Electrical connector, caliper body, brake caliper assembly, wear indicator

Abstract

The invention relates to an electrical connection (1) for a wear sensor (2), comprising: a connection body (4) made of an electrically insulating material and defining a seat (5) for a plug or socket for electrically connecting the wear sensor (2) to a wear detection circuit; a hook-like portion (6) in the shape of a hook, where the hook-like portion (6) is configured to be coupled to a tooth (107) of a caliper body (102), where the hook-like portion (6) is made in one piece with the connector body (4); and at least one elastic interference portion (7, 8) projecting from the connector body (4) in an overhanging manner, where each elastic interference portion (7, 8) is elastically bendable between a rest configuration and a maximum interference configuration to slide against a caliper body surface (108) opposite the teeth (107) by bending from the rest configuration, each elastic interference portion (7, 8) is blocked by interference against the caliper body surface (108) by tensioning the caliper body wall (106) of the caliper body (102) between the hook-like portion (6) and each elastic interference portion (7, 8) from the opposite side until the elastic interference portion (7, 8) is blocked in the maximum interference configuration by interference against the caliper body surface (108).

Description

Technical Field

[0001] The invention relates to an electrical connector as well as a caliper body, a brake caliper assembly and a wear indicator. Background Art

[0002] In the case of disc brakes for vehicles, electrical wear indicators are known that employ sensors associated with the brake caliper pads. These indicators transmit signals from the sensors indicating the wear of the pads via a cable terminating in a connection, which in turn is connected by means of corresponding electrical contact elements and another cable to a wear detection circuit that allows the wear state of the pads to be displayed, for example, on the vehicle dashboard.

[0003] In order to prevent electrical connectors and / or cables leading out of or connected to the caliper body from somehow causing obstruction problems during assembly of the caliper body and in order to prevent making the assembly of the caliper body onto the wheel hub holder of the vehicle more laborious, a solution has been proposed in which an elastic metal connecting plate is used, which is fixed to the caliper body and to which the electrical connectors are connected via a coupling device.

[0004] In some solutions, such as the one known from document WO03046403, the elastic metal connecting plate is fixed to the caliper body by means of a threaded screw threaded into a seat obtained in the elastic metal connecting plate and into a hole obtained in the caliper body. This type of solution makes it necessary to carry out machining operations on the caliper body and on the metal plate in order to produce the hole in the metal plate, the hole in the caliper body and the thread in the hole of the caliper body. Although this solution fully achieves the purpose of the solution, it requires relatively long machining times and therefore high costs.

[0005] In other solutions, such as the one known from document WO2006001036, the plate is connected by engagement in a V-shaped seat obtained on the caliper body, wherein the tongue of the metal plate interlocks between two opposite walls of the V-shaped seat, without further machining operations on the caliper body being required to connect the plate to it. Although this solution allows to reduce the costs of preparing the caliper body, it also employs a large number of parts and machining operations on the connection, in particular on the metal plate, which must be sheared and bent before use, and a large number of steps to assemble the electrical connection to the caliper body, such as for example correctly inserting the elastic metal plate into the corresponding engagement seat, connecting the electrical connection body to the elastic metal plate and finally pressing the elastic metal plate onto the caliper body.

[0006] Therefore, there is a strongly felt need in the art for a caliper body connector coupling system that allows for reduced time and cost in manufacturing the connector and caliper body, as well as reduced time and cost in assembling the connector to the caliper body, compared to the prior art. Summary of the invention

[0007] The object of the present invention is to provide an electrical connection as well as a caliper body, a brake caliper assembly and a wear indicator allowing to solve the problems complained of in the prior art.

[0008] This object and other objects and advantages are achieved by a connection according to claim 1 , a caliper body according to claim 9 , a brake caliper assembly according to claim 14 , a wear indicator according to claim 15 .

[0009] Advantageous embodiments are the subject matter of the dependent claims.

[0010] By means of the proposed solution, a secure connection between the connector and the caliper body can be ensured, finishing and drilling operations on the caliper body can be avoided, thereby reducing the number of components of the electrical connector compared to the prior art.

