Brake Piston Pushback Ring for Drag and Dust Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing brake systems suffer from brake drag and brake dust emission, which negatively impact fuel/energy consumption and environmental protection.
Innovation Solution
A pushback ring and dust shield assembly is integrated into the brake piston, allowing for optimal piston travel distance adjustment, reducing brake drag and dust emission by utilizing a coil or cylindrical pushback ring and an elastic dust shield that accumulates tension to reset the piston to its original position, creating space between brake pads and rotors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the brake piston remains in the applied position after braking, then the brake pads maintain contact with the rotor, but brake drag increases and fuel consumption rises
Solution Approach 1:
The dust shield is pre-configured with elastic material that accumulates tension during brake application, automatically preparing the pushback force needed to reset the piston after braking, eliminating the need for external resetting mechanisms
Solution Approach 2:
The brake system uses its own operational forces (brake pressure and elastic recovery) to automatically reset the piston position, with the dust shield's elasticity providing the pushback force without requiring additional energy input or external systems
2Loss of energy
If the brake piston does not fully reset after application, then brake drag is reduced, but brake dust emission increases due to continuous pad rotor contact
Solution Approach 1:
The system dynamically changes the piston position parameter by using the dust shield's elastic properties to automatically adjust the gap between brake pads and rotor, transitioning from full contact during braking to separated position during normal operation
3Reliability
If a rigid dust shield is used to prevent water/debris ingress, then protection is improved, but the shield cannot accommodate piston movement and may cause the system to fail
Solution Approach 1:
The dust shield is constructed from elastic material that flexes during piston movement and then springs back to its original shape, maintaining both protective sealing and adaptability to piston position changes throughout the braking cycle
4Reliability
If the pushback ring clamping force is increased to ensure proper piston reset, then reset reliability is improved, but the force required to advance the piston during braking increases
Solution Approach 1:
The pushback ring's clamping force is made dynamic through the elastic dust shield, which allows high clamping force during reset while permitting the ring to slide freely during brake application when brake pressure overcomes the clamping force
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 significantly reduces brake drag and dust emission, enhancing vehicle efficiency, compatibility with existing hydraulic brake systems, and offering maintenance-free, cost-effective operation.
Implementation Method 1
The dust shield has a certain degree of elasticity to accumulate a certain amount of tension in order to allow the piston to advance slightly when the brake pedal is pressed, but it has a limited distortion and becomes rigid when past a certain distortion limit
Data Source
AI summary
This concept has addressed the brake dust emission and the brake drag issues by introducing a pushback ring (press-fit on the brake piston) which pushes against the brake piston dust shield (or another elastic element if needed) when brake fluid pressure is created, thus accumulating a reactive force which is used to bring the brake piston to its original position when the brake fluid pressure is released and considerably reduce or eliminate the brake drag and the brake dust emission of any automobile in order to improve the fuel/energy consumption.