Disc Brake Piston Boot With Integrated Support Ribs
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Solution Overview
Problem
The piston boot structure in disc brakes, which includes an annular metallic member buried in an elastic body, faces challenges in productivity, leading to increased costs due to complex mold designs and potential deformation issues during assembly.
Innovation Solution
A piston boot design with an annular fitting section that encloses an annular metallic member and is fitted to a stepped section of the cylinder, featuring a bellows section capable of expansion and contraction, along with multiple holes and notches that enhance support and stability, eliminating the need for a lip section that contacts the cylinder wall, thus simplifying the mold design and improving assembly quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a piston boot with an annular metallic member buried in an elastic body is used, then the structural strength and stability are improved, but the manufacturing complexity and cost increase due to complex mold design
Solution Approach 1:
The piston boot is divided into distinct functional sections: a fitting section with integrated support ribs for structural reinforcement, a bellows section for expansion and contraction, and a sealing section. This segmentation allows each part to be optimized independently, reducing overall manufacturing complexity while maintaining structural stability.
Solution Approach 2:
The support ribs are strategically positioned only in the fitting section where maximum structural support is needed, rather than throughout the entire piston boot. This localized reinforcement provides necessary stability while minimizing material usage and mold complexity.
2Strength
If a piston boot with an annular metallic member buried in an elastic body is used, then the structural strength is improved, but the productivity decreases due to complex manufacturing processes
Solution Approach 1:
The support ribs are integrated directly into the piston boot body during a single molding operation, eliminating the need for separate manufacturing and assembly steps. This merging of functions into one component significantly improves productivity while maintaining the structural strength provided by the ribs.
Solution Approach 2:
The piston boot combines elastic material for flexibility and sealing with embedded metallic support ribs for structural strength. This composite structure achieves high strength-to-weight ratio and structural integrity without requiring complex multi-step manufacturing processes.
3Stability of the object's composition
If the piston boot structure includes an annular metallic member buried in an elastic body, then the stability is improved, but the cost increases due to complex mold design and assembly
Solution Approach 1:
The support ribs are pre-formed as integral parts of the piston boot during the molding process, rather than being added as separate components during assembly. This preliminary formation ensures precise positioning and stable assembly while eliminating the cost and complexity of separate assembly operations.
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 stabilizes assembly, improves quality, and reduces the risk of deformation, thereby suppressing the increase in cost and productivity issues associated with the traditional piston boot structure, resulting in a more cost-effective disc brake system.
Implementation Method 1
a bellows section capable of expanding and contracting with the movement of the piston
Data Source
AI summary
A piston boot has an annular fitting section which is formed on one end side of a bellows section, encloses an annular metallic member and is fitted to a stepped section. The fitting section has an outer peripheral surface section which comes into contact with an inner peripheral surface of the stepped section, and an annular plane section which comes into contact with an annular wall surface section of the stepped section. A plurality of holes each having a bottom surface at a position of the metallic member or a position near the metallic member are opened to the plane section.