[0011] By means of the proposed solution, a reliable and convenient connection of the connecting element to the caliper body can be ensured.

[0012] By means of the proposed solution, it is possible to connect the electrical connector to the caliper body in a single assembly step, thereby connecting the electrical connector directly to the caliper body and avoiding the use of additional connecting elements between the two components.

[0013] By means of the proposed solution, due to the shape of the connector and the shape of the caliper body, it is possible to correctly position the electrical connector to the caliper body, either manually or automatically by means of a pressure tool. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Further features and advantages of the electrical connector, the caliper body, the brake caliper assembly and the wear indicator will become apparent from the description of preferred embodiments thereof given by way of non-limiting indication provided below with reference to the accompanying drawings, in which:

[0015] - Figure 1 is an isometric view of a brake caliper assembly according to the invention comprising a caliper body to which an electrical connection for a wear sensor is connected;

[0016] - Figure 2 is an electrical connector according to the invention and Figure 1Exploded isometric view of a caliper body shown in , in which the electrical connector connected to the wear sensor via a cable can be seen, wherein the hook-shaped portion made in one piece with the connector body is shown, the connector body being made of electrically insulating material and compatible with brake fluid;

[0017] - Figure 3 yes Figure 1 an isometric view of a detail of , in which at least one elastic interference portion can be seen which, due to the interference, abuts against a surface of the caliper body opposite to the toothing of the caliper body to which the hook-shaped portion of the electrical connection is coupled;

[0018] - Figure 4 Shows Figure 2 Detail of a caliper body, wherein an axonometric view of a portion of the caliper body to which an electrical connector can be connected is shown, wherein a wall of the caliper body having a U-shaped profile is visible, the U-shaped profile being delimited by two radial protrusions of the wall connected by a hollow portion, wherein a hook-shaped portion of the electrical connector can be inserted into the U-shaped profile to couple with a toothed portion of the caliper body, and wherein the at least one elastic interference portion is elastically bent by sliding against a surface of the caliper body opposite to the toothed portion, on the surface of the caliper body, until the at least one elastic interference portion is blocked due to interference;

[0019] - Figure 5 is along Figure 1 The section BB in Figure 1 A partially cutaway axonometric view of the caliper body and the electrical connector in which a hook-shaped portion connected to the toothed portion of the caliper body like an undercut can be seen, wherein the hook-shaped portion is substantially counter shaped relative to the profile of the toothed portion of the caliper body;

[0020] - Figure 6 is along Figure 1 The section CC in Figure 1 a partially cutaway axonometric view of the caliper body and the electrical connector in which the at least one elastic interference portion bent in a maximum interference configuration and at least one support portion of the electrical connector resting on the caliper body at a support portion of the caliper body can be seen;

[0021] - Figure 7 is a side view of an electrical connector and a caliper body partially cut away to better illustrate the electrical connector, wherein a hook portion coupled to a caliper body tooth like an undercut can be seen, and a resilient interference portion bent in a maximum interference configuration against a caliper body surface opposite the tooth, and a connector support portion, wherein a caliper body separation line passing through the caliper body tooth can be seen;

[0022] - Figure 8 is an isometric view of a brake caliper assembly according to the invention, the brake caliper assembly comprising a caliper body to which an electrical connection for a wear sensor is connected, wherein the electrical connection comprises a flat spring connected to the caliper body;

[0023] - Fig. 9 Yes Figure 8 an exploded isometric view of an electrical connector according to the invention and a caliper body according to the invention, in which the electrical connector connected to the wear sensor via a cable can be seen, in which a hook-shaped portion made in one piece with the connector body is shown, the connector body being made of an electrically insulating material and compatible with brake fluid, and in which a flat spring is shown which can be connected by interlocking or co-molding in the connector body, preferably made of steel;

