INTEGRATED BRAKE DUST COLLECTOR ASSEMBLY

Abstract

An integrated brake dust collector assembly (100) for a steering knuckle (104) in a vehicle comprises a dust collector (102) that is integrally formed with the steering knuckle (104) of the vehicle. The brake dust collector assembly (100) includes a suction blower (106) located on a lateral surface of the dust collector, the suction blower (106) generating an airflow during operation to draw dust from the environment into the dust collector. The brake dust collector assembly (100) includes a magnetic strip (116) to attract and capture metal particles, a multi-stage filter unit (114) to capture dust particles of different sizes, and a plurality of baffle plates (110) arranged within a collection pocket (108) to aid the deposition of dust particles within the collection pocket (108).

Description

TECHNICAL AREA

[0001] The present invention relates to the technical field of automotive engineering. In particular, the present invention relates to an integrated brake dust collector arrangement in a vehicle. BACKGROUND

[0002] The background description contains information that may be useful for understanding the present invention. It does not constitute an admission that the information contained herein forms part of the prior art or is relevant to the present invention, or that any publication to which express or implicit reference is made forms part of the prior art.

[0003] Growing concerns about pollution and public health, particularly in urban areas, have brought particulate matter (PM) emissions from various sources, including road vehicles, into sharp focus. In particular, dust generated by braking and tire wear has been identified as a significant source of non-exhaust emissions. These non-exhaust emissions, consisting mainly of metal particles and other toxic compounds, are linked to numerous adverse health effects, especially with prolonged exposure. While technological advances in recent decades have led to a substantial reduction in exhaust emissions, non-exhaust PM emissions continue to pose a growing challenge to the environment and public health.

[0004] Vehicle braking systems are a major source of non-exhaust PM emissions. Braking generates wear particles from brake pads and discs, which can significantly contribute to atmospheric particulate matter concentrations, particularly PM10, PM5, and ultrafine PM2.5 particles. These fine particles are small enough to enter the respiratory system, and exposure to them has been linked to respiratory illnesses, cardiovascular problems, and other serious health conditions.

[0005] In recent years, advances in electric vehicle (EV) technology, such as the development of in-wheel motors, have presented new challenges regarding vehicle dynamics and environmental impact. In-wheel motors are increasingly integrated into modern EV designs, offering improved efficiency and performance through direct drive to individual wheels. However, a significant drawback of this technology is the increased unsprung mass. Unsprung mass refers to the weight of components not supported by a wheel suspension system, such as the wheels, tires, and wheel motors. Increased unsprung mass can negatively affect the vehicle's handling and suspension, and contribute to increased dust accumulation during braking and tire wear.This results from the increased load on the braking system, which leads to higher brake wear and consequently to more brake dust emissions.

[0006] Furthermore, the wheel motors occupy a large portion of the rim, leaving little room for other important components such as the steering knuckle. The steering knuckle, a crucial part of the wheel suspension and steering system, must be designed compactly to accommodate the space constraints imposed by the in-wheel motor. Despite these spatial limitations, the steering knuckle must be strong and rigid to ensure proper handling and vehicle safety. Existing steering knuckle designs often rely on a single material concept, limiting their ability to meet these stringent requirements.

[0007] To address the environmental problems caused by brake and tire wear, as well as the design limitations imposed by wheel motors, there is an urgent need for an integrated solution that both reduces PM emissions and optimizes the vehicle's design.

[0008] Patent DE102020000597A1 describes a steering knuckle for a vehicle axle. The steering knuckle comprises a first steering knuckle part and a second steering knuckle part, which are separately formed and connected to each other. The first and second steering knuckle parts are connected to each other via two rubber bearings or via a rubber bearing and a rigid screw connection, wherein at least one of the steering knuckle parts has a predetermined elasticity in the vicinity of the rigid screw connection, or is connected to each other via two rigid screw connections, wherein both steering knuckle parts each have a predetermined bending elasticity in the vicinity of their respective rigid screw connection.

