Integrated Caliper Brake Structure for Lower-Cost Actuation
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Solution Overview
Problem
Monoblock type calipers in high-performance vehicles require additional components for actuation, increasing manufacturing costs and complexity, while maintaining a beautiful appearance and high rigidity.
Innovation Solution
A caliper brake design with a simplified structure that integrates a caliper housing, guide rods, and a restoration device, reducing the number of parts and enabling stable braking without additional components, while maintaining a sleek appearance and improving marketability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional components (parking piston, parking caliper) are added to monoblock type caliper for actuator integration, then braking function is achieved, but manufacturing cost increases and productivity decreases
Solution Approach 1:
The patent combines the parking caliper and sliding caliper functions into a single integrated caliper body structure. The caliper body includes both the parking brake application portion and the sliding brake application portion, eliminating the need for separate parking piston and parking caliper components. This merging approach achieves the braking function while reducing part count and manufacturing complexity.
2Reliability
If additional components are added to monoblock type caliper, then actuator integration is achieved, but manufacturing period increases
Solution Approach 1:
The integrated caliper body design merges multiple brake functions into a single manufacturable component. The caliper body is designed to accommodate both parking and sliding brake operations through its structural configuration, allowing for streamlined manufacturing processes and reduced assembly time compared to separate component approaches.
3Ease of manufacture
If conventional caliper structure with multiple components is used, then ease of manufacture is improved, but appearance and rigidity are compromised
Solution Approach 1:
The patent achieves a monoblock type integrated structure that combines multiple caliper functions into one unified component. This integration provides a sleek, continuous appearance without visible joints or seams, while maintaining manufacturing feasibility through careful design of the unified structure. The single-piece construction enhances both aesthetics and structural rigidity.
Solution Approach 2:
While maintaining an integrated appearance, the caliper body is functionally segmented into distinct regions: the parking brake application portion and the sliding brake application portion. This functional segmentation allows each brake type to operate independently within the unified structure, achieving both aesthetic simplicity and functional versatility.
4Shape
If monoblock type caliper is manufactured by precisely processing one component, then appearance is improved, but manufacturing cost and period increase
Solution Approach 1:
The integrated caliper body design merges multiple functions into a single component that can be manufactured as one piece. The structure is designed to accommodate both parking and sliding brake mechanisms within the unified body, reducing the need for post-manufacturing assembly operations and associated costs while maintaining the aesthetic benefits of a monoblock construction.
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 design achieves cost-effective manufacturing, stable braking performance, and enhanced product appearance, promoting space utilization and market competitiveness.
Implementation Method 1
at least one guide rod fixed to the carrier and guiding sliding movement of the caliper housing and the caliper bridge with respect to the carrier
Implementation Method 2
a restoration device configured to elastically support the caliper housing and the caliper bridge in a direction to return to original positions with respect to the carrier
Data Source
AI summary
Disclosed herein a caliper brake includes a brake disc rotating with a wheel of a vehicle; an inner brake pad and an outer brake pad respectively disposed on opposite sides of the brake disc; a pressing member configured to press the inner brake pad against the brake disc; a caliper housing in which the pressing member is movable forward and backward; a caliper bridge connected to the caliper housing and configured to press the outer brake pad against the brake disc by a reaction force in response to operation of the pressing member; a carrier fixed to a body of the vehicle; and at least one guide rod fixed to the carrier and guiding sliding movement of the caliper housing and the caliper bridge with respect to the carrier.