Pads and brake calipers

Abstract

This invention relates to a brake pad shaft for a brake caliper, the shaft shaft comprising a shaft body and a support body. The shaft body includes a first mounting portion and a second mounting portion, extending along a longitudinal axis between the first and second mounting portions. Both the first and second mounting portions are configured to be coupled to the caliper body of the brake caliper. The support body is a separate component from the shaft body and is attached to the shaft body to movably support the brake pad of the brake caliper relative to the caliper body. The support body is disposed between the first and second mounting portions of the shaft body. The support body is made of a non-metallic material.

Description

[0001] Cross-references to related applications

[0002] This application is a continuation-in-part of U.S. Patent Application US17 / 403,882, filed August 17, 2021. The contents of that U.S. Patent Application are incorporated herein by reference in their entirety. Technical Field

[0003] This invention relates to pad shafts and brake calipers. Background Technology

[0004] Human-powered vehicles include a braking device that applies braking force to the wheels. The braking device includes a brake pad and a shim pin. The shim pin movably supports the brake pad. Due to the vibrations of the human-powered vehicle, a rattling noise is generated between the brake pad and the shim pin. On the other hand, the shim pin needs to provide sufficient strength to support the brake pad. Summary of the Invention

[0005] According to a first aspect of the invention, a pad shaft for a brake caliper includes a shaft body and a support body. The shaft body includes a first mounting portion and a second mounting portion, extending along a longitudinal axis between the first and second mounting portions. Both the first and second mounting portions are configured to be coupled to the caliper body of the brake caliper. The support body is a separate component from the shaft body and is attached to the shaft body to movably support the brake pad of the brake caliper relative to the caliper body. The support body is disposed between the first and second mounting portions of the shaft body. The support body is made of a non-metallic material.

[0006] By utilizing the axle according to the first aspect, the support body made of a non-metallic material can reduce the rattling noise generated between the axle and the brake pad due to vibrations from the human-powered vehicle. Furthermore, since the support body is positioned between the first mounting portion and the second mounting portion, the first and second mounting portions can maintain the strength of the axle. Therefore, it is possible to reduce rattling noise while simultaneously maintaining the strength of the axle.

[0007] According to a second aspect of the invention, the pad shaft of the first aspect is configured such that the support body includes a through hole. The shaft body is at least partially disposed in the through hole.

[0008] By using the pad shaft according to the second aspect, since the shaft body is at least partially disposed in the through hole, the strength of the pad shaft can be reliably maintained.

[0009] According to a third aspect of the invention, a brake pad shaft for a brake caliper includes a shaft body and a support body. The shaft body is configured to be coupled to a caliper body of the brake caliper. The support body is attached to the shaft body to movably support a brake pad of the brake caliper relative to the caliper body. The support body is made of a non-metallic material. The support body includes a through-hole. The shaft body is at least partially disposed in the through-hole.

[0010] By utilizing the axle according to the third aspect, the support body made of non-metallic material can reduce the rattling noise generated between the axle and the brake pad due to vibrations from the human-powered vehicle. Furthermore, since the axle body is at least partially disposed within a through-hole, the strength of the axle can be maintained. Therefore, it is possible to reduce rattling noise while simultaneously maintaining the strength of the axle.

[0011] According to a fourth aspect of the invention, the pad shaft is constructed in accordance with any one of the first to third aspects such that the support body is made of resin material.

[0012] By utilizing the pad shaft according to the fourth aspect, the support body made of resin material can effectively reduce rattling noise.

[0013] According to a fifth aspect of the invention, the pad shaft is constructed in accordance with any one of the first to fourth aspects such that the shaft body is made of a metallic material.

[0014] By utilizing the pad shaft according to the fifth aspect, the shaft body made of metal material can reliably maintain the strength of the pad shaft.

[0015] According to a sixth aspect of the invention, the pad shaft is constructed in accordance with any one of the first to fifth aspects such that the support body includes a support outer surface, which is capable of contacting the brake pad when the support body movably supports the brake pad. The support outer surface is made of a non-metallic material.

[0016] By utilizing the pad shaft according to the sixth aspect, the outer surface of the support member made of non-metallic material can effectively reduce rattling noise.

[0017] According to a seventh aspect of the invention, the shaft is constructed in accordance with any one of the second to sixth aspects such that the shaft body includes a first shaft body and a second shaft body. The first shaft body has a first outer diameter. The second shaft body has a second outer diameter smaller than the first outer diameter. The second shaft body is at least partially disposed in a through hole in the support body.

[0018] Using the pad shaft according to the seventh aspect, the support body can be attached to the shaft body, while maintaining the outer diameter of the pad shaft.

[0019] According to an eighth aspect of the invention, the shaft according to the seventh aspect is configured such that the shaft body includes a third shaft body having a third outer diameter. The second outer diameter is smaller than the first outer diameter and the third outer diameter. The second shaft body is disposed between the first shaft body and the third shaft body to define an attachment recess between the first shaft body and the third shaft body. A support body is at least partially disposed in the attachment recess.

[0020] Using the pad shaft according to the eighth aspect, the support body can be attached to the shaft body, while the outer diameter of the pad shaft can be reliably maintained.

[0021] According to a ninth aspect of the present invention, the pad shaft according to the eighth aspect is configured such that the first outer diameter is greater than the third outer diameter.

[0022] By utilizing the pad shaft according to aspect nine, the strength of the pad shaft can be reliably maintained.

[0023] According to a tenth aspect of the invention, the pad shaft is configured such that the support body has a support outer diameter greater than the second outer diameter.

[0024] By utilizing the pad shaft according to aspect ten, the strength of the support body can be reliably maintained.

[0025] According to the eleventh aspect of the present invention, the pad shaft according to the tenth aspect is configured such that the outer diameter of the support member is smaller than the first outer diameter.

