Utility Vehicle Disc Brake Sealing With Integrated Protection Cap
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Solution Overview
Problem
Existing disc brake systems face issues with environmental protection and seal functionality, particularly with the adjusting spindle, leading to brake force loss due to corrosion and wear, as current sealing solutions are complex and require multiple independent seals.
Innovation Solution
Integration of a piston protection cap combining primary and secondary seals made from elastic materials, with the secondary seal arranged within the brake caliper's annular space, and a holding device for secure attachment to the cover plate, reducing assembly steps and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple independent seals (primary seal, secondary seal, third seal) are used to protect the brake caliper interior, then protection against environmental influences is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines the primary seal, secondary seal, and third seal into a single integrated piston protection cap component. This merging reduces the number of separate sealing components from three to one, simplifying the overall device structure while maintaining the multi-layer sealing functionality for protecting the brake caliper interior against environmental influences
Solution Approach 2:
The piston protection cap serves multiple sealing functions simultaneously: it provides primary sealing against environmental influences, secondary sealing as backup protection, and houses the adjusting spindle mechanism. This multi-functional design eliminates the need for separate sealing components and reduces assembly complexity
2Ease of manufacture
If primary seal and secondary seal are made as separate components, then flexibility in assembly is improved, but production complexity and costs increase
Solution Approach 1:
The primary seal and secondary seal are merged into a single piston protection cap component that can be manufactured as one integrated piece. This reduces production complexity by eliminating the need to manufacture, inventory, and assemble multiple separate sealing components, while the elastic material allows the component to be stretched and installed flexibly
3Ease of repair
If multiple seals are assembled individually on the cover plate, then ease of replacement is improved, but assembly time and labor increase
Solution Approach 1:
By combining all sealing functions into a single piston protection cap, the replacement operation is simplified from installing multiple separate seals to installing one integrated component. This reduces assembly time and labor while maintaining the protective sealing functionality, as the entire sealing assembly can be replaced as a single unit
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
Enhanced protection against environmental influences, simplified assembly and disassembly, and improved durability of the disc brake system by ensuring continuous sealing functionality even if the primary seal is damaged, while reducing production complexity and costs.
Implementation Method 1
the primary seal and the secondary seal are preferably made from an elastic material
Data Source
AI summary
The invention relates to a disc brake (1) for utility vehicles, having a brake caliper, a brake disc (37), an actuating lever (4) arranged axially to a disc brake axis (A) of the brake disc (37), an adjusting device (36) comprising an adjusting spindle (12), a pressure collar (13) and an adjusting spindle head (27), wherein the adjusting device (36) is arranged at least partially within an interior (7) of the brake caliper (2), a primary seal (8) for sealing the interior (7) of the brake caliper (2), an annular space (10), which is delimited by an inner wall (6) of a through-opening (19) of the brake caliper (2) and the adjusting device, and a secondary seal (9) for at least partially sealing the interior (7) of the brake caliper (2), characterized in that the primary seal (8) and the secondary seal (9) are designed as a piston protection cap (14).