Modular Brake Piston with Conical Pressure Interface
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Solution Overview
Problem
Current brake caliper designs for motor vehicle disc brakes require different components for various actuation types and wear compensation, leading to increased manufacturing and logistics efforts and costs, with a lack of cost-effective solutions for producing identical parts across different brake configurations.
Innovation Solution
A modular piston system with conical surfaces on the pressure piece and base for brake pressure transmission, allowing for a cost-effective production process using metal-forming techniques, where the pressure piece can be omitted for disc brakes without a parking brake device or pad wear compensation, and incorporating a central through hole and anti-rotation features to secure components, enabling the use of identical parts across different configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different pistons are designed for different brake configurations (with/without parking brake, with/without wear compensation), then the brakes can be optimized for specific functions, but the manufacturing complexity and logistics costs increase
Solution Approach 1:
The patent implements a universal piston design that can serve multiple brake configurations through optional components. The base piston structure remains identical across all applications, while functional variations are achieved by adding or omitting optional elements like the pressure piece for wear compensation or the threaded nut for parking brake integration. This allows a single piston design to adapt to different brake types without increasing manufacturing complexity.
Solution Approach 2:
The piston is divided into modular components: a base piston structure and optional add-on elements (pressure piece, threaded nut). These segmented components can be selectively assembled or omitted based on the required brake configuration, enabling versatility while maintaining simple production of each individual component.
2Reliability
If specialized pistons are produced for different brake types, then functional requirements are met, but production costs and logistics efforts increase
Solution Approach 1:
By designing a universal base piston that works across all brake configurations, the patent eliminates the need for multiple specialized production lines. The same basic piston can be used for disc brakes with or without parking brake functions and with or without wear compensation, significantly reducing manufacturing costs and simplifying logistics while maintaining reliable brake function through optional components.
Solution Approach 2:
The patent merges the common functional requirements of all brake types into a single base piston design. By combining the essential piston features that are needed across all configurations into one standardized component, the patent achieves cost-effective mass production while still allowing customization through optional elements when specific functions are required.
3Ease of manufacture
If a modular piston system with optional pressure piece is used, then production costs are reduced through identical parts, but the device structure becomes more complex
Solution Approach 1:
The modular piston system segments the piston into a base structure and optional components (pressure piece, threaded nut). This segmentation allows the base piston to be produced in large quantities as an identical standard part, improving production efficiency. The optional components are only added when specific functions are needed, so the base structure remains simple while providing the capability for functional variation.
Solution Approach 2:
The pressure piece acts as an intermediary component that mediates between the base piston and the brake pad wear compensation function. By introducing this optional intermediate element, the patent enables wear compensation functionality without redesigning the entire piston, thus maintaining production efficiency while adding the necessary function only when required.
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 approach reduces production costs and logistical complexities by enabling the use of identical parts for various brake configurations, achieving cost-effective and efficient manufacturing through a modular design that adapts to different brake types without the need for specialized pistons, while ensuring secure and space-efficient component alignment.
Implementation Method 1
conical surfaces facing one another for brake pressure transmission
Implementation Method 2
the transmission has a threaded spindle and a threaded nut
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to a multi-part piston (1) for a brake saddle of a hydraulically and/or mechanically and/or electromechanically actuated disk brake, said piston designed substantially as a pot open on one side and comprising a base (6) and a wall (5) attached thereto in one piece, wherein the base (6) can be impinged by brake pressure coming from the inside of the pot (8) so that an outward-facing abutting surface (9) of the base (6) can be pressed against a brake lining (10), and wherein the inside of the pot (8) receives at least one pressure piece (17) associated with a parking brake mechanism. For simplified manufacture in the form of a modular piston system for use in various applications, it is proposed that the pressure piece (17) and the base (6) comprise conical surfaces (18) facing one another for transferring braking pressure.