Disc Brake Caliper Body with Additive Reticular Structure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing caliper bodies for disc brakes face challenges with high weight, limited heat exchange performance, and mechanical stress resistance, necessitating a solution that balances weight reduction with enhanced structural and dynamic properties.
Innovation Solution
A caliper body incorporating a reticular portion obtained through additive manufacturing techniques, which provides improved heat exchange and structural resistance while maintaining a lightweight structure, achieved by strategically positioning material for maximum reinforcement and optimizing the geometry for high structural resistance and heat exchange surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If caliper bodies are made by traditional casting or machining techniques, then structural strength and reliability are maintained, but weight is high and heat exchange performance is limited
Solution Approach 1:
The patent applies porous materials by incorporating a reticular portion with cellular structure into the caliper body. This reticular portion contains interconnected voids and channels that reduce material density while maintaining structural integrity through the cellular framework, achieving weight reduction without sacrificing strength
Solution Approach 2:
The patent transitions from traditional solid or hollow caliper body designs to a three-dimensional reticular structure with complex spatial arrangement of struts and nodes. This dimensional transformation creates a volumetric network that provides enhanced structural efficiency and heat exchange pathways in multiple directions simultaneously
2Area of stationary object
If caliper bodies are made by traditional casting or machining techniques, then manufacturing simplicity is maintained, but heat exchange surface area is limited
Solution Approach 1:
The reticular portion with its porous cellular structure provides an extensive internal surface area for heat exchange. The interconnected voids and struts create numerous heat transfer pathways between the brake disc and cooling air, dramatically increasing the effective heat exchange surface area compared to traditional solid caliper bodies
Solution Approach 2:
The reticular portion serves multiple functions simultaneously: it provides structural support to maintain caliper body integrity, enables enhanced heat exchange through its extensive surface area, and reduces overall weight. This multi-functionality resolves the contradiction between increased surface area and structural complexity
3Weight of moving object
If caliper bodies are made by traditional casting or machining techniques, then manufacturing process simplicity is maintained, but weight reduction is limited
Solution Approach 1:
The patent changes the manufacturing parameter from traditional subtractive or formative processes to additive manufacturing. This parameter change enables the creation of complex reticular geometries that would be impossible or economically unviable with conventional methods, achieving significant weight reduction while maintaining manufacturing feasibility through modern additive technologies
Data Source
Figure 1~2
Figure 3~9
Figure 5~6
AI summary
Caliper body for a disc brake, wherein said caliper body is suitable for straddling an associable brake disc having a first braking surface, or vehicle-side braking surface, and a second braking surface, or wheel-side braking surface, opposite said first braking surface; and wherein said caliper body comprises a first elongated portion, or vehicle-side elongated portion, suitable for facing said first braking surface and a second elongated portion, or wheel-side elongated portion, opposite said first elongated portion and suitable for facing said second braking surface; and wherein said caliper body comprises at least one bridge, suitable for connecting said first elongated portion with said second elongated portion, so as to straddle the brake disc, when said caliper body is assembled to the brake disc; and wherein said caliper body comprises at least one reticular portion (20), obtained by means of an additive manufacturing technique, and wherein said reticular portion (20) comprises a plurality of reticular modules (40) with geometry suitable for providing the caliper body with structural resistance and for providing at least one hollow portion, capable of high heat exchange.