Caliper body, brake caliper and method for manufacturing a caliper body

Abstract

The invention relates to a caliper body for a disc brake, to a brake caliper comprising the caliper body and to a method for manufacturing the caliper body. The caliper body is adapted to straddle an associated brake disc, wherein the caliper body comprises a first elongated portion and a second elongated portion and at least one bridge, wherein the caliper body comprises at least a first positioning reference configured to house a corresponding first carrier device for positioning and fixing the caliper body to allow material removal machining operations, the first positioning reference being convex, wherein the first positioning reference comprises at least a first rib of the first reference, a second rib of the first reference and a third rib of the first reference, wherein the ribs of the first reference are separate from each other and are arranged in a circular manner to house the first carrier device and to prevent liquid accumulation between the ribs of the first reference.

Description

TECHNICAL FIELD

[0001] The present invention relates to a caliper body of a disc brake, to a brake caliper comprising such a caliper body and to a method for manufacturing said caliper body. BACKGROUND

[0002] As known, in disc brakes comprising a caliper body, the caliper body is generally arranged astride the outer periphery of a brake disc adapted to rotate about an axis of rotation (A-A) defining an axial direction (X-X).

[0003] Typically, the caliper body comprises a first elongated portion and a second elongated portion connected by at least one bridge.

[0004] Typically, the caliper body comprises a plurality of positioning references configured to be positioned by clamping or handling devices to position the caliper body in predetermined positions, allowing machining to be performed.

[0005] In some caliper bodies of the known type, the positioning references are made as flat surfaces or recesses having angled surfaces, or in other cases, the positioning references are recessed into the caliper body and form valleys with respect to the outer surface of the caliper body.

[0006] Although such recessed positioning references meet the need to form a portion of the caliper body with respect to which the caliper body can be oriented for subsequent machining operations, such recessed positioning references form portions of the caliper body in which working fluids or water, which remain in contact with the caliper body for long periods of time and induce corrosion phenomena, can deposit in use or during machining operations. For example, document US7168529B2 shows positioning references made as recesses of conical shape in the caliper body.

[0007] Furthermore, it is worth noting that when the caliper body is manufactured by casting the material in a mould, the forming of the portions of the caliper body comprising such positioning references, such as recesses, can be unstable and can cause undesired variations in the mechanical and surface properties and in the shape of the caliper body with respect to another. Therefore, if the tolerances of such positioning references vary with respect to the design, it is necessary to discard these caliper bodies from the subsequent machining stages.

[0008] Therefore, there is a strong need in the industry to manufacture caliper bodies that can be easily and univocally positioned in at least one predetermined position and have increased corrosion resistance.

[0009] There is also a need to manufacture caliper bodies having increased dimensional stability.

[0010] Moreover, it is necessary to manufacture caliper bodies having at least one positioning reference portion with a high degree of self-centering precision.

[0011] The fundamental problem of the present application is therefore to provide a caliper body, a brake caliper and a method for manufacturing said caliper body, having structural and functional characteristics to meet the needs described above, while eliminating the drawbacks described with reference to the prior art and meeting the needs felt. SUMMARY

[0012] The object of the present application is to provide a caliper body having a high degree of dimensional stability and a low tendency to corrosion.

[0013] This and other objects and advantages are achieved by the caliper body, the brake caliper and the method for manufacturing said caliper body according to the present application.

[0014] From the analysis of this solution it can be seen how the proposed solution allows to obtain an increased resistance to corrosion, thus avoiding the stagnation of corrosive liquids at the positioning reference portions that position and fix the caliper bodies to be processed, compared to the known solutions.

[0015] Moreover, the proposed solution allows to manufacture a caliper body having an improved dimensional stability compared to the known solutions, with self-centering, drainage and a high degree of precision of the positioning reference portions.

[0016] Moreover, the proposed solution allows to reduce the chip removal machining tolerances of the finished caliper bodies.

[0017] In addition, with the proposed solution it is possible to obtain a higher yield of the caliper bodies and to reduce the waste in the production process.

