Multi-Piston Caliper Cover With Thermal Interface for Easy Mounting
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Solution Overview
Problem
Existing caliper covers face issues with inconvenient installation and disassembly, poor heat dissipation, and safety concerns due to design flaws such as loose fittings and small contact areas with the brake caliper.
Innovation Solution
A multi-piston-dedicated heat dissipating caliper cover with easy installation, featuring a caliper cover body with arc-shaped side plates, a fixing assembly with bolts and a positioning sheet, and heat dissipating assemblies including silicone sheets and thermally conductive materials to enhance fit and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a general caliper cover is used with glue fixation, then the caliper cover can be installed, but it becomes very difficult to remove and affects heat dissipation
Solution Approach 1:
The fixation method is segmented into multiple independent fixation points (buckles at both ends of the caliper cover) rather than a single glued connection. This allows the caliper cover to be securely fixed during use but easily released by simply unbuckling the fixtures, solving both the security and convenience requirements.
Solution Approach 2:
A buckle mechanism is introduced as an intermediary component between the caliper cover and the brake caliper. This intermediary allows for easy engagement and disengagement while maintaining secure fixation during operation, eliminating the need for permanent glue bonding.
2Adaptability or versatility
If a dedicated caliper cover with circular arc-shaped flat die is used, then it can cover the original caliper, but the buckle and connecting bracket are too long causing deformation and safety issues
Solution Approach 1:
The caliper cover adopts a three-dimensional curved surface design that conforms to the actual contour of the brake caliper, replacing the traditional circular arc-shaped flat die. This curved design provides better coverage and fit while allowing for shorter, more rigid fixation structures that reduce deformation and improve safety.
Solution Approach 2:
The design transitions from a two-dimensional circular arc profile to a three-dimensional curved surface that matches the brake caliper's complex geometry. This dimensional enhancement improves coverage and fit while enabling more efficient load distribution in the fixation structures.
3Ease of operation
If a dedicated caliper cover with small contact area is used, then it can be fixedly installed, but the heat dissipating effect is poor
Solution Approach 1:
The caliper cover features locally enhanced contact areas with increased surface roughness or thermal conductivity material at the interfaces with the brake caliper. This local quality enhancement improves heat transfer efficiency without compromising the fixed installation capability, addressing both the ease of operation and heat dissipation requirements.
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
Facilitates safe and easy installation and disassembly, improves heat dissipation by increasing contact area, and provides shock absorption to prevent noise and wear during vehicle operation.
Implementation Method 1
the heat dissipating silicone sheet is disposed on a side of the heat dissipating adhesive layer that is close to the brake caliper
Data Source
AI summary
A multi-piston-dedicated heat dissipating caliper cover with easy installation includes a caliper cover body, a fixing assembly and at least two first fixing bolts. One side edge of the caliper cover body extends toward a side to form a first arc-shaped side plate, and the other side edge of the caliper cover body extends toward a side to form a second arc-shaped side plate. The fixing assembly includes a bolt fixing sheet and a positioning sheet, one end of the positioning sheet is connected with the bolt fixing sheet through a second fixing bolt, and the other end of the positioning sheet passes through a strip-shaped hole and then is inserted into a slot at a top of a brake caliper. By disposing the heat dissipating silicone sheet, a contact area is increased, which allows the heat generated by the brake caliper to be quickly transferred to the caliper cover.