Vehicle Disc Brake Caliper Body Compact Design
Solution Overview
Problem
Existing caliper bodies for two-system pin slide type disk brakes face issues of increased size and unsatisfactory air bleeding properties due to deep cylinder holes and complex machining requirements, which hinder efficient fluid passage and bleeder hole placement.
Innovation Solution
A caliper body design with three cylinder holes arranged in a disc circumference direction, where two holes form the first brake system and one hole forms the second brake system, featuring a communication path and bleeder holes formed rectilinearly on the outside of an imaginary line connecting the first brake system holes, reducing size and machining complexity while maintaining air bleeding efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If two cylinder holes for the first brake system are formed to be deep to secure space for the communication path, then the communication path can be provided on the side of bottom portions, but the caliper body increases in size
Solution Approach 1:
The communication path is repositioned from the bottom portion dimension to the disc radius direction dimension. By forming the communication path to extend in the disc radius direction rather than requiring deep cylinder holes, the patent resolves the contradiction between providing adequate communication path space and maintaining compact caliper body size.
2Ease of manufacture
If rectilinear fluid passages bypass the central cylinder hole and pass through opposite cylinder holes, then the fluid passage can be connected, but the number of machining man-hours increases and the caliper body increases in size in the disc radius direction
Solution Approach 1:
The fluid passage system is segmented into distinct components: a first fluid passage connecting opposite cylinder holes through the caliper body, and a second fluid passage connecting to the central cylinder hole separately. This segmentation allows for simplified machining of each passage independently, reducing overall machining complexity and time compared to creating a single complex rectilinear passage.
3Device complexity
If a bleeder hole is formed in one end portion facing upward in the mounted state, then the structure is simple, but the air bleeding property is not satisfactory
Solution Approach 1:
Different qualities are assigned to different locations of the fluid passage system. Union holes are provided at both ends of the first fluid passage to enable air bleeding from multiple locations, while the second fluid passage includes a bleeder hole at its end portion. This localized quality distribution ensures satisfactory air bleeding performance throughout the brake system while maintaining structural simplicity.
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 reduces the caliper body's size and machining time, improves air bleeding properties, and lowers production costs by forming communication paths and bleeder holes externally, allowing for more compact and efficient brake systems without compromising performance.
Implementation Method 1
pistons inserted into the cylinder holes for the first brake system are actuated by hydraulic fluid supplied through a first fluid passage
Implementation Method 2
the piston (s) inserted into the cylinder hole (s) for the second brake system is (are) actuated by hydraulic fluid supplied through a second fluid passage
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
[Object] There is provided a caliper body for a two system-type disc brake for a vehicle, which is reduced in size and has an improved air bleeding property by employing a simple structure. [Approach] In the caliper body 6 for the two-system disc brake 1 for the vehicle, a communication path 23a, which connects cylinder holes 11 and 13 for a first brake system, and a first bleeder hole 6o are formed rectilinearly on an outside, in a disc radius direction, of an imaginary line IL1 which rectilinearly connects inner edges, in the disc radius direction, of cylinder holes 11 and 13 for a first brake system and a cylinder hole 10 for a second brake system is provided on an outside, in the disc radius direction, of the communication path 23a.