Mono-Block Caliper Brake Structure for Lower Cost and Better Packaging
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Solution Overview
Problem
Existing caliper brake systems have complex component structures and exterior shapes, leading to increased manufacturing costs, reduced productivity, and limited spatial utilization in vehicles.
Innovation Solution
A simplified caliper brake design that reduces the number of components by integrating the caliper as a single component, featuring a brake disc, inner and outer brake pads, a pressing member, a caliper housing, a caliper bridge, guide members, and a boot, which collectively enhance the braking performance and marketability of vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional caliper brake with multiple assembled components is used, then the structural complexity and exterior shape are reduced, but the manufacturing cost increases and productivity decreases
Solution Approach 1:
The patent integrates multiple caliper components into a single mono-block structure, merging the caliper housing, mounting bracket, and other structural elements into one monolithic component. This consolidation reduces the number of separate parts that need to be manufactured and assembled, thereby simplifying the component structure while improving manufacturing productivity through fewer assembly operations and reduced part count.
2Device complexity
If a conventional caliper brake with multiple assembled components is used, then the structural flexibility is maintained, but the manufacturing cost increases
Solution Approach 1:
The patent consolidates multiple components into a single mono-block caliper structure, reducing the total number of parts that require manufacturing, inventory management, and assembly. This merging approach lowers manufacturing costs by eliminating assembly operations, reducing tooling requirements, and simplifying quality control processes, while still maintaining the necessary structural functionality through the integrated design.
3Reliability
If a conventional caliper brake design is used, then the component functionality is sufficient, but the spatial utilization in vehicle increases
Solution Approach 1:
The patent integrates multiple functional components into a single compact mono-block structure, eliminating the need for separate mounting brackets, fasteners, and adjustment mechanisms that would occupy additional space. This consolidation reduces the overall volume required for the caliper assembly in the vehicle, improving spatial utilization while maintaining all necessary braking functions within the integrated structure.
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 proposed caliper brake design stabilizes vehicle braking in various conditions, reduces manufacturing costs, improves spatial utilization, and enhances marketability and competitiveness by simplifying the component structure and exterior shape.
Implementation Method 1
at least one guide member fixedly installed on the caliper housing and provided to slide along the guide hole to guide movement of the caliper housing and the caliper bridge with respect to the carrier
Implementation Method 2
a boot provided between the guide hole and the guide member
Data Source
AI summary
A caliper brake includes a pressing member configured to press an inner brake pad toward a brake disc, a caliper housing in which at least a part of the pressing member is movably disposed, a caliper bridge connected to the caliper housing to cover an upper surface of the inner brake pad and upper and outward surfaces of the outer brake pad, a carrier fixedly installed to a vehicle body and including a guide hole formed to be recessed or pass through in forward and backward directions, and at least one guide member fixedly installed to the caliper housing and configured to slidable along the guide hole of the carrier to guide movement of the caliper housing and the caliper bridge with respect to the carrier.