Disc Brake Caliper Piston Layout for Faster, Even Braking
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Solution Overview
Problem
Current disc brake calipers do not achieve prompt and immediate braking due to suboptimal piston configuration and pressure distribution, leading to uneven friction material consumption and reduced braking efficiency.
Innovation Solution
A disc brake caliper design with a specific arrangement of pistons and bridge portions, where the pressure centers of the pistons are strategically positioned to create a rigid structure with uniform load distribution, enhancing braking performance and reducing friction material consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional piston arrangement is used, then the caliper structure is simple, but the braking action is not prompt and immediate
Solution Approach 1:
The patent applies asymmetry by strategically positioning pistons at different radial distances from the disc rotation axis. The pressure centers of the pistons are arranged asymmetrically relative to the bridge portion center of gravity, creating an optimized load distribution that enhances braking response speed while maintaining structural simplicity.
Solution Approach 2:
The patent transitions from conventional single-plane piston arrangement to a multi-dimensional configuration where pistons are distributed at different radial distances and angular positions. This spatial distribution in multiple dimensions optimizes the pressure application on the friction material, achieving prompt braking action.
2Manufacturing precision
If conventional pressure distribution is used, then the caliper design is straightforward, but friction material consumption is uneven
Solution Approach 1:
The patent applies local quality by creating different pressure zones through strategically positioned pistons at varying radial distances. Each piston group applies pressure to specific local areas of the friction material, ensuring uniform consumption across the entire friction surface rather than uniform pressure distribution throughout.
Solution Approach 2:
The patent changes the pressure distribution parameters by adjusting piston positions at different radial distances from the disc axis. This parameter optimization ensures that pressure is distributed evenly across the friction material surface, preventing localized wear and extending friction material life.
3Strength
If pistons are positioned away from bridge portion center of gravity, then braking rigidity improves, but pressure distribution becomes uneven
Solution Approach 1:
The patent segments the piston arrangement into multiple groups positioned at different radial distances from the disc rotation axis. This segmentation allows the caliper to achieve both rigidity (through strategic positioning away from the bridge center of gravity) and even pressure distribution (through distributed piston groups that collectively balance the load).
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design results in a more rigid caliper capable of delivering prompt and vigorous braking with even pressure distribution and reduced friction material consumption, improving overall braking action.
Implementation Method 1
The design results in a more rigid caliper capable of delivering prompt and vigorous braking with even pressure distribution
Implementation Method 2
The caliper also holds pistons which, by being hydraulically operated, push the pads against the disc surfaces
Implementation Method 3
obtaining the braking by virtue of the action of the friction material
Data Source
AI summary
A disc brake caliper has a caliper body and a pair of pads and, in each side portion of the caliper body, a distal piston and a proximal piston, having radially distanced and aligned pressure centers.