[0024] - Fig.10 So Figure 8 A partial cutaway axonometric diagram showing Figure 8 a caliper body and an electrical connection in which at least one elastic interference portion in the form of a metal tongue of a flat spring, bent in a maximum interference configuration and at least one support portion of the electrical connection resting on the caliper body at a support portion of the caliper body can be seen;

[0025] - Fig.11 yes Figure 8 A partially cutaway axonometric view of the caliper body and the electrical connection in which a hooked portion connected to the caliper body toothing like an undercut can be seen, wherein the hooked portion has an at least partially corresponding shape relative to the contour of the caliper body toothing. DETAILED DESCRIPTION

[0026] According to a general embodiment, an electrical connection for a wear sensor 2 is indicated as a whole with reference numeral 1 .

[0027] The electrical connector 1 comprises a connector body 4 made of an electrically insulating material and defining a seat 5 for a plug or a socket to electrically connect the wear sensor 2 to a wear detection circuit.

[0028] Advantageously, the electrical connector 1 comprises a hook portion 6 in the shape of a hook, wherein said hook portion 6 is configured to be coupled to a tooth 107 of a caliper body 102 , wherein said hook portion 6 is made in one piece with said connector body 4 .

[0029] Advantageously, the electrical connector 1 comprises at least one elastic interference portion 7 , 8 protruding from the connector body 4 in a cantilevered manner.

[0030] Advantageously, each elastic interference portion 7, 8 is capable of elastically bending between a rest configuration and a maximum interference configuration so as to slide against a caliper body surface 108 opposite to the toothed portion 107 by bending from the rest configuration until each elastic interference portion 7, 8 is blocked in the maximum interference configuration due to interference against the caliper body surface 108 by tightening the caliper body wall 106 of the caliper body 102 between the hook portion 6 and each elastic interference portion 7, 8 from the opposite side.

[0031] By means of the proposed solution, it is possible to produce an electrical connector which can be connected directly to the caliper body at least directly by means of a portion of the connector body, without using joining or coupling fixing elements, such as metal plates.

[0032] By means of the proposed solution, the number of components required to reliably fix the electrical connector 1 to the caliper body 102 can be reduced.

[0033] According to an embodiment, the electrical connector 1 comprises at least one supporting portion 9, 10 made in one piece with said connector body 4, wherein said at least one elastic interference portion 7, 8 protrudes from said at least one supporting portion 9, 10 in a cantilevered manner.

[0034] According to an embodiment, said support portions 9, 10 comprise preferably flat connector support surfaces 11, 12 supported against the caliper body 102 to block each elastic interference portion 7, 8 bent in said maximum interference configuration and placed between said caliper body surface 108, 109 and said support portions 9, 10.

[0035] By providing at least one supporting portion 9, 10 of the connector body 4, the correct positioning of the electrical connector 1 relative to the caliper body 106 can be simplified when manufacturing the caliper body and the electrical connector 1, so that when the supporting portions 9, 10 abut against the caliper body, the electrical connector 1 is correctly connected to the toothed portion of the caliper body by means of the elastic interference portion in the maximum interference configuration placed between the supporting portions 9, 10 and the surface of the caliper body.

[0036] According to an embodiment, each elastic interference portion 7 , 8 is made in one piece with said connector body 4 .

[0037] According to an embodiment, the elastic interference portions 7, 8 are made by molding a polymer material. According to an embodiment, the connector body 4 is made of a thermoplastic material. According to an embodiment, the connector body 4 is made of polyamide. According to an embodiment, the connector body 4 is made of nylon 66 or polyamide 66.

[0038] With the aid of the electrical connector 1, in which the connector body 4 is molded in an integral manner with the hook portion 6 and the at least one elastic interference portion, the connector body 4 can be directly connected to the caliper body 102, thereby reducing the number of parts to be assembled for connecting the electrical connector to the caliper body as compared to the prior art.

[0039] In an embodiment, the electrical connector 1 comprises a flat spring 26, wherein the flat spring 26 comprises the at least one elastic interference portion 7, 8. In an embodiment, the flat spring 26 comprises a first elastic interference portion 7 and a second elastic interference portion 8.

