Brake Disk Shell Enclosure for Noise and Dust Control
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Solution Overview
Problem
Disk brake systems in vehicles face issues such as noise emission, brake dust generation, unstable dynamic behavior, and corrosion, which affect performance and health safety.
Innovation Solution
A disk brake system with a shell that encases the brake disk and caliper, providing noise damping and dust protection, featuring segments made of metal or plastic that can rotate with the wheel and include magnetic inserts for dust collection, and cleaning arrangements to manage brake dust.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the brake disk is exposed without encasement, then the brake system has simple structure and low cost, but noise emission increases and brake parts are unprotected
Solution Approach 1:
The shell encases the brake disk and caliper, nesting the braking components within a protective housing that dampens noise and protects against environmental factors while maintaining access to brake components for operation and maintenance
Solution Approach 2:
The shell is constructed with thin-walled segments made of plastic or metal that provide noise damping and protection while keeping the overall structure lightweight and relatively simple
2Object-affected harmful factors
If the brake disk is exposed without encasement, then the structure remains simple, but brake dust is emitted into the environment affecting health
Solution Approach 1:
The shell encloses the brake disk and caliper within a protective housing, containing brake dust generated during braking operations and preventing its release into the environment while maintaining brake functionality
Solution Approach 2:
The thin-walled shell structure provides effective containment of brake dust particles while remaining lightweight and simple in construction, using plastic or metal materials that can be easily molded into the required shape
3Reliability
If the brake disk is exposed without encasement, then the structure is simple, but corrosion can occur causing performance decline
Solution Approach 1:
The shell provides a protective enclosure around the brake disk and caliper, shielding metal components from moisture, salt, and other environmental factors that cause corrosion, thereby maintaining brake performance over time
Solution Approach 2:
The thin-walled shell constructed from plastic or metal provides effective corrosion protection by creating a barrier between brake components and the external environment, while keeping the structure lightweight and simple
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
The shell effectively reduces noise emission, protects against brake dust, enhances braking stability, and improves performance by encasing the brake components and incorporating features for dust management.
Implementation Method 1
By having this encasing, noise emitted from the brake disk is dampened
Implementation Method 2
The shell may comprise magnetic inserts for collecting metallic brake dust
Data Source
AI summary
The invention relates to a disk brake system for a vehicle, comprising a brake disk, a caliper and a shell, the shell at least partially encasing the brake disk, and optionally the caliper, at an axially outer side and/or an axially inner side and/or a circumferentially outer side.