Disk Brake Piston Composite Load Bearing Column
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Solution Overview
Problem
Current disk brake pistons face challenges in achieving a balance between being lightweight, strong, and cost-effective, with forged steel pistons being heavy and expensive, while plastic pistons lack strength and are prone to failure, and existing designs complicate assembly and maintenance.
Innovation Solution
A disk brake piston design featuring a load bearing column with a metal footing and core, where a spindle nut contacts the core to push against a brake pad, allowing for efficient force transmission and reduced weight, using a combination of materials like phenolic polymers and metals to enhance strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If forged steel piston is used, then strength is improved, but weight increases and manufacturing cost increases
Solution Approach 1:
The patent applies composite materials by combining a phenolic resin piston body with a steel reinforcement insert. The phenolic material provides lightweight properties while the steel insert provides structural strength where needed. This composite construction resolves the contradiction by achieving sufficient strength without the weight penalty of a fully steel piston.
Solution Approach 2:
The patent applies local quality by placing steel reinforcement only in specific high-stress areas rather than throughout the entire piston. The steel insert is positioned strategically to provide strength where required while leaving other areas as lightweight phenolic material, thus resolving the weight-strength contradiction.
2Manufacturing precision
If forged steel piston with machined surfaces is used, then strength and dimensional precision are improved, but manufacturing cost increases
Solution Approach 1:
The patent applies parameter changes by transitioning from a fully metallic piston requiring precision machining to a phenolic piston that can be molded to precise dimensions. The phenolic material allows for cost-effective manufacturing while achieving the required dimensional precision through molding processes rather than extensive machining.
Solution Approach 2:
The composite construction allows the phenolic portion to be molded with high precision at low cost, while the steel insert provides the necessary structural integrity. This resolves the contradiction between manufacturing precision and manufacturing cost.
3Weight of moving object
If plastic piston is used, then weight is reduced and manufacturing cost is reduced, but strength decreases and reliability decreases
Solution Approach 1:
The patent uses composite materials combining phenolic resin with steel reinforcement. The phenolic provides lightweight properties while the steel insert ensures sufficient strength and reliability. This resolves the contradiction by achieving weight reduction without sacrificing the reliability needed for brake system operation.
Solution Approach 2:
The steel reinforcement is applied locally in areas requiring high strength and reliability, while other areas remain as lightweight phenolic material. This targeted approach ensures reliability where critical while maintaining weight advantages, resolving the contradiction between weight and reliability.
4Adaptability or versatility
If complex internal structure is machined into piston, then functional capability is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent applies segmentation by dividing the piston into separate components: the phenolic piston body and the steel reinforcement insert. This allows each component to be manufactured independently using appropriate processes, then assembled together. The complex internal structures are handled in separate parts rather than requiring complex machining of a single monolithic component.
Solution Approach 2:
The composite construction allows different materials to be used for different functional requirements. The phenolic material can be molded with complex internal structures at low cost, while the steel insert provides additional structural functionality. This resolves the contradiction between functional capability and manufacturing difficulty.
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 achieves improved strength, reduced weight, and ease of assembly and maintenance by effectively transferring force to the brake pad through the load bearing column, while using lighter materials to minimize weight and operational complexity.
Implementation Method 1
a threaded spindle engaging an internally threaded nut and a nut contact surface having a conical shape which interfaces with a piston contact surface of the nut
Implementation Method 2
causing a braking action between the brake pads and the rotor
Data Source
AI summary
A disk brake piston having a spindle nut, and a load bearing column within a piston body. The load bearing column includes a footing configured to push against a brake pad and a core extending from the metal footing and slidably located within the piston body, wherein the spindle nut is configured to contact and push the metal core which pushes the metal footing which pushes on the brake pad.