[0026] Using the pad shaft according to aspect eleven, the support body can be attached to the shaft body, while the outer diameter of the pad shaft can be reliably maintained.

[0027] According to the twelfth aspect of the present invention, the pad shaft according to the tenth or eleventh aspect is configured such that the outer diameter of the support member is equal to the third outer diameter.

[0028] By using the pad shaft according to the twelfth aspect, the support body can be attached to the shaft body, while the outer diameter of the pad shaft can be maintained more reliably.

[0029] According to a thirteenth aspect of the invention, the pad shaft according to any one of the seventh to twelfth aspects is configured such that the first shaft body includes a head portion having a head outer diameter. The first outer diameter includes the head outer diameter. The head outer diameter is the largest outer diameter in the pad shaft.

[0030] By utilizing the pad shaft according to aspect thirteen, the head portion can prevent the pad shaft from falling off the caliper body.

[0031] According to a fourteenth aspect of the invention, the pad shaft of the thirteenth aspect is configured such that the first shaft body includes a shaft portion having an outer diameter. The first outer diameter includes the shaft outer diameter. The shaft outer diameter is smaller than the head outer diameter.

[0032] By utilizing the pad shaft according to aspect fourteen, the strength of the pad shaft can be effectively maintained.

[0033] According to the fifteenth aspect of the present invention, the pad shaft according to the fourteenth aspect is configured such that the shaft portion includes an external thread that is connected to the internal thread of the caliper body.

[0034] Using the pad shaft according to aspect 15, the pad shaft can be reliably connected to the caliper body via external and internal threads.

[0035] According to a sixteenth aspect of the invention, the pad shaft according to any one of the seventh to fifteenth aspects is configured such that the support body includes a support outer surface and a slot that extends radially outward from the through hole to the support outer surface.

[0036] By using the pad shaft according to the sixteenth aspect, the gap allows the support body to be easily attached to the shaft body and / or allows the support body to be easily removed from the shaft body.

[0037] According to the seventeenth aspect of the invention, the pad shaft according to the sixteenth aspect is configured such that the support body is deformable to allow the shaft body to travel from the outer surface of the support through the gap to the through hole when the support body is attached to the shaft body.

[0038] By using the pad shaft according to aspect seventeen, the gap can reliably allow the support body to be attached to the shaft body.

[0039] According to the eighteenth aspect of the invention, the pad shaft according to the sixteenth or seventeenth aspect is configured such that the support body is deformable to allow the shaft body to travel through the through hole and the gap to the outer surface of the support body when the support body is removed from the shaft body.

[0040] By using the pad shaft according to aspect eighteen, the gap can reliably allow the support body to be removed from the shaft body.

[0041] According to a nineteenth aspect of the invention, the support shaft according to any one of aspects sixteen to eighteen is configured such that the support body includes a first circumferential end and a second circumferential end. The second circumferential end is spaced apart from the first circumferential end to define a gap between the first circumferential end and the second circumferential end. The gap has a width defined between the first circumferential end and the second circumferential end. In an attached state where the support body is attached to the shaft body, the width of the gap is less than the second outer diameter of the second shaft body.

[0042] By using the pad shaft according to aspect nineteen, it is possible to keep the support body attached to the shaft body.

[0043] According to a twentieth aspect of the invention, the shaft is constructed in accordance with any one of the seventh to nineteenth aspects such that the shaft body includes a third shaft body having a third outer diameter. The support body is made of a heat-shrinkable material. The support body has an inner diameter. Before the heat shrinkage of the support body, the inner diameter of the support body is larger than the third outer diameter.

[0044] By utilizing the pad shaft according to aspect 20, since the inner diameter of the support body is larger than the third outer diameter before the heat shrinkage of the support body, it is possible to insert the shaft body into the support body before the heat shrinkage of the support body. This makes it easier to assemble the shaft body and the support body.

[0045] According to the twenty-first aspect of the present invention, the pad shaft according to the twenty-first aspect is configured such that, after the thermal shrinkage of the support body, the inner diameter of the support body is smaller than the third outer diameter.

[0046] Using the pad shaft according to aspect 21, the thermal shrinkage of the support body may be used to reliably fix the support body to the shaft body.

[0047] According to a twenty-second aspect of the invention, the pad shaft is constructed in accordance with either the twenty-first or twenty-first aspect such that the support body has a support outer diameter. After thermal shrinkage of the support body, the support outer diameter differs from the third outer diameter.

[0048] By utilizing the shim according to aspect 22, it is possible to expand the dimensional tolerance range of the outer diameter of the support member after thermal shrinkage of the support member body. This improves the productivity of the shim.

[0049] According to the twenty-third aspect of the present invention, the pad shaft is constructed in accordance with any one of the first to twenty-second aspects such that the support body is made of a heat-shrinkable material.

[0050] By using the pad shaft according to aspect 23, the heat-shrinkable material makes it easier to assemble the shaft body and the support body and / or reliably fix them to each other.

[0051] According to a twenty-fourth aspect of the invention, the shaft is constructed such that the shaft body includes a first shaft end and a second shaft end, and extends along a longitudinal axis between the first shaft end and the second shaft end. A support body is disposed between the first shaft end and the second shaft end.

[0052] By utilizing the pad shaft according to aspect twenty-four, a pad shaft of sufficient length may be provided.

[0053] According to a twenty-fifth aspect of the invention, a brake caliper for a human-powered vehicle includes: a caliper body; a brake pad including a support hole; and a pad shaft according to any one of the first to twenty-fourth aspects. The pad shaft is coupled to the caliper body. The pad shaft extends through the support hole to movably support the brake pad relative to the caliper body.

