Modular Fixed Brake Caliper Structure for Low Weight and Stiffness
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Solution Overview
Problem
Existing disc brake caliper designs face challenges in maintaining stiffness, reducing weight, and simplifying construction, as they often result in increased unsprung weight, vibrations, and complex assembly processes, which affect braking performance and efficiency.
Innovation Solution
A modular fixed caliper body design with separable components, including bridge elements and half-bodies made from different materials, optimized for alignment and connection to reduce weight and deformation, while simplifying the working of thrust device housings and improving braking comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a traditional fixed caliper body design is used, then braking force and stability are improved, but weight increases and vibrations occur
Solution Approach 1:
The caliper body is divided into two separate half-bodies (first half-body and second half-body) that are connected via bridge elements. This segmentation allows each component to be optimized independently for strength and weight, reducing the overall caliper weight while maintaining the necessary braking force through the distributed structural design.
2Stability of the object's composition
If a traditional fixed caliper body design is used, then structural stability is improved, but deformations and vibrations increase
Solution Approach 1:
By segmenting the caliper into half-bodies connected by bridge elements, the structure can better manage and distribute mechanical stresses. The bridge elements act as independent stress management components that reduce deformation propagation, thereby lowering vibrations while maintaining overall structural stability.
Solution Approach 2:
The patent employs different materials for the half-bodies and bridge elements to optimize the balance between stability and vibration reduction. The composite material approach allows selecting materials with specific damping properties for the bridge elements to reduce vibrations while maintaining structural integrity.
3Weight of moving object
If a modular design with separable components is used, then weight is reduced and assembly is simplified, but manufacturing complexity increases
Solution Approach 1:
The modular segmentation of the caliper into standardized half-bodies and bridge elements with defined connection interfaces actually simplifies manufacturing. Each component can be produced using optimized processes for its specific function, and the standardized interfaces reduce assembly complexity despite the increased number of parts.
4Strength
If bridge elements are made from different materials than half-bodies, then deformation is reduced and performance is optimized, but manufacturing complexity increases
Solution Approach 1:
The use of different materials for bridge elements and half-bodies is justified by the distinct functional requirements. Bridge elements require materials with specific properties for stress distribution and vibration damping, while half-bodies require materials optimized for piston mounting and pad retention. This material differentiation optimizes deformation resistance and overall performance.
Data Source
AI summary
A fixed brake caliper for a disc brake disc has a first half-body housing a first thrust device, and facing a first braking surface, a second half-body housing a second thrust device, and facing a second braking surface, and a first bridge element connecting and supporting the second half-body to the first half-body. The first bridge element has a first and a second guiding and resting bridge surfaces. The first half-body has a first protrusion protruding towards the opposite second half-body. The second half-body has a second protrusion protruding towards the opposite first half-body. The first and second half-bodies and the bridge element are mutually separable. The first and second protrusions each delimit a guiding and resting half-body surface, respectively. The first bridge element rests the first bridge surface against the first half-body surface and the second bridge surface against the second half-body surface.