Disc Brake Caliper Tubes for Brake Wear Particle Collection
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Solution Overview
Problem
Existing brake systems face challenges in efficiently collecting wear particles from disc brake pads due to limited installation space and high temperatures, which can lead to clogging and increased weight, especially in commercial vehicles.
Innovation Solution
A disc brake system with a brake caliper that incorporates tubes as both brake wear removal equipment and caliper releasing mechanisms, connected to a collection device, allowing for direct and reliable particle collection without additional components or space, and using high-temperature resistant materials to prevent clogging and drag torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible hoses are used for particle transport, then they can compensate displacement of brake pads and caliper, but installation space is limited and high temperature limits their use
Solution Approach 1:
The patent extracts the particle collection function from the flexible hose and implements it through rigid tubes integrated into the caliper structure. The tubes are positioned to collect particles directly at the source (brake pad contact area) and transport them through the caliper's internal passages to the exterior, eliminating the need for external flexible hoses in the high-temperature zone.
Solution Approach 2:
The particle collection tubes are nested within the caliper body structure. The tubes run through the caliper's internal passages, utilizing the existing structural space. The collection tubes are positioned within the caliper housing, allowing particle collection and transport without requiring external flexible hose connections in the high-temperature environment.
2Reliability
If suction channels are made inside the brake caliper, then particle collection is improved, but components become expensive and may clog over lifetime
Solution Approach 1:
The caliper is segmented into distinct functional zones: particle collection tubes positioned at the brake pad contact area, internal transport passages through the caliper body, and external discharge openings. This segmentation allows each component to perform its specific function efficiently while maintaining simplicity and accessibility for maintenance.
Solution Approach 2:
The patent introduces intermediate collection points within the caliper structure where particles are captured from the brake pad area and transferred into the transport passages. These intermediate collection zones act as mediators between the high-wear brake pad area and the external discharge system, preventing direct clogging of external channels while maintaining collection efficiency.
3Reliability
If additional brackets are added for wear removal equipment, then particle collection is enabled, but installation space and component count increase
Solution Approach 1:
The patent merges the particle collection function with the existing caliper structure. The collection tubes are integrated into the caliper body, utilizing the same mounting points and structural support already provided by the caliper. This integration eliminates the need for separate brackets or additional mounting hardware, as the caliper itself serves as both the braking mechanism and the particle collection system housing.
Solution Approach 2:
The caliper is designed to serve multiple functions simultaneously: it provides the braking action through piston movement, houses the particle collection tubes within its structure, and acts as the mounting platform for the entire assembly. This multi-functionality eliminates the need for dedicated particle collection brackets, as the caliper's structural elements are universally utilized for both braking and particle collection purposes.
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
Enables efficient and reliable removal of brake wear particles without additional installation space or components, with the ability to exchange tubes easily and avoid clogging, while maintaining high thermal resistance and reducing drag torque.
Implementation Method 1
a first end of which is configured to collect brake wear particles and a second end of which is connectable to the collection device
Implementation Method 2
the brake lining is attached to the back plate on an attachment face of the back plate... a friction surface of the brake lining
Data Source
Figure 1~1a
Figure 2~3
Figure 4~5
AI summary
A disc brake (2) comprising a rotatable brake disc (4) and a non-rotatable component comprising a brake caliper (6) is provided. The brake caliper (6) comprises a brake wear removal equipment configured to collect brake wear particles and to be connectable to a collection device.