[0009] As can be seen, the aforementioned document focuses on changing the design of the vehicle's steering knuckle and does not offer a comprehensive solution to the problem of particulate emissions from brake and tire wear, which remains a major environmental problem.

[0010] Therefore, it is necessary to overcome the aforementioned disadvantages, shortcomings and limitations associated with existing braking and dust collection systems. OBJECTS OF INVENTION

[0011] One object of the present invention is to provide a brake dust collector arrangement for a vehicle that overcomes the above-mentioned limitations of existing brake dust collection systems.

[0012] One object of the present invention is to provide a brake dust collector assembly assembled with a steering knuckle that effectively captures dust emitted during braking and thereby reduces environmental pollution from emissions not originating from the exhaust.

[0013] One object of the present invention is the design of a compact steering knuckle that accommodates the space limitations caused by wheel-integrated motors while simultaneously possessing the strength and rigidity required for optimal vehicle performance and safety.

[0014] One object of the present invention is to provide a brake dust collector arrangement capable of capturing dust in a wide size range, including PM10, PM5 and ultrafine PM2.5 particles, thereby ensuring highly efficient dust separation and improved air quality.

[0015] Another object of the present invention is the design of a steering knuckle that is integrated with the brake dust collector assembly in order to reduce the carbon footprint of vehicle components. SUMMARY

[0016] Aspects of the present invention relate generally to the technical field of automotive engineering. In particular, the present invention relates to a brake dust collector arrangement for a vehicle.

[0017] According to one aspect, the disclosed brake dust collector assembly comprises a dust collector integrated into a steering knuckle of the vehicle. The brake dust collector assembly includes a suction fan arranged on a lateral surface of the dust collector, the suction fan generating an airflow during operation to draw dust from the environment into the dust collector. Furthermore, the brake dust collector assembly includes a collection pocket arranged at an outlet end of the dust collector. The collection pocket includes a plurality of baffle plates (hereinafter referred to as "baffle plates") arranged within the collection pocket to assist in the separation of dust within the collection pocket.

[0018] In one or more embodiments, the dust collector may have an extended section that can be molded around an arm of the steering knuckle to secure it.

[0019] In one or more embodiments, the dust collector may have an inlet so that, when the arrangement of the dust collector is assembled around the steering knuckle, the inlet can be positioned near a brake caliper of a corresponding brake of the vehicle in order to extract brake dust from the brake.

[0020] In one or more embodiments, the collection bag can have a generally triangular shape, designed to be accommodated in an opening of the arm of the steering knuckle and to be detachably attached therein by means of one or more snap fasteners.

[0021] In one or more embodiments, the outer contour of the dust collector can have a semicircular profile that allows an aerodynamic external airflow around the dust collector and minimizes air resistance when driving the vehicle.

[0022] In one or more embodiments, the baffle plates can be arranged on an upper and lower surface of the collection bag. Each of the baffle plates can be inclined at a predefined angle to the central axis of the collection bag.

[0023] In one or more embodiments, the brake dust collector arrangement can include a magnetic strip attached to the inlet of the dust collector. The magnetic strip can be configured to attract and separate magnetic particles in the dust before they enter the dust collector.

[0024] In one or more embodiments, the dust collector may include a filter unit that is installed inside the dust collector to capture the dust.

[0025] In one or more embodiments, the filter unit can be a multi-stage filter unit configured to capture dust of different sizes.

[0026] In one or more embodiments, the multi-stage filter unit can comprise a first filter, a second filter, and a third filter. The first filter can be configured to capture or trap large dust particles of size PM10. Furthermore, the second filter can be configured to capture small dust particles of size PM5. In addition, the third filter can be configured to capture ultrafine particles of size PM2.5.