[0040] In an embodiment, the flat spring 26 is made of metal, preferably steel.

[0041] In an embodiment, the at least one elastic interference portion 7, 8 is at least one metal tongue of the flat spring 26. In an embodiment, the first elastic interference portion 7 and the second elastic interference portion 8 are the first metal tongue 27 and the second metal tongue 28 of the flat spring 26, respectively.

[0042] In an embodiment, the flat spring 26 is connected by interlocking into a spring seat obtained in the connector body 4, so that the at least one elastic interference portion 7, 8 protrudes in a cantilevered manner from the connector body 4. In an embodiment, the spring seat is at least one groove obtained in the connector body 4 and suitable for accommodating a corresponding part of the flat spring connector. In an embodiment, the flat spring 26 is partially embedded in the polymer material of the connector body 4.

[0043] In an embodiment, the flat spring 26 is connected to the connector body 4 by interlocking, so that the at least one elastic interference portion 7 , 8 protrudes from the connector body 4 in a cantilevered manner.

[0044] In an embodiment, the flat spring 26 is connected to the connector body 4 by co-molding such that the at least one elastic interference portion 7 , 8 protrudes from the connector body 4 in a cantilevered manner.

[0045] In an embodiment, the flat spring 26 is made by bending and punching a metal sheet to form the at least one elastic interference portion 7, 8 having at least one metal tongue.

[0046] By providing a flat spring 26 defining elastic interference portions 7 , 8 , it is possible to enable the electrical connection 1 to be constrained to the caliper body by means of a metal portion, which is very reliable at high temperatures and very resistant to wear over time.

[0047] According to an embodiment, each elastic interference portion 7, 8 comprises a distal portion 13 adapted to slide on said caliper body surface 108, 109 until it is blocked on said caliper body surface 108, 109 when said elastic interference portion 7, 8 is in said maximum interference configuration. In an embodiment, the distal portion 13 is a bent portion of the flat spring 26 forming a respective metal tongue of the respective elastic interference portion 7, 8.

[0048] According to an embodiment, each elastic interference portion 7, 8 comprises a proximal portion 14 connected to said connector body 4. In an embodiment, the proximal portion 14 is a connecting portion of a metal tongue of a flat spring 26 forming the respective elastic interference portion 7, 8, which is adapted to be connected to the connector body 4, for example by interlocking or co-molding.

[0049] According to an embodiment, each elastic interference portion 7, 8 includes a central portion 15, which is connected to the distal portion 13 and the proximal portion 14, wherein the central portion 15 is U-shaped or V-shaped, thereby defining a fulcrum, and the distal portion 13 elastically rotates relative to the proximal portion 14 between the rest configuration and the maximum interference configuration around the fulcrum.

[0050] According to an embodiment, each elastic interference portion 7, 8 comprises a layered body of variable thickness. According to an embodiment, the layered body of each elastic interference portion 7, 8 forms a closed profile by delimiting an open cavity in a direction that coincides with the direction of the axis around which the elastic interference portion 7, 8 bends and / or flexes, preferably coincides with or is parallel to the lateral direction ZZ.

[0051] According to an embodiment, each elastic interference portion 7, 8 comprises an abutment portion 16 joining the central portion 15 and the distal portion 13. According to an embodiment, each elastic interference portion 7, 8 comprises a counter-abutment portion 17 joining the central portion 15 and the proximal portion 14.

[0052] According to an embodiment, the abutment portion 16 faces the counter-abutment portion 17 .

[0053] According to an embodiment, the distal portion 13 is configured to elastically rotate about the central portion 15 until the abutment portion 16 abuts against the counter-abutment portion 17 , thereby preventing the distal portion 13 from further elastically rotating relative to the proximal portion 14 .

