Disc Brake Spreader Mechanism for Balanced Pad Thrust
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Solution Overview
Problem
Existing disc brakes, especially dual-piston electromechanical brakes, face challenges in distributing thrust force evenly and achieving high braking power while minimizing size and mass, which complicates integration and increases complexity.
Innovation Solution
A disc brake design incorporating an interposed spreader device between the piston and brake pad, utilizing ball joints and guide lugs to distribute thrust force over multiple zones, allowing a single piston to simulate the action of two pistons without increasing mechanical strength or weight, and reducing overall size and mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a dual-piston electromechanical brake is used to achieve high braking power, then braking power is improved, but device complexity and mass increase
Solution Approach 1:
The brake pad is divided into multiple zones (first zone and second zone) that can be independently actuated. The single piston distributes thrust force to multiple contact points on the pad, creating segmented force application areas that simulate the effect of multiple pistons without requiring additional actuator components.
Solution Approach 2:
An interposed device is introduced between the piston and the brake pad to distribute the thrust force. This intermediary component receives the single piston's force and redistributes it to multiple zones on the pad, enabling dual-piston equivalent performance with single-piston actuation.
2Power
If a dual-piston electromechanical brake is used to achieve high braking power, then braking power is improved, but mass increases
Solution Approach 1:
The functions of two separate pistons are merged into a single piston system. The interposed device combines multiple force application points into one unified actuation mechanism, reducing the total mass of moving components while maintaining the braking power equivalent to a dual-piston system.
Solution Approach 2:
The single piston is designed to perform multiple functions: it can apply force to multiple zones on the brake pad, control both inner and outer pads, and distribute thrust force across different areas. This multi-functionality replaces what would traditionally require two separate pistons, reducing overall system mass.
3Device complexity
If thrust force is applied concentratedly by a single piston, then device simplicity is improved, but thrust force distribution becomes unbalanced
Solution Approach 1:
Different zones on the brake pad are treated with different local qualities - the first zone and second zone have distinct contact characteristics. The interposed device applies thrust force with different distribution patterns to each zone, optimizing local force application while maintaining overall system simplicity.
Data Source
AI summary
Disc brake comprising a yoke, at least one first brake pad mounted so as to slide within the yoke, the first brake pad 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 in relation to the yoke, at least one actuator configured to move the piston axially, and a separators device inserted between the piston and the first brake pad forming an equaliser so as to distribute the thrust force exerted by the piston onto at least two zones of the first brake pad, at least partially distinct from the projection of the piston onto the first brake pad.