Disc Brake Dust Encapsulation with Segmented Filtration
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Solution Overview
Problem
Existing disc brake systems fail to effectively prevent fine dust emissions due to limitations in gravity separators and filter devices, leading to increased brake temperatures, wear, and high operating costs, as they either inadequately capture fine particles or require excessive cooling air and frequent filter replacements.
Innovation Solution
A disc brake design featuring an encapsulated friction ring housing with a hood-like structure, gap seals, and a dedusting system comprising a coarse dust separator followed by a fine dust filter, which allows controlled air intake and filtration, reducing environmental dirt ingestion and optimizing cooling air usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a fine dust filter is used to retain very fine dust particles, then brake dust emissions are prevented, but the filter requires frequent replacement due to dirt ingestion and short service life
Solution Approach 1:
The dedusting device is segmented into two functional stages: a coarse dust separator (first stage) and a fine dust filter (second stage). The coarse dust separator captures larger particles first, protecting the fine dust filter from excessive contamination. This segmentation allows the fine dust filter to focus on capturing smaller particles while extending its service life through reduced strain.
Solution Approach 2:
The coarse dust separator performs preliminary filtration before air reaches the fine dust filter. By removing larger dust particles in advance, the system prepares the air stream for the fine dust filter, reducing its loading and extending its operational life while maintaining effective fine particle capture.
2Object-affected harmful factors
If a fine dust filter is hermetically sealed to prevent dust escape, then environmental pollution is reduced, but cooling air must be drawn through the filter, causing rapid contamination
Solution Approach 1:
The housing is divided into two separate housing parts, each with its own coarse dust separator and shared fine dust filter. This segmentation creates two independent cooling air intake paths, allowing the system to maintain hermetic sealing while distributing the filtration load across multiple intake points, reducing contamination rate per unit area.
Solution Approach 2:
The coarse dust separator acts as an intermediary component between the cooling air intake and the fine dust filter. It pre-filters the cooling air, removing larger particles before they reach the fine dust filter, thereby reducing contamination while maintaining the hermetic seal necessary for preventing dust escape.
3Temperature
If cooling air quantities are increased to achieve sufficient heat dissipation, then brake temperatures are reduced, but the fine dust filter becomes overwhelmed and requires frequent replacement
Solution Approach 1:
The dedusting device processes cooling air in two sequential stages: coarse particle removal followed by fine particle filtration. This segmentation allows the system to handle larger cooling air quantities effectively, as the coarse dust separator pre-processes the air, protecting the fine dust filter from being overwhelmed while maintaining adequate cooling capacity.
Solution Approach 2:
The coarse dust separator performs preliminary particle removal from the cooling air stream before it reaches the fine dust filter. This preliminary action enables the system to process higher volumes of cooling air without overloading the fine dust filter, thus extending filter service life while maintaining sufficient heat dissipation capacity.
4Object-affected harmful factors
If a hood-like housing encapsulates the friction rings to control air flow, then dust escape is prevented and cooling air usage is optimized, but the device complexity increases
Solution Approach 1:
The housing is segmented into two modular housing parts that can be independently assembled and maintained. Each housing part contains its own coarse dust separator, and both share a common fine dust filter. This segmentation reduces overall device complexity by creating manageable modules while maintaining effective dust encapsulation and optimized cooling air flow control.
Solution Approach 2:
The fine dust filter serves as a universal component for both housing parts, handling fine particle filtration for cooling air from both sides. This multi-functionality reduces the total number of filters needed while maintaining effective dust capture, thereby reducing device complexity despite the encapsulated housing structure.
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 effectively minimizes brake dust escape into the environment while reducing operating costs by ensuring efficient cooling and extended filter life through controlled air flow and reduced strain on the fine dust filter, using a combination of coarse and fine dust separation and controlled suction.
Implementation Method 1
a suction device, in particular a suction fan, by means of which air laden with abrasion is sucked through the filter
Implementation Method 2
a coarse dust separator arranged first in the direction of the housing, through which the polluted, extracted air is guided to a fine dust filter
Implementation Method 3
a fine dust filter, which is connected upstream of the suction device
Implementation Method 4
On the inner and outer circumference, the housing is designed as a gap seal, for example as a labyrinth seal, which allows fresh air to be sucked in during operation of the suction device
Data Source
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AI summary
A disc brake, having a brake calliper (3) which reaches over a brake disc (1) and in which brake shoes (4) are arranged which are provided with friction linings and can be pressed in each case with their friction lining on both sides against friction rings (2) of the brake disc (1), is configured in such a way that the friction rings (2) are covered outside the overlap region of the friction linings by a housing (6) which is stationary with respect to the brake calliper (3) and is connected to a suction device, wherein a dust removal device is provided between the housing (6) and the suction device.