[0018] In addition, with the proposed solution it is possible to avoid unstable areas in the caliper bodies during the shaping and solidification phases in the production process. BRIEF DESCRIPTION OF DRAWINGS

[0019] With reference to the attached drawings, in which the caliper body, the brake disc and the method for manufacturing said caliper body further characteristics and advantages will become apparent from the following description of a preferred embodiment of the caliper body, the brake disc and the method for manufacturing said caliper body given by way of non-limiting example, in the drawings:

[0020] - Figure 1 is an axonometric view of a caliper body with a first positioning reference portion and a second positioning reference portion known in the prior art;

[0021] - Figure 2 is an axonometric view of a caliper body according to the present application;

[0022] - Figure 3 is Figure 2 a plan view of the caliper body in

[0023] - Figure 4 is Figure 2 an axonometric view of an enlarged detail of the caliper body in

[0024] - Figure 5 is Figure 2 an axonometric view of an enlarged detail of the caliper body in

[0025] - Figure 6 is Figure 4 an axonometric view of the first positioning reference in

[0026] - Figure 7 is Figure 5 an axonometric view of the positioning reference in

[0027] - Figure 8 is a cross-sectional axonometric view of a mould for manufacturing the caliper body according to the present application. DETAILED DESCRIPTION

[0028] According to a general embodiment, a brake caliper 1 for a disc brake is provided.

[0029] The caliper body 1 is adapted to straddle a brake disc associated with a rider.

[0030] The brake disc comprises a first braking surface and a second braking surface, wherein an axial direction A-A coinciding or parallel to a rotation axis of the disc, a radial direction R-R orthogonal to the axial direction A-A and a tangential direction T-T orthogonal to both the axial direction A-A and the radial direction R-R are defined.

[0031] The caliper body 1 comprises a first elongated portion 2 adapted to face the braking surface and a second elongated portion 3 opposite to the first elongated portion 2 and adapted to face the second braking surface.

[0032] The caliper body 1 comprises at least one bridge 4 adapted to connect the second elongated portion 2 to the second elongated portion 3 so as to straddle a brake disc when the caliper body 1 is assembled to the brake disc.

[0033] The caliper portion 1 comprises at least a first positioning reference 5 configured to house a corresponding first bracket device to position and fix the caliper body 1 so as to allow material removal machining operations.

[0034] The first positioning reference 5 is convex. In other words, the first positioning reference 5 protrudes from the caliper body 1.

[0035] The first positioning reference 5 comprises at least a first reference rib 6, a second reference rib 7 and a third reference rib 8. Each of the first reference ribs 6, 7, 8 is convex.

[0036] The first reference ribs 6, 7, 8 are separate from each other and arranged in a circular manner to house the first bracket device and prevent liquid accumulation between the first reference ribs 6, 7, 8.

[0037] According to an embodiment, the first reference ribs 6, 7, 8 form a self-centering structure to house the first bracket device.

[0038] According to an embodiment, the first positioning reference 5, when coupled to the corresponding first bracket device, forms a dedicated rotational constraint of the caliper body 1 and prevents translation along three mutually orthogonal directions.

[0039] According to an embodiment, each of the first reference ribs 6, 7, 8 comprises a corresponding first reference inclined surface 9, 10, 11.

[0040] According to an embodiment, the extensions of each first reference inclined surface 9, 10, 11 intersect at a single point.

[0041] According to an embodiment, the first reference inclined surfaces 9, 10, 11 are curved surfaces.

[0042] According to an embodiment, the first reference inclined surfaces 9, 10, 11 are conical surface portions.

[0043] According to an embodiment, the first reference ribs 6, 7, 8 define discontinuous conical positioning surfaces.

[0044] According to an embodiment, the ribs 6, 7, 8 of the first reference portion form petal portions arranged along a circumference. Along said circumference, the ribs of the first reference portion are arranged at 120° from each other with respect to the adjacent ribs of the first reference portion.

[0045] According to an embodiment, said first positioning reference portion 5 comprises a plurality of first reference portion channels 12, 13, 14 between each rib 6, 7, 8 of the first reference portion and the adjacent first rib of the first reference portion 6, 7, 8.

