Flat-Mount Brake Caliper Layout for Deeper Thread Engagement
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Solution Overview
Problem
Existing bicycle brake calipers, particularly flat mount designs, face challenges in achieving strong bolt thread engagement due to the obstruction of piston cylinders by threaded bore projections, which limits the depth of threaded bores and thus the load capacity of the mounting interface.
Innovation Solution
The design of a flat mount brake caliper with outboard and inboard caliper bodies, where the piston cylinders are arranged such that their central axes do not intersect with the projections of the threaded bores, allowing the threaded bores to extend deeper into the caliper body for improved bolt thread engagement and load capacity, and featuring a 4-piston configuration for enhanced braking force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the threaded bores are positioned centrally in the caliper body, then the mounting interface is simplified, but the piston cylinders obstruct the threaded bore projections, limiting thread engagement depth and load capacity
Solution Approach 1:
The patent resolves the spatial conflict between threaded bores and piston cylinders by repositioning the threaded bores from a central location to offset positions along the outer periphery of the caliper body. This dimensional relocation in the radial plane allows the threaded bore projections to extend fully without intersecting the piston cylinders, thereby achieving both simplified mounting interface design and maximum thread engagement depth for enhanced load capacity
2Strength
If the threaded bores are positioned to avoid piston cylinders, then bolt thread engagement depth is improved, but the mounting interface becomes more complex
Solution Approach 1:
The patent employs asymmetric positioning of the threaded bores relative to the caliper body's central axis. By placing the threaded bores at offset locations along the outer periphery rather than symmetrically at the center, the design achieves non-intersecting projections with the piston cylinders while maintaining a relatively simple mounting interface that leverages the natural asymmetric geometry of the caliper structure
3Strength
If deeper threaded bore penetration is achieved, then load capacity increases, but the piston cylinders obstruct the bore projections
Solution Approach 1:
By relocating the threaded bores to offset positions along the outer periphery of the caliper body, the patent enables deeper bore penetration into the caliper structure without the projections intersecting the piston cylinders. This dimensional repositioning allows maximum thread engagement depth for enhanced load capacity while maintaining straightforward bore fabrication through the caliper material
Data Source
AI summary
Flat mount brake calipers for bicycles are described herein. An example flat mount brake caliper includes a caliper body defining a first piston cylinder and a second piston cylinder. The caliper body has a flat mount surface with a first threaded bore and a second threaded bore extending into the flat mount surface. The first and second threaded bores are configured to receive threaded fasteners to couple the caliper body to a frame of the bicycle. The first and second piston cylinders are arranged such that projections of the first and second threaded bores do not intersect the first or second piston cylinders. The flat mount brake caliper also includes a brake pad and first and second pistons disposed in the respective first and second piston cylinders to move the brake pad relative to the caliper body.