Split Caliper Disc Brake for Compact Wheel Rim Retrofit
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Solution Overview
Problem
Existing drum brake systems in vehicles are less effective and prone to failure compared to disc brake systems, and retrofitting disc brakes into vehicles with drum brakes is challenging due to size constraints and inefficient space usage within the wheel rim.
Innovation Solution
A split caliper design for disc brake systems that includes a first caliper half integrally formed with a mounting plate and a second caliper half joined by a removably attached joiner plate, allowing for a slimmer profile, increased strength, and larger rotor diameter within the wheel rim, while minimizing unsprung mass and accommodating different vehicle weights and speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional disc brake system is installed, then brake performance is improved, but the wheel rim space required increases due to caliper size
Solution Approach 1:
The caliper is divided into two separate caliper halves that are positioned on opposite sides of the rotor. Each caliper half contains its own piston and brake pad, allowing the braking force to be applied from both sides of the rotor simultaneously. This segmentation enables a more compact overall caliper assembly that fits within the constrained wheel rim space while maintaining effective brake performance.
2Reliability
If drum brakes are replaced with disc brakes in existing vehicles, then braking effectiveness is improved, but the complexity of retrofitting increases due to space constraints
Solution Approach 1:
The caliper is divided into two separate caliper halves that are positioned on opposite sides of the rotor. Each caliper half contains its own piston and brake pad, allowing the braking force to be applied from both sides of the rotor simultaneously. This segmentation enables a more compact overall caliper assembly that fits within the constrained wheel rim space while maintaining effective brake performance.
Solution Approach 2:
The brake system components are nested within the existing wheel rim structure. The rotor is mounted on the wheel hub, and the compact caliper assembly with its two halves is positioned within the wheel rim's internal space, effectively nesting the entire disc brake system within the original drum brake envelope.
3Area of stationary object
If the caliper is made compact to fit wheel rim, then space usage is improved, but the strength and durability of the caliper may be reduced
Solution Approach 1:
The caliper is divided into two separate caliper halves that are positioned on opposite sides of the rotor. Each caliper half contains its own piston and brake pad, allowing the braking force to be applied from both sides of the rotor simultaneously. This segmentation enables a more compact overall caliper assembly that fits within the constrained wheel rim space while maintaining effective brake performance.
Solution Approach 2:
The two caliper halves are merged through a joining mechanism that connects them across the rotor. This merging allows the compact segmented structure to function as a unified strong assembly, distributing braking forces effectively while maintaining the space-saving compact design.
Data Source
AI summary
There is disclosed a disc brake system incorporating a split caliper having a first caliper half integrally formed with a mounting plate for mounting the caliper on a vehicle. A second caliper half is fixedly and removably attached to the first caliper half in spaced apart relation to provide room for a rotor to be disposed between the caliper halves. The joiner plates permit adjustment of the distance between the caliper halves to accommodate rotors of different thickness. The split design provides a slimmer caliper profile permitting the use of larger diameter rotors in the same space. A splined rotor carrier permits mounting of the rotor on to a wheel hub housing having a corresponding spline. The disc brake system of the present invention is particularly useful in retrofitting existing vehicles, especially light armored vehicles (LAV's).