[0046] In other words, each rib 6, 7, 8 of the first reference portion is interposed with respect to the adjacent first rib of a respective first reference portion channel 12, 13, 14.

[0047] According to an embodiment, each first reference portion channel 12, 13, 14 is inclined so as to prevent the accumulation of liquid between the ribs 6, 7, 8 of the first reference portion.

[0048] According to an embodiment, said first reference portion channels 12, 13, 14 cross each other in a central region of the first positioning reference portion 5.

[0049] According to an embodiment, said first reference portion channels 12, 13, 14 are arranged at 120° from each other.

[0050] According to an embodiment, said calliper body 1 comprises at least a second positioning reference portion 15 configured to house a respective second carriage device for positioning and fixing said calliper body 1 so as to allow chip removal machining operations.

[0051] According to an embodiment, said second positioning reference portion 15 is convex, in other words, said second positioning reference portion 15 is outwardly protruding from the calliper body 1.

[0052] According to an embodiment, said second positioning reference portion 15 comprises a first rib 16 of the second reference portion and a second rib 16 of the second reference portion.

[0053] According to an embodiment, said ribs 16, 17 of the second reference portion are separate and parallel.

[0054] According to an embodiment, said second positioning reference portion 15 comprises a second reference portion channel arranged between said ribs 16, 17 of the second reference portion, wherein said second reference portion channel is configured to prevent the accumulation of liquid between said ribs 16, 17 of the second reference portion.

[0055] According to an embodiment, said ribs 16, 17 of the second reference portion define a positioning surface substantially shaped as a V.

[0056] According to an embodiment, the rib 16, 17 of each second reference portion comprises a respective second reference portion inclined surface 21, 22, or a first second reference portion inclined surface 21 and a second second reference portion inclined surface 22.

[0057] According to an embodiment, the extensions of the inclined surfaces 21, 22 of each second reference portion meet in the direction of the calliper body 1 on the same straight line.

[0058] According to an embodiment, the inclined surfaces 21, 22 of the second reference portion are flat.

[0059] According to an embodiment, the first 5 and second 15 positioning reference portions protrude from respective calliper body surface portions 18, 19, wherein the calliper body surface portions 18, 19 are coplanar.

[0060] According to an embodiment, the first positioning reference portion 5 protrudes from the first elongated portion 2.

[0061] According to an embodiment, the second positioning reference portion 15 protrudes from the first elongated portion 2.

[0062] According to a first embodiment, the first elongated portion 2 defines at least one cylindrical portion 20 to house a thrust device which biases the brake disc.

[0063] According to an embodiment, the calliper body 1 is obtained by sand casting of molten metal.

[0064] According to an embodiment, the first positioning reference portion 5 is obtained by sand casting of molten metal.

[0065] According to an embodiment, the second positioning reference portion 15 is obtained by sand casting of molten metal.

[0066] According to an embodiment, the calliper body 1 is a calliper body of a floating calliper.

[0067] According to an alternative embodiment, the calliper body 1 is a cast product which is a semi-finished product.

[0068] The present application also relates to a brake calliper comprising a calliper body 1 as described above.

[0069] The present application also relates to a method for manufacturing a calliper body 1 as described above.

[0070] The preferred or advantageous variants of this method can comprise any step which can be inferred, even only implicitly, from the above description of the calliper body.

[0071] The method comprises the steps of:

[0072] a - providing a casting mould 23 comprising at least two half-moulds 24, 25;

[0073] b - making, in said mould 23, at least three recesses 26, 27, 28, adapted to form said first positioning reference 5 comprising a first rib 6 of said first reference, a second rib 7 of said first reference and a third rib 8 of said first reference;

[0074] c - casting a molten material into the mould 23;

[0075] d - removing the caliper body 1 comprising at least said first positioning reference 5 from the mould 23.

