Opposed-Piston Disc Brake Caliper Rib Structure for Rigidity
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Solution Overview
Problem
The existing calipers for opposed-piston type disc brakes face challenges in ensuring rigidity while minimizing weight, particularly when equipped with four or more cylinder portions, which can lead to deformation and vibration during braking, especially in high-performance vehicles.
Innovation Solution
The caliper design incorporates an inner body and an outer body with multiple cylinder portions, connected by rotation-in and rotation-out side connecting portions and center bridges, along with a belt-shaped rib on the outer body to enhance rigidity and a connecting portion between center bridges, which improves structural integrity without increasing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of pistons is increased to four or more for high-performance braking, then the braking force is improved, but the rigidity requirement increases and weight increases
Solution Approach 1:
The caliper body is divided into inner body and outer body with multiple independent cylinder portions (four or more) distributed around the rotor. This segmentation allows each piston-cylinder assembly to function independently while contributing to the overall braking force, enabling high-performance braking without requiring a single large rigid structure
Solution Approach 2:
The cylinder portions are arranged in multiple dimensions around the rotor (radial and axial positions), creating a three-dimensional distribution of braking force. This spatial arrangement allows the braking force to be applied from multiple directions simultaneously, increasing total braking power while distributing structural loads to maintain rigidity
2Power
If the number of pistons is increased to four or more for high-performance braking, then the braking force is improved, but the weight increases
Solution Approach 1:
The caliper uses light alloy materials with optimized local density distribution. The inner body and outer body are designed with varying wall thicknesses and material densities in different regions - thicker and denser where structural strength is needed, thinner and lighter where weight reduction is prioritized. This local quality optimization achieves high braking force with minimal weight increase
Solution Approach 2:
The caliper employs light alloy composite materials that combine high strength-to-weight ratio properties. These composite materials enable the construction of multiple piston assemblies and connecting structures without proportionally increasing weight, as the composite material provides both structural integrity and weight efficiency
3Weight of moving object
If the caliper structure is simplified to reduce weight, then the weight is reduced, but the rigidity decreases causing deformation and vibration during braking
Solution Approach 1:
The inner body and outer body are merged into a unified caliper structure with integrated connecting portions. The rotation-in side connecting portion and rotation-out side connecting portion merge the inner and outer bodies into a single rigid assembly that resists deformation during braking, while the overall design remains lightweight through efficient material distribution
Solution Approach 2:
The caliper adopts a curved, arc-shaped structure that follows the rotational path of the rotor. This spherical/curved geometry provides inherent structural rigidity against radial and axial loads during braking, as the curved shape naturally resists deformation forces better than straight-line configurations, while maintaining weight efficiency
Data Source
AI summary
A belt-like rib that extends in a peripheral direction is provided to the outer surface, in the axial direction, of an outer body. The inner diameter side sections of the bottoms of outer cylinders at the outer diameter side and the outer diameter side sections of the bottoms of outer cylinders at the inner diameter side, all the cylinders being provided to the outer body so as to be separated into two stages in the radial direction, are covered with the belt-like rib from outside in the axial direction so as to traverse along the peripheral direction. The outer diameter side sections of the bottoms of the outer cylinders at the outer diameter side and the inner diameter side sections of the bottoms of the outer cylinders at the inner diameter side are made to protrude from the belt-like rib in the radial direction.