[0054] By utilizing the brake caliper according to aspect 25, it is possible to apply the structure of the bearing pad to the brake caliper. Therefore, it is possible to reduce rattling noise while maintaining the strength of the bearing pad in the brake caliper. Attached Figure Description

[0055] A more complete understanding of the invention and its many advantages can be readily obtained by referring to the following detailed description taken in conjunction with the accompanying drawings, as is a better understanding of the invention.

[0056] Figure 1 It is a perspective view of the brake caliper of a human-powered vehicle.

[0057] Figure 2 It is along Figure 1 A cross-sectional view of the brake caliper cut along line II-II.

[0058] Figure 3 It is along Figure 2 A cross-sectional view of the brake caliper cut along line III-III.

[0059] Figure 4 yes Figure 1 A perspective view of the brake caliper pad and retainer shown.

[0060] Figure 5 yes Figure 3 The enlarged partial cross-sectional view of the brake caliper shown.

[0061] Figure 6 It is along Figure 4 A sectional view of the pad shaft cut along line VI-VI.

[0062] Figure 7 It is along Figure 6 A sectional view of the pad shaft cut by line VII-VII.

[0063] Figure 8 It is a cross-sectional view based on a modified pad shaft (before the thermal shrinkage of the support body).

[0064] Figure 9 It is along Figure 8 A cross-sectional view of the pad shaft (before the thermal shrinkage of the support body) cut along line IX-IX.

[0065] Figure 10It is a cross-sectional view based on a modified pad shaft (after the thermal shrinkage of the support body).

[0066] Figure 11 It is along Figure 10 A cross-sectional view of the pad shaft (after the thermal shrinkage of the support body) cut along line XI-XI. Detailed Implementation

[0067] Embodiments will now be described with reference to the accompanying drawings, wherein the same reference numerals in the drawings indicate corresponding or identical elements.

[0068] As in Figure 1 As seen in the image, the brake caliper 10 for the human-powered vehicle 2 is configured to apply braking force to the disc brake rotor 4 (see, for example, see...). Figure 2 The brake caliper 10 is configured to be connected to the operating device 6 via a hydraulic hose 8. The brake caliper 10 is configured to apply braking force to the disc brake rotor 4 in response to hydraulic pressure generated by the operating device 6 (see, for example, see...). Figure 2 ).

[0069] In this application, a human-powered vehicle is a vehicle that is propelled by the power of a human, including at least one user (i.e., a rider). Human-powered vehicles include various types of bicycles, such as mountain bikes, road bikes, city bikes, freight bikes, manual bikes, and recumbent bikes. Furthermore, human-powered vehicles include electric bicycles (e-bikes). Electric bicycles include electric-assisted bicycles constructed to use an electric motor to assist in vehicle propulsion. However, the total number of wheels on a human-powered vehicle is not limited to two. For example, a human-powered vehicle includes vehicles with one wheel or three or more wheels. In particular, human-powered vehicles do not include vehicles that use only an internal combustion engine as their power source. Generally, light road vehicles include vehicles that do not require a public road driving license, and these light road vehicles are assumed to be human-powered vehicles.

[0070] The brake caliper 10 for the human-powered vehicle 2 includes a caliper body 12. The caliper body 12 is configured to be mounted to the vehicle body 2A of the human-powered vehicle 2.

[0071] The brake caliper 10 for the human-powered vehicle 2 includes a brake pad 14. The brake pad 14 is configured to be movably coupled to the caliper body 12. The brake caliper 10 for the human-powered vehicle 2 also includes a brake pad 16. The brake pad 16 is configured to be movably coupled to the caliper body 12.

[0072] The brake caliper 10 for the human-powered vehicle 2 includes a bearing 18. The bearing 18 is coupled to the caliper body 12. The bearing 18 is configured to movably support a brake pad 14 relative to the caliper body 12. The bearing 18 is also configured to movably support a brake pad 16 relative to the caliper body 12.

[0073] The brake caliper 10 includes a biasing member 19. The biasing member 19 is configured to bias the brake pads 14 away from each other. The pad shaft 18 is configured to movably support the biasing member 19 relative to the caliper body 12.

[0074] As in Figure 2 As seen in the diagram, the brake caliper 10 includes multiple pistons 20, 22, 24, and 26. The caliper body 12 includes multiple recesses 30, 32, 34, and 36. Piston 20 is movably disposed in recess 30. Piston 22 is movably disposed in recess 32. Piston 24 is movably disposed in recess 34. Piston 26 is movably disposed in recess 36. However, the total number of pistons is not limited to four. The total number of recesses is not limited to four.

[0075] The caliper body 12 and piston 20 define a hydraulic chamber 40 in recess 30. The caliper body 12 and piston 22 define a hydraulic chamber 42 in recess 32. The caliper body 12 and piston 24 define a hydraulic chamber 44 in recess 34. The caliper body 12 and piston 26 define a hydraulic chamber 46 in recess 36. Hydraulic chambers 40, 42, 44, and 46 are configured to connect to the main chamber of the operating device 6 via a flow passage and a hydraulic hose 8.

[0076] Pistons 20, 22, 24, and 26 are configured to move brake pad 14 toward disc brake rotor 4 in response to hydraulic pressure generated by operating device 6. Pistons 20, 22, 24, and 26 are configured to move brake pad 16 toward disc brake rotor 4 in response to hydraulic pressure generated by operating device 6.

[0077] As in Figure 3 As seen in the image, the pad shaft 18 has a longitudinal axis A1 and extends along the longitudinal axis A1. The pad shaft 18 for the brake caliper 10 includes a shaft body 50 and a support body 52. ​​The shaft body 50 is configured to be coupled to the caliper body 12 of the brake caliper 10. The support body 52 is a separate component from the shaft body 50. The support body 52 is a separate component independent of the shaft body 50. The support body 52 is attached to the shaft body 50. The support body 52 is detachably attached to the shaft body 50. However, if required and / or desired, the support body 52 may be attached to the shaft body 50 but not detached from it. For example, the support body 52 may be attached to the shaft body 50 using an adhesive. The support body 52 may be attached to the shaft body 50 using insert molding.

