Asymmetric Disc Brake Caliper Pin and Pad Configuration
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Solution Overview
Problem
Existing brake systems, particularly opposed piston brake systems, face challenges in reducing weight, cost, and assembly complexity while maintaining effective braking performance.
Innovation Solution
The proposed brake system incorporates a disc brake caliper with a first and second brake pad supported by the caliper, connected via a pin that allows one or both pads to slide during braking, and features a parking brake system with a rotary to linear stage mechanism using a spindle and nut assembly to move brake pistons, reducing the need for multiple pins and enhancing assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional opposed piston brake systems use multiple pins to support brake pads, then the brake system achieves reliable pad support and movement, but the system becomes heavier, more costly, and more complex to assemble
Solution Approach 1:
The patent combines multiple pin functions into a single pin structure. The single pin supports both the inboard brake pad and outboard brake pad, eliminating the need for separate pins for each pad. This merging reduces the total number of components while maintaining the reliability of brake pad support and movement during braking operations.
Solution Approach 2:
The single pin serves multiple functions simultaneously: it acts as a support axis for the inboard brake pad, a support axis for the outboard brake pad, and a sliding surface for both pads during brake application. This multi-functionality reduces component count and simplifies assembly while maintaining system reliability.
2Strength
If traditional brake systems use multiple separate components for caliper assembly, then the system achieves robust structural support, but the assembly process becomes more time-consuming and labor-intensive
Solution Approach 1:
The caliper is designed as a single integrated piece rather than multiple separate components that require assembly. This merging maintains the structural strength and support capabilities of the caliper while eliminating the need for complex assembly procedures, thereby significantly improving assembly speed and productivity.
3Stability of the object's composition
If brake systems use symmetric caliper designs with equal components on both sides, then the system achieves balanced braking performance, but the system weight and complexity increase
Solution Approach 1:
The patent employs an asymmetric caliper design where a single pin supports brake pads on both inboard and outboard sides, rather than using symmetric dual-pin configurations. This asymmetric arrangement maintains balanced braking performance through proper force distribution while reducing overall caliper weight and complexity by eliminating redundant components.
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
This configuration results in a lighter, less costly brake system that is easier and faster to assemble and service, while maintaining effective braking performance through optimized clamping force generation.
Implementation Method 1
One or both of the brake pads move or slide along the pin during a brake apply
Implementation Method 2
a parking brake system with a rotary to linear stage mechanism using a spindle and nut assembly to move brake pistons
Implementation Method 3
a pair of pads are pushed against a corresponding side of the brake rotor by the opposed brake pistons
Data Source
AI summary
A brake system that includes a brake caliper comprising an inboard side and an outboard side, the inboard side of the brake caliper includes one or more brake pistons and the outboard side of the brake caliper comprises one or more brake pistons, and a brake pad comprising a first pad section and a second pad section. During a service brake apply, both of the first pad section and the second pad section are moved against a braking surface to create a clamping force. During a parking brake apply, only one of the first pad section and the second pad section is moved against the braking surface to create a clamping force. The first pad section comprises a friction material having a coefficient of friction that is different than a coefficient of friction of the second pad section.