Monoblock Brake Caliper Casting with Inserted U-Shaped Hydraulic Line
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Solution Overview
Problem
Conventional methods for manufacturing monoblock brake calipers face issues such as core damage, moisture absorption leading to casting defects, separate core removal processes, and limitations in forming hydraulic lines with appropriate diameters, which affect brake performance and require additional post-processing steps.
Innovation Solution
A method involving a U-shaped hydraulic pipe optimized for seating in a die during molding, with a metal core forming the cylinder and insert-casting the brake hydraulic line, eliminating the need for a sand core and allowing for integral formation of the caliper body and hydraulic line, enabling the use of various hydraulic line diameters and reducing post-processing requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a sand core is used to form the cylinder in the caliper body, then the cylinder shape can be formed during casting, but the core absorbs moisture and causes casting defects with bubbles
Solution Approach 1:
The patent removes the sand core from the casting process entirely. Instead of using a sand core to form the cylinder, the caliper body is cast with a cylindrical cavity that directly receives the piston assembly. This eliminates the moisture absorption and bubble formation issues associated with sand cores while maintaining the ability to form the cylinder shape during casting.
2Ease of manufacture
If a sand core is used to form the cylinder, then the cylinder can be formed during casting, but a separate process is required to break down and withdraw the core
Solution Approach 1:
The patent eliminates the sand core removal process by not using a sand core at all. The caliper body is cast with a pre-formed cylindrical cavity that requires no core extraction. This removes the separate breakdown and withdrawal steps, streamlining the manufacturing process and improving productivity.
3Ease of manufacture
If the hydraulic line is press-fitted into the sand core, then the hydraulic line can be positioned during casting, but the hydraulic line may be damaged due to core damage
Solution Approach 1:
The patent removes the sand core that was causing hydraulic line damage. The hydraulic line is positioned in the caliper body through direct casting into the cylindrical cavity without being press-fitted into a sand core. This eliminates the risk of core damage transferring to the hydraulic line while maintaining proper positioning during the casting process.
4Ease of manufacture
If the hydraulic line is formed with a sand core, then the monoblock structure can be achieved, but the hydraulic line diameter is limited and requires additional post-processing
Solution Approach 1:
The patent eliminates the sand core constraint that limited hydraulic line diameter options. By casting the caliper body with a cylindrical cavity that directly receives the piston assembly without a sand core, the design allows for greater flexibility in hydraulic line diameter selection. This enables optimization of brake performance without requiring additional post-processing steps to accommodate different diameter requirements.
Data Source
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AI summary
The present disclosure provides a monoblock brake caliper comprising a caliper body including an arcuate section in an arc shape to partially surround a brake disc, and a side section formed at both sides of the arcuate section and positioned in close proximity to both sides of the brake disc; a brake hydraulic line disposed inside the caliper body and configured to be insert-cast during the casting of the caliper body so as to be formed as a U-shaped pipe; and a metal core disposed on the inner side of the side section of the caliper body so as to be positioned adjoining the brake hydraulic line at a portion where a piston is to be disposed during the casting of the caliper body so that the metal core is removed from the caliper body after the casting of the caliper body to form a cylinder in the caliper body.