Compact Brake Caliper Ball Screw Layout for Even Pad Pressure
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Solution Overview
Problem
Existing brake devices require a significant overall length for the caliper body to accommodate pistons and piston driving members, increasing manufacturing costs and requiring even pressure distribution for optimal brake performance.
Innovation Solution
A brake device with a pad propulsion unit that includes a conversion assembly converting rotational motion into linear motion, utilizing a ball screw nut and bolt system to reduce the caliper body's length, and a piston design with symmetric pressurizing portions for even pressure distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the caliper body includes internal space to accommodate pistons and piston driving members, then the brake device can function properly, but the overall length of the caliper body increases
Solution Approach 1:
The conversion assembly is nested within the piston structure, with the ball screw nut and bolt integrated into the piston body. This nesting allows the piston driving members to be accommodated within the existing piston volume, eliminating the need for additional internal space and reducing the overall caliper body length.
Solution Approach 2:
The invention merges the piston and piston driving members into a single integrated piston assembly. The ball screw mechanism is combined with the piston body, and the seal portion is integrated into the piston structure, reducing the number of separate components and minimizing the required caliper body length.
2Ease of manufacture
If the caliper body is reduced in length, then manufacturing costs decrease, but the space to accommodate pistons and driving members is reduced
Solution Approach 1:
The conversion assembly components (ball screw nut, bolt, and seal) are nested within the piston body, maximizing the use of available space. This nesting allows the compact piston assembly to fit within a reduced-caliper body volume while maintaining all necessary functional components.
Solution Approach 2:
The invention changes the spatial arrangement parameters by transitioning from a linear arrangement of separate components to a three-dimensional nested configuration. This parameter change allows the same functional volume to be achieved within a smaller overall caliper body envelope.
3Reliability
If pressure is distributed evenly over the brake pad surface, then brake performance improves, but the piston structure becomes more complex
Solution Approach 1:
The seal portion is designed with an asymmetric U-shape configuration that naturally distributes pressure evenly across the brake pad surface. The asymmetric geometry of the seal creates a progressive contact pattern that ensures uniform pressure distribution without requiring additional symmetric components or complex mechanisms.
Solution Approach 2:
The seal portion is positioned at the specific local region where pressure distribution is critical, between the piston and brake pad. This localized sealing structure provides the pressure distribution function without requiring the entire piston structure to be complex, maintaining simplicity in non-critical areas.
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 solution reduces the caliper body's length and weight, lowering manufacturing costs while ensuring even pressure distribution on the brake pad, enhancing brake performance and durability.
Implementation Method 1
a conversion assembly (1320) engaged to the rotation medium (1310) and converting rotational motion into linear motion in conjunction with the rotation medium (1310), and a piston (1330) formed to surround one side of the conversion assembly (1320)
Implementation Method 2
The conversion assembly may include a ball bearing mounted on an outer circumferential surface of the ball screw nut
Implementation Method 3
The conversion assembly may include a annular seal portion coupled to an outer circumferential surface of the head, and the piston may include an insertion groove formed to allow the seal portion to be inserted thereinto
Data Source
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AI summary
A brake device (1000) includes a caliper body (1100), a brake pad (1200) mounted on one side of the caliper body (1100), a mounting portion (1700) formed inside the caliper body (1100), and a pad propulsion unit (1300) located in the mounting portion (1700) and configured for pressing one surface of the brake pad (1200). The pad propulsion unit (1300) includes a rotation medium (1310) rotating, a conversion assembly (1320) engaged to the rotation medium (1310) and converting rotational motion into linear motion in conjunction with the rotation medium (1310), and a piston (1330) formed to surround one side of the conversion assembly (1320). The brake device (1000) may secure brake performance while reducing manufacturing costs by reducing the overall length of the caliper body 1100).