Disc Brake Elastomer Bellows Thermal Protection
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Solution Overview
Problem
The existing disc brake designs face issues with thermal overloading and damage to the elastomer bellows due to frictional heat, leading to brittleness, leakage, and reduced mobility, which affects the operational reliability and service life of the brake components.
Innovation Solution
A disc brake design featuring a one-piece elastomer bellows with a circumferential collar spacer that acts as an insulating layer, minimizing direct contact with heat sources and mechanical stress, thereby reducing wear and extending the service life of the bellows and protected components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bellows is positioned in immediate vicinity of the pressure piece to seal the exit area, then sealing effectiveness is improved, but thermal overload and damage to the elastomer bellows increases
Solution Approach 1:
The patent introduces a metallic bellows as an intermediary component between the elastomer bellows and the pressure piece. The metallic bellows acts as a heat shield, absorbing and reflecting thermal radiation from the pressure piece, thereby protecting the elastomer bellows from thermal overload while maintaining the sealing function.
Solution Approach 2:
The patent divides the original single bellows structure into two separate bellows: an inner metallic bellows and an outer elastomer bellows. This segmentation allows each bellows to be optimized for its specific function - the metallic bellows for thermal protection and the elastomer bellows for sealing and flexibility.
2Ease of operation
If the bellows consists of elastomer for axial mobility during braking, then flexibility and mobility are improved, but brittleness and leakage occur due to thermal exposure
Solution Approach 1:
The patent divides the original single bellows structure into two separate bellows: an inner metallic bellows and an outer elastomer bellows. This segmentation allows each bellows to be optimized for its specific function - the metallic bellows for thermal protection and the elastomer bellows for sealing and flexibility.
Solution Approach 2:
The patent introduces a metallic bellows as an intermediary component between the elastomer bellows and the pressure piece. The metallic bellows acts as a heat shield, absorbing and reflecting thermal radiation from the pressure piece, thereby protecting the elastomer bellows from thermal overload while maintaining the sealing function.
3Reliability
If the bellows is directly exposed to frictional heat from the pressure piece, then sealing function is maintained, but service life is reduced due to thermal degradation
Solution Approach 1:
The patent divides the original single bellows structure into two separate bellows: an inner metallic bellows and an outer elastomer bellows. This segmentation allows each bellows to be optimized for its specific function - the metallic bellows for thermal protection and the elastomer bellows for sealing and flexibility.
Solution Approach 2:
The patent introduces a metallic bellows as an intermediary component between the elastomer bellows and the pressure piece. The metallic bellows acts as a heat shield, absorbing and reflecting thermal radiation from the pressure piece, thereby protecting the elastomer bellows from thermal overload while maintaining the sealing function.
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 solution significantly reduces thermal and mechanical stress on the bellows, enhancing operational reliability and extending the service life of the brake components, resulting in lower maintenance costs and reduced downtime.
Implementation Method 1
The thermal radiation of the brake lining, i.e. the backing plate leads to damage to the bellows
Implementation Method 2
For the axial mobility of the bellows, in particular when the brake is applied, the bellows consists of an elastomer in its malleable area
Implementation Method 3
both the backing plate and the pressure piece heat up very strongly due to the resulting frictional heat
Data Source
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AI summary
A disc brake for a commercial vehicle, having a brake calliper which reaches over a brake disc, brake linings which are mounted therein and make contact with the brake disc in a functional position, wherein at least one brake lining, with a carrier plate and a friction lining fastened thereto, can be pressed onto the brake disc by means of a brake application device via at least one actuating spindle which is mounted in the brake calliper and via a pressure piece which is connected thereto, wherein, in order to seal a passage opening of the actuating spindle out of the brake calliper or a closure plate, a folding bellows (7) which is fastened thereto directly or indirectly and is made from an elastomer, is configured in such a way that the folding bellows (7) has at least one spacer element (10) at least in regions on the side thereof which faces the pressure piece.