[0078] As in Figure 4As seen in the diagram, the shaft body 50 includes a first shaft end 50A and a second shaft end 50B. The shaft body 50 extends along a longitudinal axis A1 between the first shaft end 50A and the second shaft end 50B. The first shaft end 50A is spaced apart from the second shaft end 50B in an axial direction D1 defined along the longitudinal axis A1. A support body 52 is disposed between the first shaft end 50A and the second shaft end 50B. The support body 52 is disposed in the axial direction D1 between the first shaft end 50A and the second shaft end 50B.

[0079] The brake caliper 10 includes a retainer 53. The retainer 53 is configured to be detachably attached to the bearing 18. The bearing body 50 includes a recess 50G. The retainer 53 is configured to be disposed in the recess 50G when the retainer 53 is attached to the bearing 18. The retainer 53 is configured to prevent the bearing 18 from unintentionally falling off the bearing body 50.

[0080] As used herein, the term “removably attachable” covers a construction in which an element can be repeatedly detached from and attached to another element without substantial damage.

[0081] As in Figure 5 As seen in the diagram, the support body 52 is attached to the shaft body 50 to movably support the brake pad 14 of the actuator caliper 10 relative to the caliper body 12. The support body 52 is attached to the shaft body 50 to movably support the brake pad 16 of the actuator caliper 10 relative to the caliper body 12. The support body 52 is in slidable contact with the brake pads 14 and 16. The shaft body 50 is not in contact with the brake pads 14 and 16.

[0082] With the pad shaft 18 movably supporting the brake pad 14, the support body 52 is at least partially radially disposed between the shaft body 50 and the brake pad 14 relative to the longitudinal axis A1. With the pad shaft 18 movably supporting the brake pad 16, the support body 52 is at least partially radially disposed between the shaft body 50 and the brake pad 16 relative to the longitudinal axis A1.

[0083] In this embodiment, with the pad shaft 18 movably supporting the brake pad 14, the support body 52 is at least partially radially disposed between the shaft body 50 and the brake pad 14 relative to the longitudinal axis A1. With the pad shaft 18 movably supporting the brake pad 16, the support body 52 is at least partially radially disposed between the shaft body 50 and the brake pad 16 relative to the longitudinal axis A1. However, if desired and / or expected, with the pad shaft 18 movably supporting the brake pad 14, the support body 52 may be completely radially disposed between the shaft body 50 and the brake pad 14 relative to the longitudinal axis A1. If desired and / or expected, with the pad shaft 18 movably supporting the brake pad 16, the support body 52 may be completely radially disposed between the shaft body 50 and the brake pad 16 relative to the longitudinal axis A1.

[0084] The shaft body 50 includes a first mounting portion 54 and a second mounting portion 56. The shaft body 50 extends along a longitudinal axis A1 between the first mounting portion 54 and the second mounting portion 56. Both the first mounting portion 54 and the second mounting portion 56 are configured to be coupled to the caliper body 12 of the brake caliper 10. The first mounting portion 54 is spaced apart from the second mounting portion 56 in the axial direction D1. A support body 52 is disposed between the first mounting portion 54 and the second mounting portion 56 of the shaft body 56. The support body 52 is disposed in the axial direction D1 between the first mounting portion 54 and the second mounting portion 56. The support body 52 is attached to the shaft body 50 to movably support the brake pad 14 of the brake caliper 10 relative to the caliper body 12 in the axial direction D1. The support body 52 is attached to the shaft body 50 to movably support the brake pad 16 of the brake caliper 10 relative to the caliper body 12 in the axial direction D1.

[0085] The brake pad 14 includes a support hole 14A. A pad shaft 18 extends through the support hole 14A to movably support the brake pad 14 relative to the caliper body 12. With the pad shaft 18 movably supporting the brake pad 14, the support body 52 is at least partially disposed in the support hole 14A. In this embodiment, with the pad shaft 18 movably supporting the brake pad 14, the support body 52 is at least partially disposed in the support hole 14A. However, if desired and / or expected, the support body 52 may be fully disposed in the support hole 14A with the pad shaft 18 movably supporting the brake pad 14.

[0086] The brake pad 16 includes a support hole 16A. A pad shaft 18 extends through the support hole 16A to movably support the brake pad 16 relative to the caliper body 12. With the pad shaft 18 movably supporting the brake pad 16, the support body 52 is at least partially disposed in the support hole 16A. In this embodiment, with the pad shaft 18 movably supporting the brake pad 16, the support body 52 is at least partially disposed in the support hole 16A. However, if desired and / or expected, the support body 52 may be fully disposed in the support hole 16A with the pad shaft 18 movably supporting the brake pad 16.

[0087] The biasing member 19 includes a first support hole 19A and a second support hole 19B. A bearing 18 extends through the first support hole 19A and the second support hole 19B to movably support the biasing member 19 relative to the caliper body 12. With the bearing 18 movably supporting the biasing member 19, the support body 52 is at least partially disposed in at least one of the first support hole 19A and the second support hole 19B. In this embodiment, with the bearing 18 movably supporting the biasing member 19, the support body 52 is partially disposed in each of the first support hole 19A and the second support hole 19B. However, if desired and / or expected, with the bearing 18 movably supporting the biasing member 19, the support body 52 may be fully disposed in at least one of the first support hole 19A and the second support hole 19B.

[0088] The caliper body 12 includes a first shaft support 58 and a second shaft support 60. The first shaft support 58 is spaced apart from the second shaft support 60 in the axial direction D1. A support body 52 is disposed between the first shaft support 58 and the second shaft support 60 in the axial direction D1. Brake pads 14 and 16 are disposed between the first shaft support 58 and the second shaft support 60 in the axial direction D1. A biasing member 19 is disposed between the first shaft support 58 and the second shaft support 60 in the axial direction D1.

