Disc Brake Dust Extraction Layout Without Full Encapsulation
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Solution Overview
Problem
Existing disc brake systems for commercial vehicles fail to effectively prevent the escape of brake wear into the environment, leading to particulate matter dispersion due to airflow turbulence and limited encapsulation designs that can cause thermal issues.
Innovation Solution
A disc brake design featuring a brake caliper with a frame-like brake carrier, a cover element covering the opening above the brake disc, and an integrated extraction pipe arrangement connected to a suction system, which collects brake dust directly at the point of origin and directs it to a vehicle-side separation system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the brake is completely encapsulated to prevent brake dust escape, then the prevention of particulate matter emission is improved, but thermal problems occur in the friction pair
Solution Approach 1:
The suction device extracts brake dust particles directly at the point of generation (from the friction pair area) and removes them through the extraction and separation system. This prevents complete encapsulation while still achieving effective dust collection by taking out the harmful particles before they can escape into the environment.
Solution Approach 2:
The suction device acts as an intermediary between the friction pair and the environment. Instead of completely enclosing the brake system, the suction device mediates by continuously removing dust particles from the friction area, allowing heat to escape while preventing dust emission.
2Object-generated harmful factors
If cover or shielding plates are installed around the wheel brake to limit installation space, then the collection of brake dust is improved, but the brake cannot be completely encapsulated and thermal problems persist
Solution Approach 1:
The suction device uses pneumatic principles to create airflow that draws brake dust particles from the friction area. This pneumatic extraction system effectively collects dust without requiring complete mechanical encapsulation, thereby maintaining thermal exchange with the environment.
3Object-generated harmful factors
If a fine dust filter and fan are positioned in the wheel rim in a hermetically sealed manner, then the separation of brake dust is improved, but the device complexity increases
Solution Approach 1:
The system is segmented into modular components: the suction device with suction openings, the extraction pipe arrangement, and the separate dust collection system. This segmentation allows the suction device to be integrated into the brake caliper while the separation system can be positioned separately, reducing overall system complexity.
4Ease of repair
If the suction pipe arrangement is designed as a replaceable unit fastened to the brake carrier, then the ease of repair and retrofitting is improved, but the connection stability must be maintained
Solution Approach 1:
The suction pipe arrangement is designed with dynamic characteristics - it can be easily attached and detached (for maintenance and retrofitting) while maintaining stable connection during operation. The fastening mechanism allows for quick replacement while ensuring reliable connection when installed.
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 ensures high absorption of brake wear particles, minimizing their environmental dispersion and preventing thermal issues, while allowing for easy retrofitting and maintaining the brake's functionality.
Implementation Method 1
the vehicle's environment, primarily the conditions in the wheel housing and inside the rim, can ensure diffuse turbulence of the resulting brake dust through the airflow
Implementation Method 2
which on the one hand has a fine dust filter on the brake disc of a disc brake
Data Source
Figure 1
Figure 2a
Figure 2b
AI summary
The invention relates to a disk brake having: a brake caliper (3) which engages over a brake disk (1); a frame-like brake carrier (4) which engages around the brake disk edge and has lining shafts on both sides of the brake disk (1), into each of which lining shafts brake linings (51, 52) are inserted, which each have a friction lining (512, 522) and a rear plate (511, 521), wherein the brake caliper (3) has an opening (6) above the brake disk (1), through which opening the brake linings (51, 52) can be inserted into the lining shafts, wherein the brake linings (51, 52) can each be pressed with their friction lining (512, 522) onto friction ring surfaces (2) of the brake disk (1); and a suction pipe arrangement (100, 110, 120) for suctioning abraded brake particles arising during braking, wherein the opening (6) is covered completely or substantially by at least one cover element, in particular by a cover panel (7) fastened to the brake caliper (4), and wherein the suction pipe arrangement (100, 110, 120) comprises one or more suction pipes (101, 102, 111, 121) and is designed as a replaceable unit that is fastened to the brake carrier (4).