Integrated Disc Brake Caliper-Hub Bracket for Rigidity and Cooling
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Solution Overview
Problem
Existing disc brake caliper and hub bracket assemblies face challenges in achieving structural rigidity while minimizing weight and volume, especially with larger brake discs, which complicates assembly and heat evacuation.
Innovation Solution
A brake caliper and hub bracket assembly where the caliper body and hub bracket are made in single pieces, with adjustable connecting elements and a caliper opening for improved structural rigidity and reduced weight, allowing for easier assembly and disassembly, and enhanced heat ventilation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the caliper body and hub bracket are made as separate components requiring assembly, then ease of manufacture and repair are improved, but structural rigidity deteriorates and device complexity increases
Solution Approach 1:
The patent merges the caliper body and hub bracket into a single integrated component made in one piece. This eliminates the need for separate assembly of these two critical structural elements, thereby enhancing structural rigidity and reducing the total number of parts while maintaining manufacturability through single-casting or single-forging operations
2Strength
If the caliper body is made with increased volume and structural rigidity, then reliability is improved, but weight and volume increase
Solution Approach 1:
The integrated caliper-hub bracket design allows for optimized material distribution with varying local densities and structural properties. Critical load-bearing areas have enhanced rigidity through the monolithic construction, while non-critical areas maintain lower mass, achieving overall structural reinforcement without proportional weight increase
Solution Approach 2:
The patent employs advanced aluminum alloys or steel compositions that provide superior strength-to-weight ratios. These composite or alloyed materials enable the single-piece construction to achieve the required structural rigidity with reduced mass compared to traditional multi-component designs using conventional materials
3Ease of manufacture
If the caliper body is restrained only on the hub side elongated element, then ease of manufacture is improved, but deformation during braking increases
Solution Approach 1:
By integrating the hub bracket with the caliper body, the patent creates a unified structural system where the hub bracket serves as both the mounting interface and a structural reinforcement element. This monolithic construction eliminates relative movement and deformation between the caliper body and hub bracket during braking, while the integrated design maintains manufacturing simplicity through single-piece production
4Reliability
If the caliper body is made in single piece, then structural rigidity and reliability are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the caliper body and hub bracket into a single component that can be produced in one casting or forging operation. This single-piece manufacturing approach eliminates the need for separate machining, assembly, and fastening operations, thereby improving structural integrity while actually simplifying the overall manufacturing process and reducing assembly steps
Data Source
AI summary
A brake caliper and hub bracket assembly for a disc brake of a vehicle, comprising at least one caliper and at least one hub bracket, the brake caliper comprising a caliper body comprising a first elongated element, or vehicle side elongated element, suitable for directly or indirectly facing said first braking surface of the brake disc by at least a first brake pad, and a second elongated element, or wheel side elongated element, opposed to the vehicle side elongated element and suitable for directly or indirectly facing said second braking surface of the brake disc by at least a second brake pad. The vehicle side elongated element comprises at least a first thrust means seat suitable for receiving a piston for exerting a thrust action on the at least first brake pad. The wheel side elongated element comprises at least a second thrust means seat suitable for receiving a piston for exerting a thrust action on the at least second brake pad. The caliper body comprises at least one side caliper bridge suitable for straddling the brake disc, the caliper side bridge connecting the vehicle side elongated element and the wheel side elongated element. The hub bracket comprises a hub bracket body connected to at least one portion of the caliper body, the hub bracket body comprising at least one coupling surface suitable for coupling to at least one bearing for supporting a wheel hub connectable to the brake disc and to a wheel of the vehicle.