[0089] The first mounting portion 54 is configured to connect to the first shaft support 58. When the first mounting portion 54 is connected to the first shaft support 58, the first mounting portion 54 can contact the first shaft support 58. The first shaft support 58 includes a first hole 58A. When the pad shaft 18 is mounted to the caliper body 12, the first mounting portion 54 is at least partially disposed in the first hole 58A. In this embodiment, when the pad shaft 18 is mounted to the caliper body 12, the first mounting portion 54 is partially disposed in the first hole 58A. However, if desired and / or as desired, the first mounting portion 54 can be fully disposed in the first hole 58A when the pad shaft 18 is mounted to the caliper body 12.

[0090] The second mounting portion 56 is configured to connect to the second shaft support 60. When the second mounting portion 56 is connected to the second shaft support 60, the second mounting portion 56 can contact the second shaft support 60. The second shaft support 60 includes a second hole 60A. When the pad shaft 18 is mounted to the caliper body 12, the second mounting portion 56 is at least partially disposed in the second hole 60A. In this embodiment, when the pad shaft 18 is mounted to the caliper body 12, the second mounting portion 56 is partially disposed in the second hole 60A. However, if desired and / or as desired, the second mounting portion 56 can be fully disposed in the second hole 60A when the pad shaft 18 is mounted to the caliper body 12.

[0091] The first mounting portion 54 includes an external thread 54A. The caliper body 12 includes an internal thread 12A. The external thread 54A of the first mounting portion 54 engages with the internal thread 12A of the caliper body 12. In this embodiment, the first hole 58A includes an internal thread 12A. The second hole 60A does not have an internal thread. If desired and / or expected, the external thread 54A can be omitted from the first mounting portion 54. If desired and / or expected, the internal thread 12A can be omitted from the caliper body 12.

[0092] As in Figure 6 As seen in the image, the support body 52 includes a through hole 52A. The through hole 52A extends along the longitudinal axis A1. The shaft body 50 is at least partially disposed within the through hole 52A. A first mounting portion 54 is at least partially disposed outside the through hole 52A. A second mounting portion 56 is at least partially disposed outside the through hole 52A.

[0093] In this embodiment, the shaft body 50 is partially disposed within the through hole 52A. The first mounting portion 54 is completely disposed outside the through hole 52A. The second mounting portion 56 is completely disposed outside the through hole 52A. However, if desired and / or expected, the first mounting portion 54 may be completely disposed within the through hole 52A. If desired and / or expected, the first mounting portion 54 may be at least partially disposed within the through hole 52A. If desired and / or expected, the second mounting portion 56 may be at least partially disposed within the through hole 52A.

[0094] The shaft body 50 is made of a metallic material, such as aluminum, iron, or stainless steel. The support body 52 is made of a non-metallic material. The support body 52 is made of a resin material. The support body 52 is made of a high-temperature resin material (such as phenolic resin). However, the support body 52 may be made of a non-metallic material other than resin.

[0095] The shaft body 50 includes a first shaft body 62 and a second shaft body 64. The first shaft body 62 includes a first mounting portion 54. The first shaft body 62 defines a first shaft end 50A. The second shaft body 64 defines a second shaft end 50B. The first shaft body 62 has a first outer diameter DM1. The second shaft body 64 has an outer diameter DM2 smaller than the first outer diameter DM1. The second shaft body 64 is at least partially disposed in a through hole 52A of the support body 52. ​​In this embodiment, the second shaft body 64 is completely disposed in the through hole 52A of the support body 52. ​​If desired and / or expected, the second shaft body 64 may be partially disposed in the through hole 52A of the support body 52.

[0096] The shaft body 50 includes a third shaft body 66 having a third outer diameter DM3. The third shaft body 66 includes a second mounting portion 56 and a recess 50G. A first outer diameter DM1 is larger than the third outer diameter DM3. A second outer diameter DM2 is smaller than both the first outer diameter DM1 and the third outer diameter DM3. A second shaft body 64 is disposed between the first shaft body 62 and the third shaft body 66 to define an attachment recess 68 between the first shaft body 62 and the third shaft body 66. A support body 52 is at least partially disposed in the attachment recess 68. In this embodiment, the support body 52 is completely disposed in the attachment recess 68. However, if desired and / or expected, the support body 52 may be partially disposed in the attachment recess 68.

[0097] The support body 52 has a support outer diameter DM4 that is larger than the second outer diameter DM2. The support outer diameter DM4 is smaller than the first outer diameter DM1. The support outer diameter DM4 is equal to the third outer diameter DM3. However, if required and / or desired, the support outer diameter DM4 may be different from the third outer diameter DM3. If required and / or desired, the support outer diameter DM4 may be equal to or greater than the first outer diameter DM1.

[0098] The first shaft body 62 includes a head portion 70 having a head outer diameter DM5. The first outer diameter DM1 includes the head outer diameter DM5. The head outer diameter DM5 is the largest outer diameter in the pad shaft 18. The head outer diameter DM5 is larger than the second outer diameter DM2, the third outer diameter DM3, and the support outer diameter DM4. However, if desired and / or expected, the head outer diameter DM5 may be equal to or smaller than at least one of the second outer diameter DM2, the third outer diameter DM3, and the support outer diameter DM4. If desired and / or expected, the head portion 70 may be omitted from the first shaft body 62.

[0099] The first shaft body 62 includes a shaft portion 72 having an outer diameter DM6. The first outer diameter DM1 includes the outer diameter DM6. A head portion 70 extends radially outward from the shaft portion 72. The outer diameter DM6 is smaller than the outer diameter DM5 of the head.

