half-calipers work together as a coordinated unit, sharing common mounting structures and fluid supply systems, thereby achieving the braking power of dual calipers while reducing management and synchronization complexity.
Solution Approach 2:
The half-caliper design provides multi-functionality by serving both as individual braking elements and as components of a larger integrated system. Each half-caliper can function independently to some extent while also working in unison with the other, providing versatile braking capabilities without requiring complex separate control systems.
3Power
If longer calipers are made to cover a large arc of disc, then braking action is improved, but deformation of the caliper body increases
Solution Approach 1:
The long caliper structure is segmented into two separate half-calipers that each cover a portion of the brake disc arc. This segmentation reduces the length of each individual caliper body, thereby minimizing deformation while still providing comprehensive coverage of the disc surface through the combined action of both half-calipers.
Solution Approach 2:
Instead of extending a single caliper body across a large arc in one dimension, the patent uses two half-calipers positioned on opposite sides of the disc, distributing the braking function across multiple dimensions. This approach reduces the structural demands on each individual caliper body while maintaining effective braking coverage.
Data Source
Figure 1~2
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Figure 5~6
AI summary
The present invention relates to a caliper body (1) of a brake caliper (2) of disc brake (3) adapted to be arranged straddling a brake disc (4) to apply a braking action to a vehicle, wherein it comprises: - a first elongated vehicle-side element (5) adapted to face a first braking surface (6) of the brake disc (4); - a second elongated wheel-side element (7) adapted to face a second braking surface (8) of the brake disc (4) opposite to said first braking surface (6); - each of said elongated vehicle-side and wheel-side elements (5, 7) comprises at least one thrust seat (9, 10, 11, 12) to receive at least one thrust device (13) adapted to bias at least one brake pad (14, 15, 16, 17) against said braking surfaces (6, 8) to apply a braking action to the vehicle; - at least one caliper bridge (18, 19, 20) which connects said first elongated vehicle-side element (5) to said second elongated wheel-side element (7); said at least one caliper bridge (18, 19, 20) being arranged straddling said brake disc (4); - and wherein said first elongated vehicle-side element (5), said second elongated wheel-side element (7) and said at least one caliper bridge (18, 19, 20) are in one piece; - and wherein said caliper body comprises caliper fixing elements (21, 22, 23) to connect said caliper body (1) to a vehicle mount, such as for example a steering knuckle; - and wherein said caliper fixing elements (21, 22, 23) are at least three in number; - said caliper fixing elements (21, 22, 23) are distributed along said elongated vehicle-side element (5); wherein - said elongated vehicle-side and caliper-side elements (5, 7) each comprise at least two pad seats (24, 25, 26, 27), each adapted to receive at least one brake pad (14, 15, 16, 17); wherein - said elongated vehicle-side and wheel-side elements (5, 7) each comprise at least two opposite abutment elements (29, 30, 31, 32) each adapted to abuttingly receive a brake pad (14, 15, 16, 17) for relieving the braking action on said caliper body (1); and wherein - each of said at least two opposite abutment elements (29, 30, 31, 32) is placed between two of said brake pads (14, 15, 16, 17).