[0076] According to a possible operating mode, the method comprises the steps of:

[0077] e - positioning said caliper body 1 on a device of a CNC working machine and in at least one predetermined position by means of at least said first positioning reference 5,

[0078] f - fixing said caliper body 1 on said device in said at least one predetermined position, g - performing at least one material removal machining operation on said caliper body 1.

[0079] According to a possible operating mode, the method comprises the step of making, in said casting mould 23, simultaneously with step b-, two further recesses 29, 30, adapted to form said second positioning reference 15 comprising a first rib 16 of said second reference and a second rib 17 of said second reference.

[0080] According to a possible operating mode, the method comprises, before step e-, the step of handling said caliper body 1 by gripping it at least at said first positioning reference 5.

[0081] According to an embodiment, said casting mould 23 is made of sand.

[0082] According to an embodiment, said caliper body 1 is positioned and / or fixed in said at least one predetermined position by means of at least said first positioning reference 5 and said second positioning reference 15.

[0083] The person skilled in the art can make changes to the embodiments of the caliper body, the brake caliper and the method described above, or can replace the elements with other elements that are functionally equivalent, in order to meet specific needs.

[0084] List of reference signs

[0085] 1 caliper body

[0086] 2 first elongated portion

[0087] 3 second elongated portion

[0088] 4 bridge

[0089] 5 first positioning reference

[0090] 6 first rib of the first reference

[0091] 7 second rib of the first reference

[0092] 8 third rib of the first reference

[0093] 9 first inclined surface of the first reference

[0094] 10 second inclined surface of the first reference

[0095] 11 third inclined surface of the first reference

[0096] 12 first channel of the first reference

[0097] 13 second channel of the first reference

[0098] 14 third channel of the first reference

[0099] 15 second positioning reference

[0100] 16 first rib of the second reference

[0101] 17 second rib of the second reference

[0102] 18 first surface portion of the caliper body

[0103] 19 second surface portion of the caliper body

[0104] 20 cylindrical portion

[0105] 21 first inclined surface of the second reference

[0106] 22 second inclined surface of the second reference

[0107] 23 mold

[0108] 24 first mold half

[0109] 25 second half-die

[0110] 26 first die recess

[0111] 27 second die recess

[0112] 28 third die recess

[0113] 29 fourth die recess

[0114] 30 fifth die recess

[0115] P1 first datum section plane

[0116] P2 second datum section plane

[0117] B-B direction and orientation of first datum section view

[0118] D-D direction and orientation of second datum section view

[0119] A-A axial direction

[0120] R-R radial direction

[0121] C-C tangential direction

Claims

1. A caliper body (1) for a disc brake, wherein, The caliper body (1) is adapted to straddle the associated brake disc, The caliper body (1) includes a first elongated portion (2) and a second elongated portion (3), the second elongated portion (3) being opposite to the first elongated portion (2), and wherein the caliper body (1) includes at least one bridging member (4) adapted to connect the first elongated portion (2) to the second elongated portion (3), wherein the caliper body (1) includes at least a first positioning reference portion (5) configured to accommodate a corresponding first bracket device for positioning and fixing the caliper body (1), thereby allowing material removal processing operations, characterized in that... The first positioning reference part (5) is protruding, wherein the first positioning reference part (5) includes rib-shaped parts (6, 7, 8) of the first reference part, wherein the rib-shaped parts (6, 7, 8) of the first reference part include at least the first rib-shaped part, the second rib-shaped part and the third rib-shaped part of the first reference part, wherein the rib-shaped parts (6, 7, 8) of the first reference part are separated from each other and arranged in a circular manner to accommodate the first bracket device and prevent liquid from accumulating between the rib-shaped parts (6, 7, 8) of the first reference part.

2. The caliper body (1) according to claim 1, wherein, Each rib-shaped portion (6, 7, 8) of the first reference portion includes a corresponding inclined surface (9, 10, 11) of the first reference portion, wherein the extensions of the inclined surface (9, 10, 11) of the first reference portion intersect at the same point, and / or wherein the rib-shaped portion (6, 7, 8) of the first reference portion defines a discontinuous tapered positioning surface.

