Disc Brake Piston Weight Reduction via Segmented Plate Reinforcement
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Solution Overview
Problem
Existing disc brake pistons are inefficient in reducing weight due to uniform sheet thickness distribution, leading to high stress concentrations and limited weight reduction opportunities.
Innovation Solution
A piston design featuring a body member with a bottomed cylindrical shape and a plate-shaped member bonded to the external bottom surface, allowing for optimized sheet thickness distribution and stress management, with the plate-shaped member reinforcing the piston bottom portion and side portion to achieve effective weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If pistons are configured with inner members and outer members fitted and fixed onto the outer side, then structural integrity is maintained, but piston weight cannot be efficiently reduced
Solution Approach 1:
The piston is divided into multiple members: a bottomed cylindrical body member and a separate plate-shaped member. This segmentation allows each part to be optimized independently for weight and strength requirements, enabling efficient weight reduction while maintaining structural integrity through the coordinated design of separate components.
Solution Approach 2:
The plate-shaped member is specifically positioned at the bottom center region of the piston where stress concentrations occur. This local reinforcement strategy provides targeted strength enhancement in critical areas without adding unnecessary weight to the entire piston structure, achieving efficient weight reduction while maintaining required structural integrity.
2Weight of moving object
If uniform sheet thickness is used throughout the piston, then manufacturing is simplified, but stress concentrations occur and weight reduction opportunities are limited
Solution Approach 1:
The plate-shaped member with optimized thickness is strategically placed at the bottom center region where stress concentrations occur during braking operations. This creates a non-uniform thickness distribution that provides localized reinforcement exactly where needed, reducing stress concentrations and enabling weight reduction in non-critical areas while maintaining overall structural performance.
Data Source
AI summary
Provided are a disc brake and a piston whose weights can be effectively reduced. A disc brake includes a piston configured to press a pad against a disc. The piston includes a body member formed into a bottomed cylindrical shape and including a cylinder portion and a bottom portion. The cylinder portion and the bottom portion are approximately equal in wall thickness. The piston further includes a plate-shaped member fixed to an external bottom surface of the body member and disposed within a range of the external bottom surface and in a region including a center of the external bottom surface.