Brake Pad Suction Tube Assembly for Disc Brake Dust Extraction
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Solution Overview
Problem
Current disc brake systems for commercial vehicles fail to effectively minimize and prevent the emission of fine brake dust, which is exacerbated by turbulence in the wheel housing and thermal issues with further encapsulation.
Innovation Solution
A disc brake design with a brake caliper and brake pads equipped with suction tubes integrated directly onto the pads, forming a pre-assembled unit for efficient abrasion material extraction, featuring suction openings circumferentially arranged around the friction linings and guided by springs to maintain contact with the wear surface, along with a connection interface for external suction and separation devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If a suction and separation system with cover plates is used to collect brake dust, then brake dust emission is reduced, but thermal problems occur due to encapsulation of the brake
Solution Approach 1:
The suction system is segmented into multiple suction tubes distributed across the brake pad assembly, allowing localized dust extraction without requiring complete encapsulation. This segmentation enables thermal management by leaving the brake environment partially open while still achieving effective dust collection through distributed suction points
Solution Approach 2:
The harmful brake dust is extracted directly at its source (the friction interface between pad and disc) using suction tubes positioned on the brake pads. By removing the dust at the point of generation rather than enclosing the entire brake assembly, the system prevents dust emission without causing thermal problems from encapsulation
2Ease of repair
If suction tubes are integrated directly onto brake pads, then pad replacement becomes easier, but the complexity of the brake pad assembly increases
Solution Approach 1:
The suction tubes are merged with the brake pad assembly to form a single integrated unit. This combination means that when the brake pad is replaced, the suction tube is replaced simultaneously, eliminating the need for separate installation of suction components and simplifying the overall replacement process despite the integrated design
3Productivity
If suction openings are arranged circumferentially around friction linings, then abrasion material collection efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The suction openings are arranged with different characteristics in different locations - circumferentially around the friction lining area to maximize dust collection efficiency. This local optimization of opening placement targets the specific dust generation zone without requiring uniform precision across the entire component, reducing overall manufacturing precision requirements while maintaining high collection efficiency
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 significantly reduces brake dust emission by collecting a high proportion of abrasion material at the point of origin, ensuring efficient extraction and easy pad replacement while minimizing noise and thermal issues.
Implementation Method 1
a suction tube arrangement for extracting abrasion material resulting from braking, wherein one or more suction tubes of the suction tube arrangement is/are arranged on each of the two brake pads
Implementation Method 2
guided by springs to maintain contact with the wear surface
Data Source
AI summary
A disc brake has a brake caliper which engages over a brake disc and in which brake pads each provided with a friction lining and with a back plate are arranged that can each be pressed with their friction lining on both sides onto friction ring surfaces of the brake disc. A suction tube arrangement is provided through which abrasion material resulting from braking is sucked, wherein the suction tube arrangement includes one or more suction tubes arranged directly on the two brake pads. A corresponding brake pad set is also provided.