[0100] Shaft portion 72 corresponds to the first mounting portion 54. Shaft portion 72 includes an external thread 54A. The external thread 54A is connected to the internal thread 12A of the caliper body. The shaft outer diameter DM6 is the main outer diameter of the external thread 54A.

[0101] The shaft body 50 has a first length L1 defined along the longitudinal axis A1. The support body 52 has a second length L2 defined along the longitudinal axis A1. The first length L1 is defined along the longitudinal axis A1 from the first shaft end 50A to the second shaft end 50B. The first length L1 is greater than the second length L2.

[0102] The support body 52 includes a first end 74 and a second end 76. The support body 52 extends along a longitudinal axis A1 between the first end 74 and the second end 76. A second length L2 is defined along the longitudinal axis A1 from the first end 74 to the second end 76 of the support body 52.

[0103] As in Figure 7 As seen in the image, the support body 52 includes the support outer surface 52B. (As in...) Figure 5 As seen in the diagram, when the support body 52 movably supports the brake pad 14, the outer surface 52B of the support can contact the brake pad 14. When the support body 52 movably supports the brake pad 16, the outer surface 52B of the support can contact the brake pad 16. The outer surface 52B of the support is made of a non-metallic material.

[0104] As in Figure 7 As seen in the diagram, the support body 52 includes a slot 52C. The slot 52C extends radially outward from the through-hole 52A to the outer surface 52B of the support. The slot 52C extends radially outward from the through-hole 52A to the outer surface 52B of the support relative to the longitudinal axis A1. However, the slot 522 can be omitted from the support body 52. ​​In such embodiments, for example, the support body 52 can be attached to the shaft body 50 using an insert molding process.

[0105] The support body 52 includes a first circumferential end 52D and a second circumferential end 52E. The second circumferential end 52E is spaced apart from the first circumferential end 52D to define a gap 52C between the first circumferential end 52D and the second circumferential end 52E.

[0106] The gap 52C has a width W1 defined between a first circumferential end 52D and a second circumferential end 52E. With the support body 52 attached to the shaft body 50, the width W1 of the gap 52C is less than the second outer diameter DM2 of the second shaft body 64. The width W1 includes a maximum width W11 and a minimum width W12. With the support body 52 attached to the shaft body 50, both the maximum width W11 and the minimum width W12 are less than the second outer diameter DM2 of the second shaft body 64. However, if desired and / or expected, with the support body 52 attached to the shaft body 50, the width W1 may be equal to or greater than the second outer diameter DM2 of the second shaft body 64. If desired and / or expected, with the support body 52 attached to the shaft body 50, at least one of the maximum width W11 and the minimum width W12 may be equal to or greater than the second outer diameter DM2 of the second shaft body 64.

[0107] Before the shaft body 50 contacts the brake pads 14 and / or 16, the support body 52 may contact the brake pads 14 and / or 16. Specifically, a first minimum distance DS1 is defined in a cross-section along a plane perpendicular to the longitudinal axis A1 between the longitudinal axis A1 and line LN, which connects the first radially outermost point P1 of the first circumferential end 52D and the second radially outermost point P2 of the second circumferential end 54D. A second minimum distance DS2 is defined in a cross-section along a plane perpendicular to the longitudinal axis A1 between the longitudinal axis A1 and the outer circumferential surface 64a of the second shaft body 64. The first minimum distance DS1 is longer than the second minimum distance DS2. However, if required and / or desired, the first minimum distance DS1 may be equal to or shorter than the second minimum distance DS2.

[0108] The support body 52 is deformable to allow the shaft body 50 to travel from the outer surface 52B of the support through the slot 52C to the through hole 52A when the support body 52 is attached to the shaft body 50. The support body 52 is also deformable to allow the shaft body 50 to travel from the through hole 52A through the slot 52C to the outer surface 52B of the support when the support body 52 is removed from the shaft body 50. Figure 4 As seen in the image, the slot 52C extends along the longitudinal axis A1. The slot 52C extends along the longitudinal axis A1 from the first end 74 of the support body 52 to the second end 76. Therefore, the support body 52 can be attached to and detached from the shaft body 50.

[0109] As in Figure 6As seen in the diagram, the first shaft body 62 includes a first tapered surface 62A. The third shaft body 66 includes a second tapered surface 66A. The first tapered surface 62A is inclined relative to the longitudinal axis A1 from the outer peripheral surface of the first shaft body 62 to the outer peripheral surface of the second shaft body 64 to reduce the outer diameter of the first tapered surface 62A. The second tapered surface 66A is inclined relative to the longitudinal axis A1 from the outer peripheral surface of the third shaft body 66 to the outer peripheral surface of the second shaft body 64 to reduce the outer diameter of the second tapered surface 66A.

[0110] The first end 74 of the support body 52 can contact the first conical surface 62A. The second end 76 of the support body 52 can contact the second conical surface 66A. The first end 74 of the support body 52 includes a first inclined surface 74A that can contact the first conical surface 62A. The second end 76 of the support body 52 includes a second inclined surface 76A that can contact the second conical surface 66A.

[0111] The first inclined surface 74A is inclined relative to the longitudinal axis A1 from the outer surface 52B of the support member to the inner circumferential surface of the through hole 52A, thereby reducing the inner diameter of the first inclined surface 74A. The second inclined surface 76A is inclined relative to the longitudinal axis A1 from the outer surface 52B of the support member to the inner circumferential surface of the through hole 52A, thereby reducing the inner diameter of the second inclined surface 76A. When the support member body 52 is attached to the shaft body 50, the first inclined surface 74A contacts the first tapered surface 62A. When the support member body 52 is attached to the shaft body 50, the second inclined surface 76A contacts the second tapered surface 66A. However, if desired and / or expected, at least one of the first inclined surface 74A and the second inclined surface 76A can be omitted from the support member body 52. ​​If desired and / or expected, at least one of the first tapered surface 62A and the second tapered surface 66A can be omitted from the shaft body 50.