[0027] Various objects, features, aspects and advantages of the subject matter according to the invention will become clearer from the following detailed description of preferred embodiments together with the accompanying drawing figures, in which the same numbers represent the same components. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] The accompanying drawings serve to further understand the present invention and are an integral part of this description. The drawings illustrate exemplary embodiments of the present invention and, together with the description, serve to explain the principles of the present invention. Fig. Figure 1A shows an exemplary representation of the proposed brake dust collector arrangement for wheel hub motor congolmerate steering knuckle in a vehicle according to one or more embodiments of the present invention. Fig. Figure 1B shows an exemplary representation of a dust collector of the brake dust collector arrangement of Fig. 1A with a filter unit which is installed inside the dust collector to capture dust, according to one or more embodiments of the present invention. Fig. Figure 1C shows an interior view of the dust collector from Fig. 1B, which shows the positioning of a suction blower such that, when the suction blower is in operation, an airflow is generated to draw dust from the environment into the dust collector, in accordance with one or more embodiments of the present invention. Fig. Figure 1D shows an exemplary representation of a collection pocket of the proposed brake dust collector arrangement by Fig. 1A, comprising a plurality of baffle plates arranged inside the collection bag to assist in the settling of dust in the collection bag, according to one or more embodiments of the present invention. DETAILED DESCRIPTION

[0029] A detailed description of the embodiments of the invention illustrated in the accompanying drawings follows. The embodiments are described in sufficient detail to ensure the invention is clearly understandable. However, the intention is not to limit foreseeable variations of embodiments with the necessary level of detail; rather, the aim is to cover all modifications, equivalents, and alternatives that fall within the spirit and scope of the present invention as defined by the accompanying claims.

[0030] The embodiments described herein relate to the technical field of automotive engineering. In particular, the present invention relates to an active integrated brake dust collector arrangement for wheel hub motor congolerate steering knuckles in a vehicle.

[0031] Existing brake and tire wear monitoring systems face several challenges in reducing particulate emissions from brakes and tires, particularly when integrating wheel motors into electric vehicles (EVs). The motors in the wheels increase the unsprung mass of the EV, leading to greater brake and tire wear and consequently higher PM concentrations. Furthermore, the limited space within a wheel rim due to the integrated motor makes it challenging to design a compact steering knuckle that still provides the necessary strength and rigidity for adequate vehicle performance. Existing steering knuckle designs, largely based on a single material concept, do not effectively address these space and performance constraints and also lack efficient PM (or brake dust) capture systems.Furthermore, conventional brake dust separation methods often lack the necessary filter capacity to capture the wide range of particle sizes generated, such as PM10, PM5, and PM2.5, contributing to ongoing pollution and public health problems. Consequently, existing systems do not fully meet increasing regulatory requirements for reducing emissions outside the tailpipe or effectively mitigating the harmful impact of brake and tire abrasion particles.

[0032] The present design of a steering knuckle not only solves the compactness problem caused by the wheel hub motor, but also integrates an active aerodynamic dust collector. This dust collector is designed to effectively capture dust emitted during braking through a multi-stage filter unit. By using recycled plastics to replace a section of the aluminum in the steering knuckle, the present invention achieves the necessary strength and rigidity while simultaneously addressing environmental sustainability concerns. The integration of the active aerodynamic dust collector into the steering knuckle serves a dual purpose: reducing PM emissions from braking and tire wear, and improving the overall environmental performance of the vehicle in accordance with upcoming legal standards.

[0033] With reference to Fig. In Figures 1A-1D, the disclosed brake dust collector assembly 100 comprises a dust collector 102 integrated into a steering knuckle 104 of the vehicle. The forming process can be selected from one of the following methods: injection molding, compression molding, injection casting, and the like. In a preferred embodiment, the dust collector 102 is injection molded with the steering knuckle 104. The dust collector 102 can be made from a material selected from, among others, high-strength plastics such as polycarbonate, acrylonitrile butadiene styrene (ABS), or nylon, recycled plastics, carbon fiber composites, thermoelastic elastomers, glass fiber reinforced plastics, and the like.In a preferred embodiment, the steering knuckle 104 can be manufactured from recycled plastics that replace a section of aluminum, maintaining the required strength and stiffness while also considering environmental sustainability and reducing the carbon footprint of vehicle components. It is evident that replacing a section of the aluminum with the recycled plastic in the steering knuckle 104 not only contributes to sustainability goals by reducing the carbon footprint, but also offers practical advantages such as weight reduction, cost savings, and the ability to maintain or improve the component's strength and stiffness. This approach aligns with general efforts to improve environmental performance in the automotive industry and supports the transition to more sustainable vehicle manufacturing.

