Disc Brake Equaliser for Balanced Single-Piston Pad Thrust
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Solution Overview
Problem
Existing disc brakes with electrical actuation face challenges in distributing thrust force evenly and achieving balanced braking power, particularly in large or high-power vehicles, where integrating an electromechanical parking brake with a two-piston disc brake increases size and mass, and complexity.
Innovation Solution
A disc brake design featuring a caliper, yoke, brake pad, piston, and an intermediate spreader device that distributes the thrust force of a single piston across multiple zones of the brake pad, simulating the application of thrust forces from two pistons, thereby reducing mass and size while maintaining mechanical strength, using an electromechanical actuator for balanced braking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a twin-piston disc brake with electromechanical actuation is used to generate high braking power, then braking power is improved, but mass and size increase due to requiring two motors
Solution Approach 1:
The single piston is segmented into two functional zones through the interposing device, creating two distinct thrust force application areas on the brake pad. This segmentation allows one piston to perform the work of two pistons, achieving twin-piston braking power with single-piston mass and size.
Solution Approach 2:
An interposing device is introduced between the piston and the brake pad to distribute the thrust force. This intermediary component receives the single piston's thrust and redirects it to two separate zones on the brake pad, enabling balanced force distribution without requiring a second piston or motor.
2Power
If a twin-piston disc brake with electromechanical actuation is used to generate high braking power, then braking power is improved, but the overall size of the brake increases
Solution Approach 1:
The interposing device segments the single piston's thrust force into two directional components, each acting on a different zone of the brake pad. This allows the brake system to maintain compact single-piston dimensions while achieving the braking power equivalent of a twin-piston system.
Solution Approach 2:
The single piston is made multi-functional through the interposing device, allowing it to simultaneously generate thrust forces in two different directions and zones. This universality enables one piston to replace the function of two pistons, reducing the overall brake system size.
3Device complexity
If thrust force is applied directly by the piston onto the brake pad, then the mechanical structure is simple, but the thrust force distribution is unbalanced
Solution Approach 1:
The interposing device serves as an intermediary between the piston and brake pad, transforming the single-point thrust application into a distributed two-zone force application. This intermediary component maintains mechanical simplicity while achieving balanced thrust force distribution across the brake pad surface.
Solution Approach 2:
The interposing device transforms the one-dimensional thrust force from the piston into a two-dimensional force distribution pattern on the brake pad. By projecting the single piston thrust onto two separate zones, it creates a balanced force distribution without significantly increasing mechanical complexity.
Data Source
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AI summary
Disc brake comprising a yoke (15), at least one first brake pad (P1) mounted so as to slide within the yoke (15), the first brake pad (P1) comprising a pad support and a friction material, a caliper comprising at least one piston mounted so as to slide within the caliper in such a way as to move the first brake pad (P1) in relation to the yoke (15), at least one actuator configured to move the piston axially, and a separator device (34) inserted between the piston and the first brake pad (P1) forming an equaliser so as to distribute the thrust force exerted by the piston onto at least two zones of the first brake pad (P1), at least partially distinct from the projection of the piston onto the first brake pad (P1).