Disc Brake Carrier Structure for Lightweight Rigidity
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Solution Overview
Problem
Existing disc brake carriers lack sufficient rigidity, which can compromise their performance and durability, especially when made from materials with low longitudinal elastic modulus like aluminum alloys.
Innovation Solution
The disc brake carrier design incorporates an arm part and an inner beam part with specific torque receiving parts, attachment parts, and outward protruding features, which enhance the carrier's rigidity by distributing loads more effectively and providing additional structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the carrier is made from materials with low longitudinal elastic modulus like aluminum alloys, then the weight is reduced, but the rigidity is insufficient
Solution Approach 1:
The carrier is divided into multiple functional parts including an attachment part for mounting, an inner beam part extending in the circumferential direction, and arm parts extending radially. This segmentation allows each part to be optimized for its specific function while collectively providing the required rigidity. The inner beam part specifically is designed to receive torques from both friction pads, distributing mechanical loads effectively.
Solution Approach 2:
Different regions of the carrier are designed with different structural characteristics to optimize local performance. The attachment part has reinforcement structures for secure mounting, the inner beam part has increased thickness and stiffness for torque reception, and the arm parts have geometries optimized for caliper support. This local quality differentiation enables the aluminum alloy carrier to achieve sufficient rigidity in critical areas without increasing overall weight.
2Ease of manufacture
If the carrier structure is simplified, then the manufacturing cost is reduced, but the rigidity and load distribution are insufficient
Solution Approach 1:
Multiple functions are merged into the carrier structure itself. The inner beam part simultaneously serves as a structural element for rigidity, a torque receiving component for both friction pads, and a mounting structure for the arm parts. The attachment part integrates multiple attachment points and reinforcement features into a single integrated component, reducing the need for separate fasteners and support structures while maintaining manufacturing simplicity.
Solution Approach 2:
The carrier is designed as a multi-functional component that performs attachment to the wheel hub, supports the caliper assembly, receives torques from both friction pads, and provides structural rigidity. This universal design consolidates multiple functions into a single component, reducing the total part count and assembly complexity while ensuring adequate rigidity through the integrated structure.
Data Source
AI summary
The present disc brake includes a caliper and a carrier. In the carrier, a pair of inner beam part side torque receiving parts are provided inside an arm part in a radial direction of a disc and provided on both sides in a circumferential direction so that a pair of lug parts provided on a first friction pad of a pair of friction pads are respectively housed therein. An attachment part is provided inside the pair of inner beam part side torque receiving parts in a radial direction and is disposed at a position overlapping each of the pair of inner beam part side torque receiving parts in the circumferential direction to be connected to a wheel support part. A first outward protruding part is formed to protrude toward the wheel support part with respect to an attachment surface of the attachment part in a rotation axis direction.