Floating Brake Caliper Plate Section for Uniform Pad Pressure
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing brake calipers with a finger design often fail to provide optimal brake performance due to non-uniform brake pressure distribution, vibration characteristics, and elastic deformation issues during braking.
Innovation Solution
A floating brake caliper design featuring a plate-shaped section that covers at least half of the rear face of the brake pad, providing a more uniform pressure distribution and increased axial stiffness, along with a method and tool for surface machining that eliminates the need for separate finger portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a finger design with gaps is used in the brake caliper, then tool insertion for machining is enabled, but brake pressure distribution becomes non-uniform and vibration characteristics deteriorate
Solution Approach 1:
The brake caliper is divided into multiple fingers separated by gaps, enabling tool insertion for machining while maintaining structural integrity. The segmentation allows manufacturing access through the gaps while the fingers collectively provide sufficient contact area with the brake pad to ensure uniform pressure distribution.
Solution Approach 2:
Different regions of the brake caliper have different properties: the fingers have localized contact areas with the brake pad, while the gaps provide machining access. The plate-shaped section covers at least half of the brake pad's rear face to ensure uniform pressure distribution in the critical contact region.
2Ease of manufacture
If a finger design with gaps is used in the brake caliper, then tool insertion for machining is enabled, but vibration characteristics and elastic deformation under brake load worsen
Solution Approach 1:
The brake caliper is divided into multiple fingers separated by gaps, enabling tool insertion for machining while maintaining structural integrity. The segmentation allows manufacturing access through the gaps while the fingers collectively provide sufficient contact area with the brake pad to ensure uniform pressure distribution.
Solution Approach 2:
The brake caliper combines metallic material properties with a specific geometric configuration (fingers and plate-shaped section) to achieve both manufacturability and dynamic stability. The composite structure of fingers and plate section provides appropriate stiffness and vibration characteristics while allowing tool access.
3Reliability
If a plate-shaped section covering at least half of the brake pad rear face is used, then pressure distribution uniformity and axial stiffness are improved, but device complexity increases
Solution Approach 1:
Different regions of the brake caliper have different properties: the fingers have localized contact areas with the brake pad, while the gaps provide machining access. The plate-shaped section covers at least half of the brake pad's rear face to ensure uniform pressure distribution in the critical contact region.
Solution Approach 2:
The patent combines the finger design with a plate-shaped section into a single integrated brake caliper structure. The plate section merges with the fingers to form a unified component that provides both the machining accessibility of fingers and the pressure distribution uniformity of a plate, reducing overall device complexity.
4Stability of the object's composition
If a plate-shaped section covering at least half of the brake pad rear face is used, then vibration characteristics and eigenfrequencies are improved, but device complexity increases
Solution Approach 1:
Different regions of the brake caliper have different properties: the fingers have localized contact areas with the brake pad, while the gaps provide machining access. The plate-shaped section covers at least half of the brake pad's rear face to ensure uniform pressure distribution in the critical contact region.
Solution Approach 2:
The patent combines the finger design with a plate-shaped section into a single integrated brake caliper structure. The plate section merges with the fingers to form a unified component that provides both the machining accessibility of fingers and the pressure distribution uniformity of a plate, reducing overall device complexity.
Data Source
AI summary
The invention concerns a floating brake caliper for a vehicle disc brake, the brake caliper comprising a first portion that is arrangeable adjacent to a first side face of a brake disc of the vehicle disc brake and that is configured to receive a brake piston, a second portion that is arrangeable adjacent to a second side face of the brake disc wherein the second portion is configured to rest against a rear face of a brake pad of the vehicle disc brake, and wherein the second portion has a plate-shaped section that is configured to cover a geometric centre of the rear face of the brake pad and to cover at least half of the surface of the rear face of the brake pad and the invention also concerns a toll and method for surface machining of a brake caliper.