Single-Body Sliding Brake Caliper for Faster Hub-Mounted Assembly
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Solution Overview
Problem
Conventional vehicle brake systems are complex and time-consuming to assemble/disassemble due to multiple interconnected components and varying torque requirements for mounting bolts and slider pins, leading to increased assembly time and potential noise during operation.
Innovation Solution
A single body sliding brake caliper assembly is integrally formed as a singular component, mounting directly to the wheel hub via attachment posts, which simplifies assembly and improves stiffness by eliminating the need for multiple components and fasteners, while directly supporting both inner and outer brake pads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional caliper assembly with multiple interconnected components (caliper housing, caliper anchor bracket, slider pins) is used, then the brake system can be assembled with standardized parts, but the assembly process becomes time-consuming and complex due to multiple mounting steps and varying torque requirements
Solution Approach 1:
The patent combines the caliper housing and caliper anchor bracket into a single integrally formed caliper assembly. This merging eliminates the need for separate mounting of the caliper anchor bracket to the wheel hub and removes the need for slider pins, reducing the number of assembly steps and fasteners while maintaining the functional separation between the housing and anchor bracket components
2Reliability
If multiple fasteners (mounting bolts and slider pins) are used to secure the caliper assembly, then the components can be properly positioned and secured, but the assembly complexity increases due to different torque requirements and installation procedures for each fastener type
Solution Approach 1:
The caliper housing and caliper anchor bracket are integrally formed as a single unit, eliminating the need for slider pins to connect them. This reduces the variety of fasteners required and simplifies the fastening procedure while maintaining secure mounting through the reduced number of mounting bolts needed for the integrated assembly
3Ease of manufacture
If the caliper housing is mounted indirectly to the wheel hub via the caliper anchor bracket, then the components can be separately manufactured and assembled, but the overall stiffness of the brake system is reduced due to additional connection points and potential flex in the mounting structure
Solution Approach 1:
The caliper housing and caliper anchor bracket are merged into a single integrally formed assembly that mounts directly to the wheel hub. This eliminates the intermediate connection through slider pins and separate bracket mounting, creating a stiffer, more rigid structure while maintaining the functional characteristics of both original components through integral design
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 solution reduces the complexity and time required for brake system assembly, enhances the stiffness of the brake system, and minimizes noise during vehicle operation by integrating the brake caliper and wheel hub as a single component.
Implementation Method 1
the hydraulic cylinder of the caliper housing is pushed away from the brake disk, which moves the caliper such that the caliper arm pulls the outer brake pad into contact with an outer surface of the brake disk
Implementation Method 2
The slider pins have a shank long enough to permit the caliper housing to move, such as by sliding along the shank, relative to the caliper anchor bracket and the wheel hub
Data Source
AI summary
A brake system for a vehicle is disclosed. The brake system includes a wheel hub, a brake disk, and a brake caliper. The wheel hub includes a hub and attachment posts. The hub defines a bore adapted to receive an axle of the vehicle. The attachment posts extend away from the hub adjacent to the bore. The attachment posts are singularly and integrally formed with the hub. The brake disk is disposed adjacent the wheel hub. The brake caliper includes a piston housing and a body. The piston housing is adapted to hold a piston. The piston housing defines mounting holes used to movably mount the brake caliper directly to the wheel hub at the attachment posts. The body is positioned radially outward of the brake disk. The piston housing and the body are integrally formed as a singular component.