One-Piece Disc Brake Housing for Brake Dust Containment
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Solution Overview
Problem
Existing disc brakes for commercial vehicles generate brake dust, which is hazardous to health and the environment, and their complex structural connections limit universal applicability.
Innovation Solution
A one-piece housing design for the brake caliper and carrier, potentially cast, with a coupling section for the actuation mechanism, reduces separation points and enhances dust retention, allowing for a simpler structural connection to the vehicle axle and adaptable geometry for different vehicle types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the brake caliper and brake carrier are designed as separate components with structural connections, then the assembly allows for modular manufacturing and installation, but it creates multiple separation points that increase brake dust release into the environment
Solution Approach 1:
The patent combines the brake caliper and brake carrier into a single integrated housing part formed as one piece. This merging eliminates the separation points between separate components, thereby preventing brake dust from escaping through gaps at connection interfaces. The single-piece design maintains manufacturing feasibility through cast or stamped production methods while effectively reducing environmental pollution from brake dust.
2Ease of repair
If the brake caliper and brake carrier are designed as separate components, then it allows for independent replacement and maintenance, but it increases the complexity of the structural connection and limits universal applicability
Solution Approach 1:
By integrating the brake caliper and brake carrier into one housing part, the patent simplifies the structural connection to a single unified component rather than multiple connected parts. This reduces the overall device complexity and eliminates the need for complex mounting structures, while the housing part can still be replaced as a single unit for maintenance purposes.
3Reliability
If multiple separate components are used for the brake assembly, then it allows for specialized optimization of each component, but it increases the number of separation points and gaps that release brake dust
Solution Approach 1:
The patent merges the brake caliper and brake carrier functions into a single housing part that is optimized for its combined purpose. The one-piece construction eliminates all separation points and gaps between components, creating a sealed structure that prevents brake dust from escaping. The housing part can be optimized as a unified component for both braking function and dust containment.
4Ease of manufacture
If a traditional multi-component brake assembly is used, then it provides established structural connections, but it fails to provide adequate encapsulation of the brake disc for dust retention
Solution Approach 1:
The patent creates a unified housing part that simultaneously serves as both the brake caliper and brake carrier, forming an integrated encapsulation structure around the brake disc. This merged design provides complete dust retention by eliminating separation points, while the housing part can be manufactured using established cast or stamped processes for structural connections.
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 discharge, simplifies the structural connection, and allows for adaptable production to meet various vehicle requirements while maintaining effective braking performance.
Implementation Method 1
The braking effect generated between the brake disc and the brake pads
Data Source
Figure 1
Figure 2~3
Figure 4~7
AI summary
The invention relates to a disc brake (1, 1') for a motor vehicle (100), in particular a fixed caliper brake for a commercial vehicle (102), comprising a brake caliper (6) and two brake pads (8, 8') mounted on the brake caliper (6) and movable relative to each other, and a brake carrier (10) for receiving the brake caliper (6), wherein the brake carrier (10) is configured to couple the brake caliper (6) to a rigid axle section (4) of the motor vehicle (100). The brake carrier (10) and the brake caliper (6) form a one-piece housing part (12, 12') which is configured to at least partially enclose a brake disc (2) that interacts with the brake pads (8, 8').