Hydraulic Brake Caliper Piston Tool for Threaded and Unthreaded Designs
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Solution Overview
Problem
Existing tools for pushing back pistons/plungers in disc brakes are either slow or laborious and cannot be applied to all types of disc brakes due to differences in piston/plunger structures, such as threaded vs. unthreaded designs.
Innovation Solution
A hydraulic brake caliper piston/plunger tool comprising a handle with a fluid reservoir, a barrel, a shaft, and an operation lever, featuring a fluid circuit system with check valves and a return spring, allowing for efficient operation on both threaded and unthreaded pistons/plungers by alternately depressing and releasing the operation lever to push the piston/plunger back into the caliper.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional threaded rod tools are used to push back pistons, then the piston can be pushed back into the caliper, but the operation becomes slow and laborious
Solution Approach 1:
The patent employs a hydraulic system where a plunger compresses fluid in a fluid chamber, generating hydraulic pressure that acts on the piston through a shaft to push it back into the caliper. This hydraulic mechanism replaces manual threading operations, significantly reducing operational effort and increasing productivity while maintaining effective piston retraction force.
2Adaptability or versatility
If conventional tools are used for disc brakes, then they can push back unthreaded pistons, but they cannot be applied to threaded pistons/plungers
Solution Approach 1:
The patent designs a universal tool structure where the shaft can accommodate both threaded and unthreaded pistons. The shaft features a universal interface that can engage with different piston types, allowing the same hydraulic tool to push back both threaded and unthreaded pistons into various caliper designs, eliminating the need for multiple specialized tools.
3Reliability
If multiple specialized tools are used for different piston types, then each tool can be optimized for its specific application, but the overall tool cost increases
Solution Approach 1:
The patent creates a single multi-functional hydraulic tool that can handle both threaded and unthreaded pistons through a universal shaft design. This eliminates the need for maintaining multiple specialized tools while preserving effective performance for different piston types, thereby reducing overall tool costs and simplifying the toolset required for brake maintenance.
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 tool is labor-saving, easy to use, and applicable to all types of disc brakes, reducing tool costs and operational effort.
Implementation Method 1
a fluid circuit system is provided in the handle such that the fluid chamber is communicated with the fluid reservoir and the circumferential passage. The operation lever is spring-biased and provided with a plunger inserted into the fluid chamber. In use, alternately depressing and releasing the operation lever enables the plunger to force fluid to flow into the central hole of the barrel by way of the fluid circuit system and the circumferential passage, thus pushing the piston together with the shaft to move forward
Implementation Method 2
A first check valve is provided at the fluid supply passage to ensure fluid to unidirectionally flow from the fluid reservoir to the fluid chamber. A second check valve is provided at the first fluid feed passage to ensure fluid to unidirectionally flow from the fluid chamber to the central hole of the barrel
Implementation Method 3
A return spring is fitted around the shaft in a central hole of the barrel, between the piston and the front tube. The operation lever is spring-biased and provided with a plunger inserted into the fluid chamber
Data Source
AI summary
A hydraulic brake caliper piston/plunger tool includes a handle, a barrel with rear and front tubes, and a shaft. The handle is provided therein with a fluid reservoir and a fluid chamber, and pivotally connected with an operation lever having a plunger inserted into the fluid chamber. The shaft is attached with a piston and fitted through the rear tube, the barrel and the front tube. A return spring is fitted around the shaft in a central hole of the barrel, between the piston and the front tube. A front end of the shaft is adapted to be fitted with an accessory for a disc brake. A rear end of the shaft is adapted to be connected with a turning tool. In use, alternately depressing and releasing the operation lever enables fluid to enter the central hole of the barrel to have the piston together with the shaft moved forward.