[0034] The dust collector 102 can include an extended section 102a that can be molded around an arm 104a of the steering knuckle 104 for attachment. Furthermore, the dust collector 102 can have an inlet 112 so that, when the dust collector 102 is assembled around the steering knuckle 104, the inlet 112 can be positioned near a brake caliper of a corresponding brake of the vehicle to extract brake dust from the brake. In one embodiment, an outer contour of the dust collector 102 can have a semicircular profile that allows for an aerodynamic external airflow around the dust collector 102 and minimizes air resistance during vehicle operation.

[0035] A professional will appreciate that mounting the dust collector 102 above the steering knuckle 104 ensures it is located near the vehicle's braking system, where most dust, such as brake dust, is generated by friction between brake pads and a brake disc. Therefore, positioning the dust collector 102 above the steering knuckle 104 maximizes the efficiency of brake dust collection.

[0036] As in Fig. As shown in Figure 1B, the dust collector 102 can include a filter unit 114, which is integrated into the dust collector 102 to capture the dust particles. The filter unit 114 can be a multi-stage filter unit configured to capture dust particles of different sizes. The multi-stage filter unit 114 can include a first filter 114-1, which is configured to capture or trap large PM10 dust particles. The first filter 114-1 can capture large dust particles, such as worn brake pads, tires, or foreign objects on the road, but is not limited to these. The first filter 114-1 can prevent these large dust particles from clogging the finer particles located downstream and reduce the load on the subsequent filter stages. The first filter can be any type of filter except mesh, fiber, or foam.Furthermore, the multi-stage filter unit 114 can include a second filter 114-2, configured to capture small dust particles of size PM5. These small dust particles can include, among other things, tiny dust particles, soot, and other small pollutants. The second filter 114-2 can be, but is not limited to, a HEPA (High-Efficiency Particulate Air) filter, an electrostatic filter, or an activated carbon filter. The second filter 114-2 can have a higher efficiency than the first filter 114-1, with a greater ability to capture fine dust particles. These filters often have a medium efficiency, capturing most fine dust particles, but allowing a slightly higher airflow compared to ultrafine filters. Additionally, the multi-stage filter unit 114 can include a third filter 114-3, configured to capture ultrafine particles of size PM2.5.Ultrafine particles can include, among other things, fine dust, smoke, and combustion byproducts. The third filter, 114-3, could be one of the following: a HEPA filter, a ULPA (Ultra-Low Penetration Air) filter, or a nanofiber filter.

[0037] Ultrafine particles, especially PM2.5, pose a significant threat to the environment and public health. By capturing these particles before they are released into the atmosphere, the multi-stage filter unit can help improve air quality and reduce pollution, particularly in areas with high traffic volumes or industrial activity, such as brake dust generation. In one embodiment, a removable snap-fit ​​connection 118 can be located near the filter unit 114. The snap-fit ​​connection 118 allows the filter unit 114 to be easily removed and replaced without the need for tools. The snap-fit ​​connection 118 can include a clip or snap mechanism that securely fastens the filter unit 114 in the dust collector 102.

[0038] According to Fig. In 1C, the brake dust collector assembly 100 comprises a suction blower 106 arranged on a lateral surface of the dust collector 102, wherein the suction blower 106, during operation, generates an airflow to draw dust from the environment into the dust collector 102. The suction blower 106 can be selected from, but is not limited to, a centrifugal or axial blower. In some embodiments, the suction blower 106 can be positioned near components of the brakes to maximize its ability to capture the dust particles generated during braking. In one embodiment, the shape of the vanes of the suction blower 106 can be designed such that the airflow is sufficient for capturing the dust particles. The shape of the louvers can be designed to reduce the noise caused by the turbulent airflow during operation of the suction blower 106.In a preferred embodiment, the shape of the lamellae can be curved or angular. Furthermore, the lamellae of the suction blower 106 can be made of durable and corrosion-resistant material to withstand the effects of dust and moisture in the airflow.

