Multi-piston Caliper Radially Staggered Bores Weight Reduction
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Solution Overview
Problem
Existing brake systems with fixed opposed calipers face challenges in reducing weight while maintaining stopping power and performance, particularly in the arrangement and configuration of pistons and bores relative to a rotor, which affects braking efficiency and weight distribution.
Innovation Solution
The caliper design features radially staggered and asymmetrically located bores on both sides, with some bores partially or entirely covered by pockets and boot grooves, allowing for the formation of non-overlapping circumferential tracks on the rotor and optimized piston alignment for improved braking performance and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fixed opposed brake systems use two or more pistons on each side of a rotor arranged in a line following the curvature of the rotor, then stopping power and performance are maintained, but weight reduction is limited
Solution Approach 1:
The patent applies asymmetry by radially staggering the bores on the inboard and outboard sides of the caliper, creating an asymmetric piston arrangement relative to the rotor. This asymmetric configuration allows for optimized weight distribution and material removal while maintaining effective braking force through proper piston positioning.
Solution Approach 2:
The patent transitions from a conventional linear arrangement of pistons to a multi-dimensional configuration by radially staggering bores at different positions and introducing asymmetric positioning. This dimensional change allows pistons to be distributed more efficiently in three-dimensional space, enabling weight reduction while preserving stopping power.
2Weight of moving object
If pistons are staggered within the respective sides of the caliper to reduce weight, then weight is reduced, but braking efficiency may be compromised
Solution Approach 1:
The patent applies local quality by positioning specific bores at different radial locations on the inboard and outboard sides of the caliper. Each bore is strategically placed to optimize its local contribution to braking efficiency while allowing overall weight reduction through the staggered configuration.
Solution Approach 2:
The patent incorporates pockets that partially or entirely radially cover the bores, performing preliminary material removal and structural preparation. This preliminary action optimizes the piston arrangement for both weight reduction and braking efficiency before the actual braking operation occurs.
3Weight of moving object
If bores are radially staggered and asymmetrically located on trailing and leading sides of a bisecting plane, then weight is reduced and performance optimized, but manufacturing complexity increases
Solution Approach 1:
The patent segments the caliper structure by dividing the bore positions into distinct groups on the inboard and outboard sides, with each side having its own staggered pattern. This segmentation allows for modular manufacturing approaches and simplifies the production of complex asymmetric configurations.
Solution Approach 2:
The patent uses pockets that partially or entirely cover the bores, creating a nested structure where the pocket contains the bore. This nesting simplifies manufacturing by combining multiple features into integrated structures, reducing the number of separate machining operations required.
4Reliability
If multiple non-overlapping circumferential tracks are formed on the rotor, then braking performance is improved, but the complexity of piston alignment increases
Solution Approach 1:
The asymmetric and radially staggered bore arrangement naturally creates non-overlapping circumferential tracks on the rotor when pistons are positioned. This asymmetric configuration simplifies the alignment process by eliminating the need for complex overlapping track designs while maintaining effective braking performance.
Solution Approach 2:
The patent uses radial staggering to create tracks at different radial positions, adding a radial dimension to the track configuration. This dimensional approach allows multiple non-overlapping tracks to be formed without increasing circumferential complexity, as the tracks are differentiated by their radial positions rather than just their circumferential locations.
Data Source
AI summary
A caliper comprising: (a) an inboard side; (b) an outward side, wherein the inboard side and the outboard side include three or more bores that are radially staggered relative to two or more of the bores; and (c) a pocket located within a central region of the inboard side, the outboard side, or both; wherein the bores on the inboard side, the outboard side, or both are positioned so that: (i) all of the bores are located entirely radially below the pocket; (ii) none of the bores are located below the pocket; (iii) one or more of the bores are located partially radially below the pocket; (iv) one or more of the bores are located entirely radially below the pocket; (v) one or more of the bores are not located partially or entirely radially below the pocket; or (vi) a combination of (iii) through (v).