Pivot Pad Brake Caliper Managing Rotor Thickness Variation
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Solution Overview
Problem
Existing brake caliper assemblies face issues with brake torque variation due to rotor thickness variations, leading to pulsation and juddering sensations, and reducing caliper stiffness results in decreased brake performance, including increased brake drag, brake pad taper wear, and longer stopping distances.
Innovation Solution
The brake caliper assembly features caliper fingers with a pivot edge that allows the outer brake pad to pivot, modifying the response to radial disc thickness variations, reducing brake torque variation, and improving brake pad taper wear without compromising caliper stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the stiffness of the caliper assembly is reduced to control brake torque variation, then brake torque variation is reduced, but brake performance decreases (increased brake drag, brake pad taper wear, and brake distance)
Solution Approach 1:
The patent applies local quality by creating a pivot edge only at the outer brake pad contact point with the caliper finger, while the rest of the caliper assembly maintains its original stiff structure. This localized pivot mechanism allows the outer brake pad to rotate independently to compensate for rotor thickness variation, controlling brake torque variation without requiring reduction of the overall caliper assembly stiffness, thereby avoiding increased brake drag and energy loss
2Reliability
If the stiffness of the caliper assembly is reduced to control brake torque variation, then brake torque variation is reduced, but brake pad taper wear increases
Solution Approach 1:
The pivot edge is localized at the outer brake pad contact point, allowing only the outer brake pad to rotate for compensation while the inner brake pad and caliper structure remain stable. This localized rotation equalizes brake pad wear across both pads by compensating for rotor thickness variation, preventing the taper wear that would result from reducing overall caliper stiffness
3Reliability
If the stiffness of the caliper assembly is reduced to control brake torque variation, then brake torque variation is reduced, but stopping distance increases
Solution Approach 1:
The pivot mechanism is implemented only at the outer brake pad contact point with the caliper finger, while the caliper housing and piston assembly maintain their original stiff structure. This localized pivot allows the outer brake pad to rotate and compensate for rotor thickness variation, controlling brake torque variation without compromising the overall stiffness needed for effective braking and short stopping distance
4Reliability
If the stiffness of the caliper assembly is reduced to control brake torque variation, then brake torque variation is reduced, but pedal feel deteriorates
Solution Approach 1:
The pivot edge is created only at the outer brake pad contact point, allowing localized rotation to compensate for rotor thickness variation while the main caliper structure remains stiff. This preserves the direct mechanical connection and stiffness felt by the driver through the brake pedal, maintaining good pedal feel while controlling brake torque variation
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 reduces juddering sensations during braking, enhances brake pad wear resistance, and maintains overall caliper stiffness, thereby improving brake performance and fuel efficiency.
Implementation Method 1
each of the caliper finger defines a pivot edge extending between the outer brake pad and the flat surface of the caliper fingers allowing the outer brake pad to pivot about the pivot edge
Data Source
AI summary
A caliper housing including a piston bore and a bridge extending between the piston bore and a pair of caliper fingers interconnecting the caliper fingers and the piston bore. The caliper fingers of the caliper housing extend downwardly from the bridge to define a flat surface. A rotor having a disc shape defines a first side and a second side and disposed adjacent to the caliper fingers. An outer brake pad defining a first centroid is disposed adjacent to the first side of the rotor abutting the caliper fingers allowing the caliper fingers to urge the outer brake pad into engagement with the first side of the rotor. Each of the caliper fingers defines a pivot edge extending between the outer brake pad and the flat surface of the caliper fingers allowing the outer brake pad to pivot about the pivot edge.