Partially Cast Pipe Layout for Lightweight Piston Housing
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Solution Overview
Problem
Conventional piston housing bodies require thicknesses that are 3.5 times the outer diameter of aluminum pipes to prevent defects, limiting downsizing and weight reduction for improved vehicle driving performance.
Innovation Solution
A piston housing body design where both ends of an aluminum alloy pipe are cast into the main body, with the intermediate portion exposed outside, and featuring annular flanges or grooves for enhanced bonding and reinforcement, allowing for partial embedding of the pipe within the main body to achieve downsizing and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire aluminum pipe is cast in the piston housing body, then defects such as positional accuracy, melt loss, weld lines, and gas generation are prevented, but the thickness requirement of 3.5 times the outer diameter limits downsizing and weight reduction
Solution Approach 1:
The pipe is divided into two parts: the intermediate portion remains separate while the end portions are cast in the piston housing body. This segmentation allows the housing body to be thinner and lighter while still preventing defects at the critical connection points where the pipe meets the housing.
Solution Approach 2:
The intermediate portion of the pipe is extracted from the casting process and remains as a separate component. This extraction eliminates the need for the entire pipe to be embedded in the housing body, enabling weight reduction while maintaining defect prevention at the connection points.
2Strength
If the entire aluminum pipe is cast in the piston housing body, then structural integrity is maintained, but downsizing and weight reduction are limited
Solution Approach 1:
The pipe structure is segmented into an intermediate portion and end portions, with only the end portions being cast in the housing body. This maintains structural integrity at the critical connection points while reducing the overall volume of the housing body required for embedding the entire pipe.
Solution Approach 2:
Instead of casting the entire pipe in the housing body, only the necessary end portions are cast in. This partial action is sufficient to maintain structural integrity while allowing for downsizing of the housing body.
3Weight of moving object
If the pipe is partially embedded in the main body portion, then downsizing and weight reduction are achieved, but joining strength and adhesion between pipe and caliper body need enhancement
Solution Approach 1:
Annular flanges, grooves, or roughened portions are added at the specific locations where the pipe meets the housing body. These local modifications concentrate the bonding strength at the critical interface without requiring the entire pipe to be embedded, thus maintaining weight reduction while enhancing joining strength.
Solution Approach 2:
The annular flanges, grooves, or roughened portions are prepared in advance on the pipe before casting. This preliminary action ensures that when the pipe is cast in the housing body, the bonding interface is already optimized for strong adhesion, eliminating the need for post-processing or additional strengthening measures.
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
This design achieves significant downsizing and weight reduction while maintaining structural integrity and sealing, reducing defects like weld lines and gas generation, and enhancing the bonding strength between the pipe and the caliper body.
Implementation Method 1
both end portions of the pipe are cast in the main body portion
Implementation Method 2
a portion where flux of the pipe is melted and wetted is in close contact with the piston housing body
Implementation Method 3
a portion where flux of the pipe is melted and wetted is in close contact with the piston housing body
Implementation Method 4
flux is applied at least to the flange, the groove, or the roughened portion
Data Source
AI summary
The present invention provides a piston housing body capable of achieving downsizing and weight reduction.In a piston housing body having a main body portion provided with at least a pair of piston housing portions for housing at least a pair of opposing pistons, an operating fluid circulation flow path connecting the piston housing portions, and a connection portion for connecting an operating fluid supply flow path to the operating fluid circulation flow path, the operating fluid circulation flow path is constituted by a pipe, both end portions of the pipe are cast in the main body portion, and an intermediate portion of the pipe and the connection portion are exposed outside the main body portion.