Multilayer Brake Caliper Body for High-Pressure Weight Reduction
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Solution Overview
Problem
Current disc brake caliper bodies face challenges in achieving a balance between mechanical resistance, structural rigidity, and weight reduction, with existing solutions failing to adequately address the need for a lightweight yet robust design that can withstand complex shapes and high stresses without deformation.
Innovation Solution
A multilayer caliper body design featuring an inner body portion with complex geometry for stress distribution and an outer body portion made of a polymeric matrix with embedded reinforcing fibers, providing enhanced mechanical properties and resistance to high pressures, achieved through co-molding and injection molding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum or steel caliper bodies are used, then mechanical resistance and structural rigidity are sufficient, but weight increases
Solution Approach 1:
The patent applies composite materials by combining a polymeric matrix with embedded reinforcing fibers (such as glass, carbon, or aramid fibers) to create a caliper body that achieves both lightweight properties and high mechanical resistance. This composite structure allows the caliper to maintain sufficient strength while significantly reducing weight compared to traditional aluminum or steel calipers.
2Stability of the object's composition
If aluminum or steel caliper bodies are used, then structural rigidity is sufficient, but weight increases
Solution Approach 1:
The composite material structure with reinforcing fibers embedded in the polymeric matrix provides high structural rigidity while maintaining low weight. The fiber reinforcement prevents deformation under stress, ensuring the caliper body maintains its structural integrity during braking operations without the weight penalty of traditional metallic materials.
3Strength
If reinforcement elements are embedded in the caliper body, then mechanical resistance improves, but weight reduction is not satisfactory
Solution Approach 1:
The patent achieves satisfactory weight reduction by integrating the reinforcement fibers directly into the polymeric matrix during the molding process, creating a homogeneous composite structure. This approach distributes the reinforcement throughout the entire caliper body, providing uniform mechanical resistance while maintaining lightweight properties, unlike discrete reinforcement elements that add significant weight.
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 solution results in a lighter caliper body with increased rigidity and reduced deformation, improved comfort due to damping properties, and enhanced durability and safety, while maintaining strength and adaptability to complex components.
Implementation Method 1
obtain shapes having complex geometry capable of distributing the stress received from the supports (5) and feeding pipes (9)
Implementation Method 2
rigid and resistant (also with high elastic modulus) to allow a reduced deformation of the caliper body also when stressed by high pressures
Implementation Method 3
increased comfort is achieved due to the employment of intrinsically damping materials
Data Source
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AI summary
The present invention relates to a caliper body (1) of a brake caliper (2) of disc brake (3) adapted to be arranged straddling a brake disc (4) to apply a braking action on a vehicle, where it comprises: supporting elements or supports (5) for supporting thrust or actuation devices (6) and/or supporting brake pads (7) or supporting at least one attaching element of the caliper body (8) for attaching the caliper body (1) to a support of the caliper, as well as feeding pipes (9) for supplying the thrust devices (6), wherein the supports (5) and feeding pipes (9) are made of a first material capable of withstanding high pressures; - at least one inner body portion (10) made of a second material adapted to incorporate therein at least partially said supports (5) and feeding pipes (9) and obtaining shapes having complex geometry capable of distributing the stress received from the supports (5) and feeding pipes (9); said at least one inner body portion (10) forms a first vehicle side elongated element (11) adapted to face a first braking surface (12) of the brake disc (4); and a second wheel side elongated element (13) adapted to face a second braking surface (14) of the brake disc (4) opposite to said first braking surface (12); said caliper body (1) further comprises at least one outer body portion (15) made of a third material adapted to form a reinforcement with mechanical resistance; wherein said supports (5) and feeding pipes (9) are embedded at least partially in said at least one inner body portion (10); and said inner body portion (10) is surrounded and encircled by said at least one outer body portion (15).