Trailing-Link Fork Brake Caliper Layout for Lower Unsprung Mass
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Solution Overview
Problem
The existing location of disc brake calipers on bicycle suspension forks as unsprung mass affects suspension performance, adds aerodynamic drag, and hinders optimal cooling, leading to reduced braking efficiency and increased risk of overheating.
Innovation Solution
The disc brake caliper is fixedly connected to a portion of the sprung fork, located forward of the trailing-link linkage member and wheel axle, minimizing unsprung mass and optimizing airflow for enhanced cooling and reduced aerodynamic drag.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the disc brake caliper is mounted on the unsprung mass portion of the suspension fork, then the braking function is achieved, but the suspension performance deteriorates due to increased unsprung mass
Solution Approach 1:
The suspension fork is divided into sprung mass and unsprung mass portions. The disc brake caliper is specifically mounted on the sprung mass portion (fork crown or upper tube), separating the braking component from the unsprung mass. This segmentation allows the braking function to be maintained while the unsprung mass remains minimized, improving suspension performance.
Solution Approach 2:
Instead of the conventional approach of mounting the brake caliper on the unsprung mass (lower fork), this invention inverts the mounting location to the sprung mass portion (upper fork). This inversion resolves the contradiction by placing the braking component where it does not contribute to unsprung mass, thereby maintaining both braking reliability and suspension performance.
2Ease of manufacture
If the disc brake caliper is located rearward of the fork, then the mounting is conventional, but the aerodynamic drag increases and cooling efficiency decreases
Solution Approach 1:
The brake caliper location is inverted from the conventional rearward position to a forward position on the sprung mass portion of the fork. This inversion places the caliper in a location that experiences less aerodynamic drag and is in the path of oncoming air, improving cooling efficiency while reducing the harmful aerodynamic effects.
Solution Approach 2:
The brake caliper is positioned in a specific location on the sprung mass portion that optimizes its exposure to airflow. This local positioning ensures the caliper receives maximum cooling from passing air while minimizing aerodynamic drag on the overall bicycle system, addressing the local quality of airflow interaction at the brake location.
3Device complexity
If the disc brake caliper is mounted in a location not exposed to maximum cooling potential, then the mounting structure is simplified, but the braking performance deteriorates due to overheating
Solution Approach 1:
Instead of mounting the caliper in a sheltered location that simplifies the mounting structure but poor cooling, the invention inverts the approach by mounting the caliper in a location that maximizes cooling exposure. The caliper is positioned on the sprung mass portion where it is directly exposed to oncoming airflow, using the natural airflow to provide cooling without requiring complex active cooling systems.
Solution Approach 2:
The brake caliper mounting location is designed to utilize the natural airflow generated by the bicycle's forward motion to cool the brakes. The caliper's position on the sprung mass portion ensures it is in the path of oncoming air, allowing the system to self-cool using the environment rather than requiring additional active cooling mechanisms, thus maintaining simple mounting structure while achieving effective cooling.
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
This configuration improves suspension performance by reducing unsprung mass, enhances braking efficiency through better cooling, and decreases aerodynamic drag, resulting in improved handling and safety.
Implementation Method 1
the disc brake caliper is located where it is not exposed to the maximum cooling potential of the passing airflow
Data Source
AI summary
The present disclosure relates to the location of a disc brake caliper mounted to a trailing-link suspension fork. In one aspect, the disc brake caliper is attached to a sprung portion of the fork, hence adding zero mass and corresponding inertia to the un-sprung portion of the suspension system. Further, the disc brake caliper is positioned forward of the wheel axle and linkage member.