Floating Caliper Brake Guide With Elastomer Clearance Control
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Solution Overview
Problem
Existing floating caliper brakes face challenges in ensuring a delay-free braking process while maintaining sufficient distance between brake pads and the brake disc, particularly during wear phenomena, and in managing vibrations and forces effectively.
Innovation Solution
A floating caliper brake design featuring a guiding device with a guiding element and limiting device, incorporating a metal and elastomer section to allow precise positioning, vibration damping, and adjustable release clearance, ensuring a non-positive connection that adjusts to wear and vibration conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a floating caliper brake is designed with a material-saving fist-type structure, then weight and material usage are reduced, but the complexity of ensuring delay-free braking and adequate pad-disc clearance increases
Solution Approach 1:
The patent employs parameter changes by utilizing the elastomer section's variable stiffness characteristics and its ability to change shape under different loading conditions. The elastomer section transitions between deformed and undeformed states to dynamically adjust the release clearance parameter, ensuring both material efficiency and reliable braking without complex additional mechanisms.
Solution Approach 2:
The patent applies composite materials by combining metal sections with an elastomer section in the limiting element. This composite structure leverages the metal's structural integrity and the elastomer's elastic deformation properties to automatically control pad-disc clearance, resolving the contradiction between material savings and clearance control complexity.
2Manufacturing precision
If the brake caliper is guided relative to the brake carrier, then positioning precision is improved, but vibration and force transmission to the vehicle component increases
Solution Approach 1:
The patent introduces an elastomer section as an intermediary element between the metal sections in the limiting device. This elastomer mediator absorbs vibrations and dampens force transmissions while still enabling the guiding function to maintain positioning precision, thus resolving the contradiction between precision and vibration transmission.
Solution Approach 2:
By combining metal and elastomer materials in the limiting element, the patent creates a composite structure where the metal provides guidance and positioning while the elastomer component absorbs vibrations and reduces harmful force transmissions to the vehicle component.
3Loss of time
If the release clearance is reduced to ensure delay-free braking, then braking response time is improved, but the risk of pad-disc contact during non-braking increases
Solution Approach 1:
The patent applies dynamics by using the elastomer section's dynamic deformation characteristics. The elastomer dynamically adjusts the release clearance based on operational conditions - maintaining a small clearance for rapid braking response while preventing excessive contact during non-braking states, thus resolving the contradiction between response time and reliability.
Solution Approach 2:
The elastomer section changes its physical state and dimensions under different loading conditions, dynamically adjusting the release clearance parameter to optimize both braking response time and prevent unwanted pad-disc contact during normal 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
Ensures a delay-free braking process with adequate pad-disc clearance and optimized vibration damping, allowing for material-efficient design and reliable force transmission.
Implementation Method 1
the first elastomer section is deformed elastically in such a way that a spring force acts on the first metal section in the axial direction
Data Source
AI summary
A floating caliper brake is shown including a first metal section fastened non-positively to a guiding element and is-arranged in a recess so that, in a first position, a first section of the first metal section rests in an axial direction, with positive engagement, against a first section of a wall, which defines the recess, on a first side of a limiting element, wherein, in a second position, in which the first metal section and the first section of the wall are arranged at a distance from one another in the axial direction, a first elastomer section is deformed elastically such that a spring force acts on the first metal section-in an axial direction and towards the first section of the wall, and wherein, when the spring force is equal to or greater than a predetermined non-positive engagement force threshold, the non-positive connection between the first metal section and the guiding element is cancelled, resulting in that the first metal section moves relative to the guiding element in the axial direction, and when the spring force is less than the predetermined non-positive engagement force threshold, the non-positive connection between the first metal section and the guiding element is re-established.