[0054] According to an embodiment, the abutment portion 16 and the opposing abutment portion 17 comprise an abutment surface and an opposing abutment surface, respectively. According to an embodiment, the abutment surface and the opposing abutment surface are oriented at an angle between 45 and 20 degrees, preferably between 40 and 35 degrees, relative to each other. According to an embodiment, in the maximum interference configuration, the abutment surface and the opposing abutment surface are in contact at least at one point and / or are oriented parallel to each other. According to an embodiment, in the rest configuration, the abutment surface and the opposing abutment surface are flat surfaces.

[0055] According to an embodiment, between said rest configuration and said maximum interference configuration, each distal portion 13 is rotated relative to the corresponding proximal portion 14 by an interference angle between 45 and 20 degrees, preferably between 40 and 35 degrees.

[0056] According to an embodiment, each distal portion 13 has a convex profile to facilitate sliding against the caliper body surfaces 108, 109 by rotating the distal portion 13 around the central portion 15. According to an embodiment, each distal portion 13 has at least a first sliding portion 18 connected to a second sliding portion 19 by a sharp portion 20 configured to be tensioned due to interference on the caliper body surfaces 108, 109.

[0057] According to an embodiment, the connector body 4 extends mainly along an extension axis defining an axial direction AA between a wear sensor-side connection end 21 and a seat 5 of the plug or socket for connecting the wear sensor 2 to a wear detection circuit.

[0058] According to an embodiment, each elastic interference portion 7, 8 extends mainly in a direction parallel to said axial direction AA.

[0059] According to an embodiment, the at least one elastic interference portion 7, 8 includes a first elastic interference portion 7 and a second elastic interference portion 8, and the first elastic interference portion 7 and the second elastic interference portion 8 are laterally connected to the connector body 4 through two completely opposite parts of the connector body 4 along the lateral direction ZZ, and the lateral direction ZZ is orthogonal and / or intersecting with the axial direction AA.

[0060] According to an embodiment, the first and second elastic interference portions 7, 8 protrude in a cantilevered manner from the connector body 4 in a direction parallel to the extension axis AA in such a way as to be elastically bent around a bending axis parallel to the lateral direction ZZ.

[0061] According to an embodiment, the at least one supporting portion 9, 10 comprises a first supporting portion 9 and a second supporting portion 10. According to an embodiment, the first supporting portion 9 and the second supporting portion 10 are integrally connected to the connector body 4 laterally via diametrically opposite portions in the lateral direction ZZ.

[0062] According to an embodiment, each supporting portion 9, 10 includes a corresponding connecting member supporting surface 11, 12 supported against the caliper body 102, so as to block each elastic interference portion 7, 8 bent in the maximum interference configuration and placed between the corresponding caliper body surface 108, 109 and the corresponding supporting portion 9, 10 when the hook portion 6 is connected to the toothed portion 107.

[0063] According to an embodiment, each connector support surface 11 , 12 comprises at least one support plane intersecting a support direction XX transverse to said lateral direction ZZ and transverse to a direction parallel to said axial direction AA.

[0064] According to an embodiment, the first and second elastic interference portions 7, 8 protrude from the first and second supporting portions 9, 10, respectively, in a cantilevered manner in a direction parallel to the axial direction AA in the following manner: elastically bent around a bending axis parallel to the lateral direction ZZ.

[0065] According to an embodiment, said hook portion 6 is rigid.

[0066] According to an embodiment, the hook portion 6 has a coupling edge 22, which is configured to be coupled to the toothed portion 107. According to an embodiment, the coupling edge 22 has a profile of a corresponding shape relative to the profile of the toothed portion 107. According to an embodiment, the coupling edge 22 comprises at least a first hook portion 23, a second hook portion 24 and a third hook portion 25 away from the connector body 4, the first hook portion 23, the second hook portion 24 and the third hook portion 25 being mutually connected to form a concave hook profile. According to an embodiment, the third hook portion 25 is the free end of the hook portion 6.

[0067] According to an embodiment, the first hook portion 23 is inclined with respect to a direction parallel to the axial direction AA at a first angle comprised between 10 and 40 degrees, preferably between 30 and 35 degrees.

[0068] According to an embodiment, the second hook portion 24 is inclined with respect to the axial direction AA at a second angle comprised between 80° and 120°, preferably between 100° and 110°.

