Disc Brake Dust Filter With Caliper-Sealing Filter Medium
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Solution Overview
Problem
Brake dust particles from disc brake systems contribute to environmental pollution and contamination, affecting the functionality and aesthetics of motor vehicles.
Innovation Solution
A disc brake assembly incorporating a brake dust particle filter with a U-shaped filter housing and a filter medium, such as a metal fiber fleece, that surrounds the brake disc and abuts the brake caliper to effectively capture and retain brake dust particles, enhancing sealing and separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a filter housing is introduced to capture brake dust particles, then the separation efficiency is improved, but the device complexity increases
Solution Approach 1:
The filter system is segmented into a filter housing and a separate filter medium that can be independently installed and maintained. The filter medium is divided into multiple sections that can be arranged in different configurations within the housing, allowing for modular assembly and easier maintenance while maintaining high separation efficiency.
Solution Approach 2:
The filter medium acts as an intermediary element between the brake dust source and the environment. It is positioned within the filter housing to intercept particles in the airflow, serving as a mediator that captures contaminants while allowing the housing structure to provide support and positioning.
2Reliability
If the filter medium extends beyond the filter housing to abut the brake caliper assembly, then the sealing is improved and particle escape is prevented, but the manufacturing precision requirements increase
Solution Approach 1:
The filter medium is designed as a flexible element that can extend beyond the rigid filter housing to abut against the brake caliper assembly. This flexibility allows the filter medium to conform to slight variations in the positioning of the brake caliper, maintaining effective sealing without requiring extremely tight manufacturing tolerances on the housing components.
Solution Approach 2:
The filter medium extends in the circumferential direction beyond the filter housing to create an overlapping arrangement with the brake caliper assembly. This dimensional extension creates a multi-layer sealing approach where the filter medium bridges gaps that would be difficult to seal with the housing alone, improving reliability while accommodating manufacturing variations.
3Object-affected harmful factors
If the filter medium is used to retain brake dust particles, then the environmental pollution is reduced, but the loss of substance increases due to trapped particles
Solution Approach 1:
The filter medium is designed to accumulate brake dust particles during operation, effectively removing them from the environment. The system is configured to allow for periodic maintenance where the accumulated particles are removed from the filter medium, enabling reuse of the filter medium while maintaining continuous particle capture capability.
Solution Approach 2:
The filter medium extracts brake dust particles from the airflow path between the brake assembly and the environment. By positioning the filter medium in the circumferential direction to overlap with the brake caliper assembly, it selectively removes harmful particles from the air stream while allowing clean air to pass through.
4Ease of manufacture
If the filter housing and brake caliper are designed as separate components, then the ease of manufacture is improved, but the sealing at the interface may be compromised
Solution Approach 1:
The filter medium serves as a flexible sealing element that bridges the interface between the rigid filter housing and brake caliper assembly. This flexible component can deform to accommodate slight misalignments or dimensional variations at the interface, maintaining effective sealing while allowing the housing and caliper to remain as separate, easily manufactured components.
Solution Approach 2:
The filter medium acts as an intermediary sealing element at the interface between the filter housing and brake caliper assembly. It fills and seals gaps that naturally occur at the joint between two separate rigid components, maintaining particle containment while preserving the manufacturing advantages of having separate components.
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 the emission of brake dust into the environment by improving the sealing between the filter housing and brake caliper assembly, ensuring a high separation efficiency and maintaining effective operation under vehicle vibrations and temperature conditions.
Implementation Method 1
The filter medium serves to retain and collect brake dust particles
Implementation Method 2
The protruding section of the filter medium can guide an air stream laden with brake dust particles from the brake caliper into the filter housing
Implementation Method 3
The filter medium can be in elastic tension. The elastic tension prevents the filter medium from lifting off the brake caliper assembly during vibrations
Implementation Method 4
the filter medium is malleably deformed by abutting on the brake caliper assembly. Through the malleable deformation, the filter medium can conform to a contour of the brake caliper assembly
Data Source
AI summary
A disc brake assembly including a brake disc, a brake caliper assembly with a brake caliper, and a brake dust particle filter with a filter housing and a filter medium arranged in sections in the filter housing, wherein the filter medium extends beyond the filter housing in the circumferential direction of the brake disc and abuts against the brake caliper assembly. A brake dust particle filter for such a disc brake assembly is included, including a filter housing and a filter medium arranged in sections in the filter housing, which extends beyond the filter housing in the circumferential direction.