Composite Brake Piston Structure for Low Weight and Deformation Resistance
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Solution Overview
Problem
Conventional electronic caliper brake pistons made of metal increase vehicle weight, leading to reduced fuel efficiency and braking response, while lightweight resin pistons are prone to deformation and damage from metal spindle and brake pad forces.
Innovation Solution
A piston design combining a lightweight synthetic resin body with a metal footing, featuring anti-rotation and sealing structures to minimize weight increase, fluid volume, and prevent deformation and damage, achieved through integrally molded components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the piston is made of metal, then the strength and durability are improved, but the weight of the electronic caliper brake increases
Solution Approach 1:
The piston is constructed as a composite structure combining synthetic resin (body) with metal components (footing and footing rod). This allows the piston to achieve the necessary strength and durability through the metal footing that contacts the brake pad, while the synthetic resin body keeps the overall weight reduced. The composite design resolves the contradiction by strategically placing metal only where structurally necessary.
2Weight of moving object
If the piston is made of lightweight synthetic resin material, then the weight is reduced, but the piston is worn or deformed by the metal spindle unit
Solution Approach 1:
The piston uses a composite structure where the synthetic resin body provides lightweight properties while the metal footing rod and footing provide durability and resistance to wear from the spindle unit and brake pad. The metal components are strategically positioned at contact points to protect the synthetic resin from mechanical degradation.
Solution Approach 2:
The piston structure transitions from uniform material composition to localized material properties. The synthetic resin is used for the main body where weight reduction is critical, while metal materials are applied locally at the footing and footing rod where strength and wear resistance are required. This local differentiation resolves the contradiction between lightweight design and durability.
3Weight of moving object
If the piston is made of lightweight synthetic resin material, then the weight is reduced, but the piston is deformed or damaged due to reaction force from the brake pad
Solution Approach 1:
The piston employs a composite structure where the metal footing and footing rod provide the necessary strength to withstand reaction forces from the brake pad, while the synthetic resin body maintains lightweight properties. The metal components form a load-bearing framework that protects the synthetic resin from deformation under braking loads.
Solution Approach 2:
The piston structure implements local quality by concentrating metal materials at the footing and footing rod where brake pad reaction forces are applied, while the synthetic resin constitutes the main body. This strategic material distribution allows the piston to resist deformation at critical load points while maintaining overall lightweight characteristics.
4Weight of moving object
If the piston uses minimum material to reduce weight, then the weight is reduced, but the internal volume increases causing deterioration of braking response
Solution Approach 1:
The composite structure allows the piston to achieve minimal weight through synthetic resin while the metal footing components provide structural rigidity that maintains compact dimensions. This prevents excessive internal volume expansion that would occur with purely minimal material designs, thereby preserving fast fluid response characteristics.
Solution Approach 2:
The piston design applies local quality by using dense metal materials at critical structural points (footing and footing rod) to maintain compact geometry and minimize internal volume, while using lightweight synthetic resin for the main body. This ensures that the piston achieves weight reduction without compromising the compactness needed for fast braking response.
Data Source
AI summary
Disclosed herein is a piston for a brake. The piston for a brake according to the present embodiment includes a body made of a synthetic resin, the body having both ends communicating with each other and both sides hollowed in a cup shape, and a footing made of metal provided from one end side of the body to one side of the inside of the body to prevent external force from being applied directly to the body by a spindle and a brake pad.