[0112] The pad shaft 18 may include a rotation limiting structure configured to limit relative rotation between the shaft body 50 and the support body 52. ​​In this variant embodiment, for example, the rotation limiting structure includes a concave-convex shape. The rotation limiting structure includes at least one recessed portion and at least one protruding portion configured to engage with each other to limit relative rotation between the shaft body 50 and the support body 52. ​​At least one recessed portion is disposed on one of the shaft body 50 and the support body 52. ​​At least one protruding portion is disposed on the other of the shaft body 50 and the support body 52. ​​At least one recessed portion may include a slit 52C, wherein at least one recessed portion is disposed in the slit 52C if at least one recessed portion is disposed to the support body 52. ​​For example, the rotation limiting structure may be configured to position the support body 52 relative to the shaft body 50 such that the depth direction of the slit 52C (e.g., in) Figure 7 The direction of the first minimum distance DS1 shown is set along the rotation direction of the disc brake rotor 4.

[0113] As in Figures 8 to 11 As seen in the image, the support body 52 can be made of a heat-shrinkable material. Figure 8 and Figure 9 The shaft body 50 and the support body 52 are shown before the thermal shrinkage of the support body. Figure 10 and 11 The image shows the shaft body 50 and support body 52 after heat shrinkage of the support body. The shaft body 50 includes a third shaft body 66 having a third outer diameter DM3. The support body 52 has an inner diameter DM7. The support body 52 has a support outer diameter DM4. The inner diameter DM7 of the support body 52 differs in size before and after heat shrinkage. The support outer diameter DM4 of the support body 52 also differs in size before and after heat shrinkage.

[0114] As in Figure 8 and Figure 9 As seen in the diagram, before the support body 52 heat-shrinks, the inner diameter DM7 of the support body 52 is larger than the third outer diameter DM3. Therefore, before the support body 52 heat-shrinks, the third shaft body 66 of the shaft body 50 is inserted into the through hole 52A of the support body 52. ​​However, if needed and / or desired, the inner diameter DM7 of the support body 52 can be less than or equal to the third outer diameter DM3 before the support body 52 heat-shrinks. When the inner diameter DM7 of the support body 52 is equal to the third outer diameter DM3 before the support body 52 heat-shrinks, the third shaft body 66 deforms the support body 52 to expand the inner diameter DM7 when the third shaft body 66 is inserted into the through hole 52A of the support body 52 before the support body 52 heat-shrinks.

[0115] In one variation, before the support body 52 heat-shrinks, the inner diameter DM7 of the support body 52 is smaller than the first outer diameter DM1 of the first shaft body 62. Before the support body 52 heat-shrinks, the inner diameter DM7 of the support body 52 is smaller than the outer diameter DM6 of the shaft portion 72. However, if required and / or desired, before the support body 52 heat-shrinks, the inner diameter DM7 of the support body 52 may be greater than or equal to the first outer diameter DM1 of the first shaft body 62. If required and / or desired, before the support body 52 heat-shrinks, the inner diameter DM7 of the support body 52 may be greater than or equal to the outer diameter DM6 of the shaft portion 72.

[0116] As in Figure 8As seen in the image, the support body 52 has a second length L2. The attachment recess 68 has a third length L3 defined along the longitudinal axis A1. In this variant, the second length L2 is longer than the third length L3 of the attachment recess 68 before the thermal shrinkage of the support body 52. ​​However, if desired and / or as desired, the second length L2 may be equal to or shorter than the third length L3 of the attachment recess before the thermal shrinkage of the support body 52.

[0117] As in Figure 10 and Figure 11 As seen in the diagram, after the support body 52 undergoes heat shrinkage, its inner diameter DM7 is smaller than its third outer diameter DM3. After heat shrinkage, the inner diameter DM7 of the support body 52 is equal to the second outer diameter DM2 of the second shaft body 64. If needed and / or desired, after heat shrinkage, the inner diameter DM7 of the support body 52 can be larger than the second outer diameter DM2 of the second shaft body.

[0118] After the support body 52 has undergone heat shrinkage, the outer diameter DM4 of the support is different from the third outer diameter DM3 of the support body 52. ​​In this variant, after the support body 52 has undergone heat shrinkage, the outer diameter DM4 of the support is smaller than the third outer diameter DM3. However, if required and / or desired, after the support body 52 has undergone heat shrinkage, the outer diameter DM4 of the support can be greater than or equal to the third outer diameter DM3.

[0119] As in Figure 10 As seen in the diagram, after the support body 52 has undergone heat shrinkage, the second length L2 is shorter than the third length L3 of the attachment recess 68. However, if needed and / or desired, the second length L2 may be equal to the third length L3 of the attachment recess 68 after the support body 52 has undergone heat shrinkage.

[0120] As in Figure 9 and Figure 11 As seen in the image, the support body 52, made of heat-shrinkable material, has a tubular shape. However, if needed and / or desired, the support body 52 can be coupled with... Figure 7 The illustrated embodiment also includes gap 52C.

[0121] In this application, as used herein, the term "comprising" and its derivatives are intended to be open-ended terms that specify the presence of the listed features, elements, components, groups, integers, and / or steps, but do not exclude the presence of other unlisted features, elements, components, groups, integers, and / or steps. This concept also applies to words with similar meanings, such as the terms "having," "comprising," and their derivatives.

[0122] The terms “component,” “section,” “part,” “component,” “element,” “body,” and “structure” can have a dual meaning of a single component or multiple components when used in the singular.

[0123] Ordinal numbers such as “first” and “second” used in this application are merely identifiers and do not have any other meaning, such as a specific order. Moreover, for example, the term “first element” does not by itself imply the existence of a “second element,” and the term “second element” does not by itself imply the existence of a “first element.”

