Flexible Sheathing for Disc Brake Piston-Cylinder Units
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Solution Overview
Problem
Existing solutions for flexible sheathing in disc brakes increase the overall dimensions of the brake caliper and weaken the cylinder's resisting section, reducing stiffness and performance.
Innovation Solution
A flexible sheathing design that accommodates folds within a disc-shaped configuration, using hooking rings for attachment to the caliper and piston, allowing extension without the need for additional housing within the caliper body, thereby maintaining stiffness and reducing overall dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a housing is provided within the caliper body to accommodate the retracted flexible sheathing, then the sheathing can be protected and stored, but the overall dimensions of the brake caliper increase
Solution Approach 1:
The flexible sheathing is nested within the piston-cylinder unit structure itself. The sheathing is anchored to the piston and extends to the caliper body, with its retracted folds naturally accommodated within the existing cylindrical space, eliminating the need for a separate housing structure.
Solution Approach 2:
The piston-cylinder assembly serves multiple functions: it houses the piston for braking action, provides structural support, and simultaneously accommodates the retracted flexible sheathing. This multi-functionality eliminates the need for dedicated sheathing housing, maintaining compact caliper dimensions.
2Reliability
If an annular groove is provided in the caliper body for the sheathing folds, then the sheathing can be accommodated, but the resisting section of the cylinder is weakened
Solution Approach 1:
The sheathing accommodation function is extracted from the caliper body structure and transferred to the piston-cylinder assembly. By anchoring the sheathing to the piston and utilizing the cylindrical space, the need for weakening the caliper body with annular grooves is eliminated, preserving the structural integrity and resisting section of the cylinder.
3Ease of manufacture
If clearance is left between pads and piston when piston is entirely accommodated, then the sheathing can be installed, but the overall dimensions of the brake caliper increase
Solution Approach 1:
The design accommodates the dynamic range of piston movement without requiring additional static clearance. The flexible sheathing naturally adapts to the piston position, being compressed when the piston is retracted and extending when the piston moves outward, eliminating the need for fixed clearance spaces that would increase caliper dimensions.
Data Source
AI summary
Flexible sheathing for the protection of piston-cylinder units for disc brakes are provided. Such flexible sheathing may be arranged in a retracted condition wherein the piston is completely accommodated within the cylinder and in an extended condition wherein the piston is completely extracted from a caliper body defining the cylinder. Pistons incorporating such flexible sheathings and calipers incorporating such pistons are also provided.