Disc Brake Caliper Protective Plate for Dust Sealing and Rigidity
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Solution Overview
Problem
Existing motor vehicle disc brake calipers face challenges in maintaining mechanical rigidity and preventing dust entry into the spaces between fingers, which compromises braking effectiveness and allows dust ingress.
Innovation Solution
A protective plate with cylindrical studs, each featuring radial lugs shaped like a letter U cutout, is attached to the caliper body using holes in the fingers, providing a cost-effective solution to cover and secure these spaces, enhancing mechanical strength and dust protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the caliper body is made with high mechanical rigidity through molding and machining, then braking effectiveness is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The caliper body is divided into modular components: a molded base structure and separate fingers that can be independently manufactured and assembled. This segmentation allows each part to be optimized for its specific function while simplifying overall manufacturing.
Solution Approach 2:
The invention transitions from traditional heavy machining operations to molded material construction, changing the manufacturing parameter from subtractive machining to additive molding, thereby reducing manufacturing complexity while maintaining structural integrity.
2Ease of manufacture
If fingers are spaced apart to allow tool passage for boring actuator housing, then ease of manufacture is improved, but dust entry into the space between fingers increases
Solution Approach 1:
A simple, inexpensive protective plate is introduced to cover the spacing between fingers. This disposable-like component effectively prevents dust entry without requiring complex modifications to the finger structure or spacing.
Solution Approach 2:
The protective plate acts as an intermediary element between the spaced fingers and the external environment, blocking dust particles from entering the gap while allowing the fingers to remain spaced for manufacturing accessibility.
3Object-affected harmful factors
If a protective plate is added to cover fingers and prevent dust entry, then dust protection is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The protective plate incorporates integrated studs with radial lugs that automatically engage with corresponding holes in the fingers during assembly. This self-aligning, self-securing mechanism eliminates the need for complex fastening procedures or specialized assembly tools.
Solution Approach 2:
The protective plate combines multiple functions into a single component: dust protection, structural reinforcement, and finger retention. The integrated studs serve both as attachment mechanisms and as alignment guides, merging fastening and positioning functions.
Data Source
Figure 1~3
Figure 4~6
AI summary
The invention relates to a disc-brake caliper (1) comprising a body (2) made from a moulded material including a base (3) extended by an arch (4), and fingers (6, 7, 8) extending this arch (4), a protective plate (14) which is fixed and attached against its fingers (6, 7, 8) to cover these fingers (6, 7, 8) and the spaces separating these fingers (6, 7, 8). The body (2) comprises two blind holes produced at the level of the fingers (6, 8), and the protective plate (14) comprises at least two studs (16, 17) each engaging in a corresponding hole of the body (2) so as to secure this plate (14) to the body (2), each stud (16, 17) comprising at least one radial lug acting as a claw to hold the stud (16, 17) in the drilling.