Disc Brake Caliper Housing Integration
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Solution Overview
Problem
Existing disc brake systems for lighter duty applications require a separate cover plate, leading to increased complexity, weight, and cost due to additional machining and bolted connections, which can be weak and prone to contamination.
Innovation Solution
A disc brake design that eliminates the need for a separate cover plate by using a guide insert and retaining insert within the caliper housing, allowing for a simpler manufacturing process and improved sealing, with a single piston actuation mechanism and a monolithic caliper structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate cover plate is used to assemble actuation and adjustment mechanisms, then the mechanisms can be properly contained and sealed, but the brake unit becomes heavier, more complex, and more expensive to manufacture
Solution Approach 1:
The patent combines the cover plate function with the caliper housing by integrating the actuation and adjustment mechanisms directly into the housing structure. The operating shaft is mounted directly in the caliper housing without requiring a separate cover plate, merging multiple components into a single integrated structure that reduces complexity while maintaining sealing capability through direct integration.
2Reliability
If a separate cover plate is used to assemble actuation and adjustment mechanisms, then the mechanisms can be properly contained, but additional machining and bolted connections are required, increasing manufacturing cost and time
Solution Approach 1:
The patent merges the cover plate function into the caliper housing structure, eliminating the need for separate machining operations and bolted connections. The operating shaft and other mechanisms are directly mounted in the housing, reducing manufacturing steps and costs while maintaining structural integrity through integrated design.
3Reliability
If a separate cover plate is used, then a larger housing is needed to accommodate all components, but this increases the overall size and weight of the brake unit
Solution Approach 1:
The patent combines the cover plate and housing into a single integrated caliper housing structure. The operating shaft and adjustment mechanisms are directly mounted in the housing without requiring additional space for a separate cover plate, reducing the overall size and weight of the brake unit while maintaining proper component containment.
4Ease of manufacture
If bolted connections are used to assemble the caliper housing, then the components can be joined together, but this creates weak points that are prone to contamination ingress
Solution Approach 1:
The patent merges the cover plate function into the caliper housing, eliminating bolted connections between separate housing parts. The integrated structure removes weak points and sealing requirements, preventing contamination ingress while maintaining assembly capability through direct integration of mechanisms into the housing.
Data Source
Figure 1
Figure 2
Figure 2A
AI summary
A disc brake comprising a caliper (2) having a bridge portion arranged to extend over a rotor (20) and a housing portion inboard of the bridge portion and rotor, a housing bore extending inboard from an outboard face of the housing portion (6), a separate guide insert (60) having an inner guide bore (61) and being mounted within the housing bore such that an inner surface of the housing bore limits transverse movement of the guide insert, a piston (15) slideable within the inner guide bore, relative to the guide insert, so as to urge a brake pad towards the rotor and apply the brake, wherein the inner guide bore (61) is dimensioned relative to the piston (15) to restrain movement of the piston transverse to the longitudinal axis of the piston.