Monoblock Disc Brake Caliper Structure for Lower Manufacturing Cost
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Solution Overview
Problem
There is a need to reduce the cost of disc brakes and calipers used in vehicles.
Innovation Solution
The disc brake and caliper design incorporates a monoblock caliper main body with integrated cylinder parts and connection parts formed via casting, featuring a unique piston arrangement and a pad spring attachment mechanism that reduces material usage and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional multi-part caliper structure is used, then assembly flexibility and adjustability are improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The caliper main body integrates multiple functional components that were previously separate parts. The cylinder housing, piston mounting structure, friction pad retention features, and mounting interfaces are all combined into a single monoblock structure, eliminating the need for multiple separate components and reducing assembly complexity while maintaining manufacturing feasibility through casting processes
2Ease of repair
If multiple separate components are used in the caliper, then ease of repair and replacement are improved, but manufacturing cost and material usage increase
Solution Approach 1:
While the caliper main body is integrated, the design maintains separability of wear-prone components such as friction pads and seals. These components can be independently replaced without replacing the entire caliper assembly, balancing the need for repairability with the benefits of an integrated structure that reduces overall material usage and manufacturing cost
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 design achieves cost reduction by minimizing material waste and simplifying assembly processes while maintaining effective braking performance.
Implementation Method 1
a pad spring configured to press the friction pad toward the disc rotor
Implementation Method 2
apply frictional resistance to the disc rotor
Data Source
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AI summary
A disc brake according to the present invention includes a locking member which locks a friction pad to be movable in a disc axial direction, and a pressing member which presses the friction pad against a disc rotor, in which: the friction pad includes a lining material which comes into contact with the disc rotor, and a back plate to which the lining material is affixed; an extended part extending in a direction inclined with respect to a longitudinal direction of the friction pad is formed in the back plate on an end portion side in a disc rotation direction; the locking member includes a pad support part having a flat surface portion extending in a direction in which the extended part extends; and the extended part is locked to the pad support part.