Composite Brake Piston Structure for Weight and Airtightness
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Solution Overview
Problem
Existing caliper brake pistons made of heavy metal materials increase vehicle weight, leading to decreased fuel efficiency and airtightness issues when dualized with lighter materials.
Innovation Solution
A brake piston design comprising a lightweight main body made of aluminum and a rigid footing made of iron, coupled through rotary friction welding, which minimizes weight transfer and enhances airtightness by using a tapered footing and inclined inner surfaces for improved fluid flow and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the piston is made of heavy metal material to ensure durability and rigidity, then the structural strength is improved, but the vehicle weight increases leading to decreased fuel efficiency
Solution Approach 1:
The piston is divided into two separate components: a lightweight main body made of aluminum alloy and a footing made of heavy-duty metal material. This segmentation allows each component to be optimized for its specific function while achieving overall system performance that balances weight and strength requirements.
Solution Approach 2:
The invention uses composite construction by combining aluminum alloy (lightweight material) for the main body with heavy-duty metal material (strong material) for the footing. This composite approach enables the piston to achieve both weight reduction and structural strength by strategically placing different materials in different locations based on their respective advantages.
2Weight of moving object
If the piston is dualized with light-weight and heavy-weight materials to reduce weight, then the fuel efficiency is improved, but the airtightness deteriorates
Solution Approach 1:
By segmenting the piston into main body and footing components that can be manufactured separately and then joined, the invention achieves weight reduction through material optimization while maintaining airtightness through proper joining techniques and sealing design at the interface between components.
Solution Approach 2:
The invention changes the material parameters by selecting aluminum alloy for the main body and heavy-duty metal for the footing, optimizing the balance between weight and strength. Additionally, the joining parameters are controlled to ensure airtight connection between the two different materials.
3Duration of action of stationary object
If the footing is made of heavy-weight material to withstand external force, then the durability is improved, but the overall piston weight increases
Solution Approach 1:
The invention applies local quality by using heavy-duty metal material specifically for the footing portion that requires high strength and durability to withstand external forces from the spindle and brake pad, while the main body uses lightweight aluminum alloy where full strength is not required, achieving local optimization of material properties.
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 design achieves weight reduction, improved airtightness, and reduced fluid usage, enhancing fuel efficiency and manufacturing productivity while maintaining structural rigidity.
Implementation Method 1
coupled to the footing by rotary friction welding
Implementation Method 2
coupled to the footing by rotary friction welding
Data Source
AI summary
A brake piston includes a main body including a first metal material, and a footing including a second metal material that is different from the main body such that an external force generated by a spindle and a brake pad is not transferred to the main body, wherein the main body is coupled to the footing by rotary friction welding.