3. The caliper body (1) according to claim 1, wherein, The first positioning reference part (5) includes a plurality of channels (12, 13, 14) of the first reference part located between the rib-shaped part (6, 7, 8) of each first reference part and the rib-shaped part of the first reference part adjacent to the rib-shaped part (6, 7, 8) of the first reference part, wherein the channel (12, 13, 14) of each first reference part is inclined to prevent liquid from accumulating between the rib-shaped parts (6, 7, 8) of the first reference part.

4. The caliper body (1) according to claim 1, wherein the caliper body (1) includes a second positioning reference portion (15), the second positioning reference portion (15) being configured to accommodate a corresponding second bracket device to position and fix the caliper body (1), thereby allowing material removal processing operations, wherein, The second positioning reference part (15) is protruding.

5. The caliper body (1) according to claim 4, wherein, The second positioning reference portion (15) includes rib-shaped portions (16, 17) of the second reference portion, the rib-shaped portions (16, 17) of the second reference portion including a first rib-shaped portion of the second reference portion and a second rib-shaped portion of the second reference portion, wherein the rib-shaped portions (16, 17) of the second reference portion are separated and parallel, wherein the rib-shaped portions (16, 17) of the second reference portion define a V-shaped caliper body positioning surface, and / or wherein, The first positioning reference portion (5) and the second positioning reference portion (15) protrude from corresponding coplanar portions (18, 19) on the surface of the caliper body, and / or wherein The first positioning reference part (5) protrudes from the first elongated part (2), and / or wherein, The second positioning reference part (15) protrudes from the first elongated part (2), and / or wherein, The first elongated portion (2) defines at least one cylindrical portion (20) for housing a thrust device that biases a brake disc.

6. The caliper body (1) according to claim 1, wherein, The caliper body (1) is obtained by sand casting of molten metal, and / or wherein the first positioning reference part (5) is obtained by sand casting of molten metal, and / or wherein the caliper body (1) includes a second positioning reference part (15) configured to accommodate a corresponding second bracket device to position and fix the caliper body (1) thereby allowing material removal processing operations, the second positioning reference part (15) being obtained by sand casting of molten metal, and / or wherein the caliper body (1) is a floating caliper body, and / or wherein the caliper body (1) is a semi-finished casting product.

7. A brake caliper comprising a caliper body (1) according to any one of claims 1 to 6.

8. A method for manufacturing a caliper body (1), said caliper body being a caliper body (1) according to any one of claims 1 to 6, said method comprising the following steps: a- Provides a casting mold (23), said casting mold (23) comprising at least two half-molds (24, 25), b - At least three recesses (26, 27, 28) are manufactured in the casting mold (23), the at least three recesses (26, 27, 28) being adapted to form the first positioning reference portion (5), the first positioning reference portion (5) including a first rib portion, a second rib portion, and a third rib portion of the first reference portion. c- Pour the molten material into the casting mold (23), d - Remove the caliper body (1), including at least the first positioning reference part (5), from the casting mold (23).

9. The method for manufacturing a caliper body (1) according to claim 8, the method comprising the following steps: e-The caliper body (1) is positioned on the CNC machine tool and in at least one predetermined position by means of at least the first positioning reference part (5). f- Secure the caliper body (1) in the at least one predetermined position on the device. g- Perform finishing on the caliper body (1).

10. The method for manufacturing a caliper body (1) according to claim 9, wherein, The method includes, simultaneously with step b), the creation of two additional recesses (29, 30) in the casting mold (23), the two additional recesses (29, 30) being adapted to form a second positioning reference portion (15), the second positioning reference portion (15) comprising a first rib portion of the second reference portion and a second rib portion of the second reference portion, and / or wherein, Prior to step e, a step is provided in which the caliper body (1) is processed by gripping the caliper body (1) at least from the first positioning reference (5), and / or wherein, The casting mold (23) is made of sand, and / or wherein, The caliper body (1) is positioned and / or fixed in the at least one predetermined position by at least the first positioning reference part (5) and the second positioning reference part (15).

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