Brake assembly with air cooling system

[0002] This invention generally relates to vehicle brake systems. More particularly, this invention relates to a vehicle brake system that includes using air to cool portions of the brake system.

[0003] Vehicle brake systems typically include friction pads that engage a rotating member such as a rotor or drum. The components of the brake assembly naturally heat up during a braking application because of the friction between the rotating and stationary parts. Under most circumstances some heat build up does not pose any real problem. Under some conditions, however, excessive heat buildup may compromise b rake performance over the lifetime of the system. Further, brake systems in heavy duty vehicles are subjected to greater stresses than most passenger vehicles.

[0004] There is a need for an effective cooling system that can prevent excessive heat buildup in a brake assembly. One example proposed arrangement is shown in U.S. Pat. No. 3,347,344. In that patent a separate air reservoir is provided to direct air onto a rotor during braking applications. The arrangement in that patent has certain drawbacks, which resulted in it not being adopted in the marketplace. For example, a separate reservoir adds additional cost and weight to a vehicle, which is something that vehicle designers and manufacturers are striving to avoid.

[0005] Prior to this invention, a cost-effective and efficient brake cooling arrangement has not been developed. This invention utilizes compressed air from a compressed air source that is already associated with the braking system. The use of such compressed air is new because it provides a cooling effect for a brake assembly.

[0006] In general terms, this invention is a device that uses compressed air for cooling components of a brake assembly. A system designed according to this invention includes a rotating member and brake pads that engage the rotating member to apply a braking force. A compressed air source is connected with at least one conduit that maintains the air in a compressed state while it is within the conduit. A discharge nozzle at one end of the conduit directs the air at a portion of the brake system such that the air decompresses at it passes through the discharge nozzle, which reduces the temperature of the air and facilitates cooling the components of the brake assembly.

[0007] In the preferred embodiment, the conduit that carries the compressed air is a flexible tube. The preferred discharge nozzle is a high velocity air nozzle. The preferred embodiment also includes a solenoid actuated valve that selectively allows air to flow from the compressed air source to the conduit.

[0008] The various features and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawing that accompanies the detailed description can be briefly described as follows.

[0009] The FIGURE schematically illustrates a brake system designed according to this invention.

[0010] A brake assembly 20 includes a conventional rotor 22 that rotates with a wheel of a vehicle in a conventional manner. A brake caliper 24 supports friction pads 26 of the brake assembly in a conventional fashion. During a braking application, the friction pads 26 are moved into engagement with a surface on the rotor 22 to slow down the vehicle wheel in a conventional fashion. A backing plate 28 is associated with the rotor 22.

[0011] A compressed air source 30 supplies air for actuatng the components of the brake assembly 20 on the vehicle. Such compressed air sources are well known and commonly used in heavy duty vehicles. A selectively activated valve 32 preferably is coupled with the compressed air source 30. The preferred embodiment includes a solenoid actuated valve 32. A plurality of conduits 34 extend from the valve 32 and terminate in a corresponding plurality of discharge nozzles 36. The conduits 34 preferably are flexible tubes such as rubber hoses. The conduits 34 maintain the air in a compressed state (as it is received from the compressed air source 30). The air from the air source 30 that travels through the conduits 34 preferably does not experience any decompression until it exits the discharge nozzles 36.

[0012] The illustrated example includes discharge nozzles 36 supported on the brake caliper structure 24 and the backing plate 28. This arrangement provides cooling air directly onto the rotor 22 and the pads 26. Other arrangements are within the scope of this invention.

[0013] In one example, the conduits 34 are 1½ inch flexible hoses and the discharge nozzles 36 are {fraction (1/16)} of an inch air nozzle outlets. The preferred embodiment includes high velocity discharge nozzles 36. This ensures that air flowing through the discharge nozzles is directed at the brake components at high velocity.

[0014] As the compressed air leaves the conduits 34 through the discharge nozzles 36, the decompress ion of the air results in a reduction of air temperature. In one example, the conduits 34 have a two inch inside diameter and the discharge nozzles 36 have a ¼ inch opening. This results in the air flow changing from a rate of 2 meters per second in the conduits 34 to a rate of 100 meters per second at the discharge nozzles 36. By maintaining the compression of the air within the conduits 34, the cooling effect of the air exiting the discharge nozzles 36 is maximized.

[0015] A significant advantage to this invention is that it utilizes compressed air from the compressed air source 30 that is already present on most heavy duty vehicles. Typical heavy duty vehicle brake systems have hydraulically activated components and include an air reservoir that is capable of holding 60 to 80 gallons and maintaining air at approximately 100 pounds per square inch. The valve 32 is selectively activated by a controller 40 to allow air to flow from the air source 30 through the conduits 34 to the discharge nozzles 36.

[0016] The controller 40 can be a selectively programmed portion of an onboard vehicle electronic controller or can be a dedicated circuit or microprocessor, for example. The controller 40 preferably is programmed to operate the valve 32 such that air is supplied to the braking components during a braking application and under any circumstances where the temperature of one or more of the braking components passes a preselected threshold. Accordingly, the preferred embodiment includes a temperature sensor 42 strategically placed within the brake assembly 20 to communicate temperature information to the controller 40 so that the valve 32 can be operated as needed.

[0017] Given this description, those skilled in the art will be able to choose from among commercially available microprocessors or to design custom circuitry or software to realize the functions of the controller 40 described in this specification.

[0018] Additionally, given this description, those skilled in the art will be able to choose from among commercially available discharge nozzles and types of conduit to realize this invention.

[0019] The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art that do not necessarily depart from the purview and spirit of this invention. The scope of legal protection given to this invention can only be determined by studying the following claims.