Monoblock Brake Caliper Transfer Port Layout With Single Plug
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Solution Overview
Problem
Conventional monoblock disc brake calipers face issues such as increased machined features and costs due to multiple transfer ports, which require sealing and plugging, and compromise brake lever feel due to numerous sealed ports.
Innovation Solution
A monoblock disc brake caliper design featuring a single transfer port plug with a crossover portion connecting inner and outer portions, utilizing a metal-to-metal seal through a transfer port aperture and O-ring recess to enhance structural integrity and fluid flow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple transfer ports are bored through the caliper, then fluid communication is achieved, but manufacturing complexity and cost increase due to multiple sealed ports
Solution Approach 1:
The patent consolidates multiple transfer ports into a single transfer port aperture located in the crossover portion. This single aperture provides fluid communication to both the inner piston bore and outer piston bore, eliminating the need for multiple separate ports and their associated sealing requirements.
Solution Approach 2:
The single transfer port aperture serves multiple functions by providing hydraulic fluid communication to both the inner and outer piston bores simultaneously. This multi-functional design replaces what would traditionally require multiple dedicated transfer ports.
2Strength
If multiple transfer ports are sealed and plugged, then structural integrity is maintained, but brake lever feel deteriorates
Solution Approach 1:
By merging multiple transfer ports into a single aperture, the patent reduces the number of sealed interfaces from multiple to just one. This minimizes the cumulative effect of sealed ports on brake lever feel while maintaining structural integrity through the unified design.
3Reliability
If proprietary boring processes are used for multiple transfer ports, then fluid transfer is achieved, but manufacturing cost increases
Solution Approach 1:
The patent reduces the number of boring operations from multiple to a single transfer port aperture. This consolidation significantly reduces manufacturing cost by eliminating redundant boring processes, sealing operations, and plugging operations while maintaining reliable fluid transfer functionality.
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 design improves brake lever feel and reduces manufacturing complexity and costs by minimizing the number of transfer ports, while ensuring reliable sealing and improved fluid communication.
Implementation Method 1
an O-ring seal in the O-ring recess to form a metal-to-metal seal with the transfer port plug
Data Source
AI summary
A monoblock disc brake caliper is provided. The monoblock disc brake caliper includes an inner portion, an outer portion, and a crossover portion formed between the inner portion and the outer portion. The inner portion, the outer portion and the crossover portion are formed as a single, unitary body. The monoblock disc brake caliper further includes a transfer port aperture formed in the crossover portion located at a centerline of the monoblock disc brake caliper. The monoblock disc brake caliper further includes an inner transfer port extending from the transfer port aperture to an inner piston bore and an outer transfer port extending from the transfer port aperture to an outer piston bore. The monoblock disc brake caliper further includes a transfer port plug that is coupled to the transfer port aperture to seal the transfer ports with a single plug.