[0124] As used herein, the term “paired” can include, in addition to constructions in which the paired elements have the same shape or structure as each other, constructions in which the paired elements have different shapes or structures.

[0125] The terms “one” (or “a”), “one or more” and “at least one” are used interchangeably here.

[0126] As used in this disclosure, the phrase “at least one” means “one or more” of the desired choices. For example, if the number of choices is two, the phrase “at least one” as used in this disclosure means “only one single choice” or “both of the two choices.” For other examples, if the number of choices is equal to or greater than three, the phrase “at least one” as used in this disclosure means “only one single choice” or “any combination of two choices equal to or greater than two choices.” For example, the phrase “at least one of A and B” includes: (1) A alone; (2) B alone; and (3) both A and B. The phrase “at least one of A, B, and C” includes: (1) A alone; (2) B alone; (3) C alone; (4) both A and B; (5) both B and C; (6) both A and C; and (7) all of A, B, and C. In other words, in this disclosure, the phrase “at least one of A and B” does not mean “at least one of A and at least one of B.”

[0127] Finally, as used herein, degree terms such as “substantially,” “approximately,” and “about” refer to a reasonable amount of deviation from the term being modified such that the final result is not significantly altered. All numerical values ​​described in this application may be interpreted as including terms such as “substantially,” “approximately,” and “about.”

[0128] Obviously, in view of the above teachings, numerous modifications and alterations to the present invention are possible. Therefore, it should be understood that the invention can be practiced in ways other than those specifically described herein, within the scope of the appended claims.

Claims

1. A washer shaft for a brake caliper, the washer shaft comprising: A shaft body, the shaft body including a first mounting portion and a second mounting portion, and extending along a longitudinal axis between the first mounting portion and the second mounting portion, both the first mounting portion and the second mounting portion being configured as a caliper body connected to a brake caliper; and A support body, which is a component distinct from the shaft body and attached to the shaft body, movably supports the brake pad of the brake caliper relative to both the support body and the caliper body. The support body is disposed between a first mounting portion and a second mounting portion of the shaft body and is made of a non-metallic material to reduce noise. in The support body includes a through hole. The shaft body includes: The first shaft body has a first outer diameter. The second shaft body has a second outer diameter. The third shaft body has a third outer diameter. The second outer diameter is smaller than the first and third outer diameters. The second shaft body is disposed between the first shaft body and the third shaft body to define an attachment recess between the first shaft body and the third shaft body.

2. The pad shaft according to claim 1, wherein The shaft body is at least partially disposed in the through hole.

3. The pad shaft according to claim 1, wherein The support body is made of a heat-shrinkable material.

4. The pad shaft according to claim 1, wherein The support body is made of resin material.

5. The pad shaft according to claim 1, wherein The shaft body is made of metal.

6. The pad shaft according to claim 1, wherein The support body includes an outer surface, which, when the support body movably supports the brake pad, can contact the brake pad. The outer surface of the support is made of non-metallic material.

7. The pad shaft according to claim 2, wherein The second shaft body is at least partially disposed in the through hole of the support body.

8. The pad shaft according to claim 7, wherein The support body is at least partially disposed in the attachment recess.

9. The pad shaft according to claim 8, wherein The first outer diameter is greater than the third outer diameter.

10. The pad shaft according to claim 8, wherein The support body has a support outer diameter that is larger than the second outer diameter.

11. The pad shaft according to claim 10, wherein The outer diameter of the support component is smaller than the first outer diameter.

12. The pad shaft according to claim 10, wherein The outer diameter of the support component is equal to the third outer diameter.

13. The pad shaft according to claim 7, wherein The first shaft body includes a head portion with a head outer diameter. The first outer diameter includes the outer diameter of the head, and The outer diameter of the head is the largest outer diameter in the pad shaft.

14. The pad shaft according to claim 13, wherein The first shaft body includes a shaft portion having an outer diameter. The outer diameter of the shaft is smaller than the outer diameter of the head.

15. The pad shaft according to claim 14, wherein The shaft portion includes external threads that connect to the internal threads of the caliper body.

16. The pad shaft according to claim 7, wherein The support body includes outer surface of the support component A gap that extends radially outward from the through-hole to the outer surface of the support.

17. The pad shaft according to claim 16, wherein The support body is deformable to allow the shaft body to travel from the outer surface of the support through the gap to the through hole when the support body is attached to the shaft body.

18. The pad shaft according to claim 16, wherein The support body is deformable to allow the shaft body to travel through the through-hole and slot to the outer surface of the support body when the support body is removed from the shaft body.

19. The pad shaft according to claim 16, wherein The support body includes a first circumferential end and a second circumferential end. The second circumferential end is spaced apart from the first circumferential end to define the gap between the first circumferential end and the second circumferential end. The gap has a width defined between the first circumferential end and the second circumferential end. In the attached state where the support body is attached to the shaft body, the width of the gap is less than the second outer diameter of the second shaft body.

20. The pad shaft according to claim 7, wherein The support body is made of a heat-shrinkable material. The support body has an inner diameter, and Before the thermal shrinkage of the support body, the inner diameter of the support body is greater than the third outer diameter.

21. The pad shaft according to claim 20, wherein After the thermal shrinkage of the support body, the inner diameter of the support body is smaller than the third outer diameter.

22. The pad shaft according to claim 20, wherein The support body has an outer diameter, and After the thermal shrinkage of the support body, the outer diameter of the support is different from the third outer diameter.

23. The pad shaft according to claim 1, wherein The shaft body includes a first shaft end and a second shaft end, and extends along a longitudinal axis between the first shaft end and the second shaft end. The support body is positioned between the first shaft end and the second shaft end.

Images