[0039] According to Fig.Figure 1D comprises the brake dust collector assembly 100, which includes a collection pocket 108 located at an outlet end of the dust collector 102. The collection pocket 108 can generally have a triangular shape, designed to fit into an opening in the arm 104a of the steering knuckle 104 and to be detachably secured therein by one or more snap fits 116. It is evident that the triangular configuration allows for an efficient flow of brake dust into the collection pocket 108 while minimizing interference with the movement or placement of other components. The collection pocket 108 includes a plurality of baffle plates 110 (hereinafter referred to as "baffle plates 110") arranged inside the collection pocket 108 to assist in the separation of dust within the collection pocket 108.The baffle plates 110 can be arranged on an upper and a lower surface 108-1, 108-2 of the collection pocket 108, and each of the baffle plates 110 can be inclined at a predefined angle to a central axis of the collection pocket 108. By inverting the baffle plates 110, it can be ensured that the dust particles have sufficient time to settle by altering the flow dynamics. The angled baffle plates 110 can generate turbulent airflows or deflect the dust particles downwards towards the bottom of the collection pocket 108.

[0040] When dust particles enter the collection bag 108, the baffle plates 110 slow the airflow, causing the dust particles to settle. The inclined baffle plates 110 help to redirect the airflow so that the dust particles fall to the bottom of the collection bag 108 and settle there. The entire design helps to optimize the performance of the arrangement 100 by balancing the airflow and dust deposition and minimizing the risk of dust escaping back into the environment.

[0041] In one embodiment, the brake dust collector assembly 100 can include a magnetic strip 116 attached to the inlet of the dust collector 102. The magnetic strip 116 can be configured to attract and separate magnetic particles in the dust before they enter the dust collector 102. The magnetic strip 116 can be made of flexible rubber or vinyl material mixed with magnetic particles, such as ferrite or rare-earth magnets. The magnetic strip 116 can be self-adhesive, which makes installation easy. Optionally, the magnetic strip 116 can be coated with laminated coatings to protect it from damage, corrosion, or wear and to ensure that the magnetic strip 116 retains its magnetic strength over a long period of time.The laminated containers can be made from a material selected from polyurethane (PU), epoxy resin, polyester, nylon, fluoropolymer coatings and the like.

[0042] A person skilled in the art will understand that the inclusion of the magnetic strip 116 at the inlet of the dust collector 102 can help to improve the efficiency of the brake dust collector arrangement 100 by removing magnetic particles that would otherwise clog the filter unit 114 or interfere with the operation of the dust collector 102.

[0043] An expert would appreciate the introduction of a steering knuckle design 104 that effectively addresses the compactness issues caused by the wheel hub motor while simultaneously integrating an active aerodynamic dust collector 102. This dust collector 102 is specifically designed to capture dust generated during braking, with a multi-stage filter unit 114 ensuring efficient filtration. Furthermore, the design replaces some of the aluminum in the steering knuckle 104 with recycled plastics, allowing the component to maintain the required strength and rigidity while contributing to environmental sustainability.The integration of the aerodynamic dust collector 102 into the steering knuckle 104 fulfills a dual function: it not only reduces particulate emissions from braking and tire wear, but also improves the vehicle's overall environmental performance and ensures compliance with future legal regulations. This solution represents a significant advancement in both vehicle design and environmental impact, and is a more sustainable and efficient alternative to conventional systems.

[0044] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention can be developed without deviating from the fundamental scope of the invention. The scope of the invention is defined by the following claims. The invention is not limited to the described embodiments, versions, or examples, which are included to enable a person with ordinary technical knowledge to manufacture and use the invention when combined with information and knowledge available to such a person. ADVANTAGES OF THE INVENTION

[0045] The present invention provides an active integrated brake dust collector arrangement for wheel hub motor congolmerate steering knuckles in a vehicle, which overcomes the above-mentioned limitations of existing dust collector systems.

[0046] The present invention provides a brake dust collector assembly mounted with a steering knuckle, which effectively captures dust emitted during braking and thereby reduces environmental pollution from emissions not originating from the exhaust.

[0047] The present invention provides a compact steering knuckle designed to accommodate the space limitations imposed by wheel-integrated motors while maintaining the necessary strength and rigidity for optimal vehicle performance and safety.

[0048] The present invention provides a brake dust collector arrangement capable of capturing or trapping dust particles in a wide size range, including PM10, PM5 and ultrafine PM2.5 particles, thereby ensuring highly efficient dust separation and improved air quality.

[0049] The present invention provides for a steering knuckle integrated with the brake dust collector assembly, which is designed to reduce the carbon footprint of vehicle components.

[0050] The present invention provides a brake dust collector arrangement that is cost-effective. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] DE 102020000597A1

[0008]

Claims

[1] Active integrated brake dust collector assembly (100) for a wheel hub motor congolmerate steering knuckle (104) in a vehicle, wherein the brake dust collector assembly (100) comprises: a dust collector (102) which is integrated into the steering knuckle (104) of the vehicle; a suction blower (106) arranged on a lateral surface of the dust collector (102), wherein the suction blower (106) generates an airflow during operation to draw dust from the environment into the dust collector (102); and a collection bag (108) configured at an outlet end of the dust collector (102), wherein the collection bag (108) comprises a plurality of baffle plates (110) positioned within the collection bag (108) to assist in the deposition of dust within the collection bag (108). [2] Brake dust collector arrangement (100) according to claim 1, wherein the dust collector (102) comprises an extension section (102a) which is injection molded around an arm (104a) of the steering knuckle (104) to secure it. [3] Brake dust collector arrangement (100) according to claim 1, wherein the dust collector (102) comprises an inlet (112) such that when the brake dust collector arrangement (100) is mounted around the steering knuckle (104), the inlet (112) is located near a brake caliper of a corresponding brake of the vehicle in order to extract brake dust from the brake. [4] Brake dust collector arrangement (100) according to claim 1, wherein the collection pocket (108) is generally triangular in shape to be accommodated in an opening of the arm (104a) of the steering knuckle (104) and is detachably fastened therein by one or more snap connections (116). [5] Brake dust collector arrangement (100) according to claim 1, wherein an outer contour of the dust collector (102) has a semicircular profile configured to create an aerodynamic external airflow around the dust collector (102) and to minimize air resistance during operation of the vehicle. [6] Brake dust collector arrangement (100) according to claim 1, wherein the plurality of impact plates (110) are arranged on an upper and lower surface (108-1, 108-2) of the collection pocket (108) and each of the plurality of impact plates (110) is inclined at a predefined angle to a central axis of the collection pocket (108). [7] Brake dust collector arrangement (100) according to claim 1 comprises a magnetic strip (116) attached to an inlet of the dust collector (102), wherein the magnetic strip (116) is configured to attract and separate magnetic particles in the particulate dusts before they enter the dust collector (102). [8] Brake dust collector arrangement (100) according to claim 1, wherein the dust collector (102) comprises a filter unit (114) which is installed in the dust collector (102) to capture the dusts. [9] Brake dust collector arrangement (100) according to claim 8, wherein the filter unit (114) is a multi-stage filter unit configured to capture dust of different sizes. [10] Brake dust collector arrangement (100) according to claim 9, wherein the filter unit (114) comprises: a first filter (114-1) configured to capture large dust particles of size PM 10; a second filter (114-2) configured to capture small dust particles of size PM 5; and a third filter (114-3) configured to capture ultrafine particles of size PM 2.5.

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