[0069] According to an embodiment, the third hook portion 25 is inclined at least 130° relative to the axial direction AA. Preferably, the third hook portion 25 is inclined at least 140° relative to the axial direction AA.

[0070] According to an embodiment, at least the third hook portion 25 faces the distal portion 13 of each elastic interference portion 7, 8, wherein each elastic interference portion 7, 8 rotates toward the third portion 25 when each elastic interference portion 7, 8 switches from the maximum interference configuration toward the rest configuration.

[0071] According to an embodiment, the third hook portion 25 is configured to abut against the toothed portion like an undercut.

[0072] The invention also relates to a caliper body 102 for a brake caliper. The caliper body 102 comprises at least one caliper body wall 106, comprising a toothed portion 107 protruding from the caliper body wall 106 and at least one caliper body surface 108, 109 delimiting the caliper body wall 106 on the opposite side of the toothed portion 107. Thus, the hooked portion 6 of the electrical connector 1 can be coupled to the toothed portion 107, and by coupling the electrical connector 1 to the caliper body wall 106 between the hooked portion 6 and each elastic interference portion 7, 8, at least one elastic interference portion 7, 8 can be elastically bent to be blocked due to interference against the caliper body surfaces 108, 109, thereby avoiding the use of a screw fastening system and / or fixing holes in the caliper body 102 or the metal plate.

[0073] According to an embodiment, the caliper body wall 106 requires no finishing operations and the at least one caliper body surface 108 , 109 has a surface roughness to allow the elastic interference portions 7 , 8 of the connection piece 1 to be blocked due to interference.

[0074] According to an embodiment, the caliper wall 106 defines a self-centering seat with a U-shaped profile, which is bounded by the first wall portion 110, the hollow portion 111 and the second wall portion 112. Therefore, the hook portion 6 can be inserted into the self-centering seat to couple with the toothed portion 107, and the hook portion 6 protrudes from the caliper body wall in the axial direction AA, thereby guiding the connector body 4 laterally towards the hollow portion 111 by the edges of the first wall portion 110 and the second wall portion 112 facing each other from opposite sides.

[0075] According to an embodiment, the toothed portion 107 protrudes from the hollow portion 111, and the caliper body surfaces 108, 109 include a first caliper body surface 108 delimiting a first wall portion 110 located on the opposite side relative to the toothed portion 107 and a second caliper body surface 109 delimiting a second wall portion 112 located on the opposite side relative to the toothed portion 107. Therefore, the first elastic interference portion 7 and the second elastic interference portion 8 slide on the first caliper body surface 108 and the second caliper body surface 109, and are bent from the rest configuration to the maximum interference configuration by elastically tensioning the caliper body wall 103 located between the hook portion 6 on the one hand and the first elastic interference portion 7 and the second elastic interference portion 8 on the other hand from completely opposite sides in the axial direction AA (relative to which the connector body 4 mainly extends) in an interfering manner.

[0076] According to an embodiment, the caliper body 102 is made by melt molding a metal material, such as cast iron or aluminum.

[0077] According to an embodiment, the teeth 107 are traversed by a caliper body separation line 117 defined on the caliper 102 by two mold halves during melt molding.

[0078] According to an embodiment, the caliper body 102 includes a sharp-edged molded burr 122 located on the toothed portion 107 along the caliper body dividing line 117, and the sharp-edged molded burr 122 is configured to stick into the hook portion 6 by plastically deforming the portion of the hook portion 6 directly facing the sharp-edged molded burr 122, thereby enhancing the connection between the electrical connector 1 and the caliper body 102.

[0079] According to an embodiment, the tooth 107 comprises a tooth coupling edge 118 configured to be coupled by the hook portion 6. According to an embodiment, the tooth coupling edge 118 comprises at least a first tooth portion 119, at least a second tooth portion 120 and a third tooth portion 121 protruding on opposite sides of the caliper body surfaces 113, 114.

[0080] According to an embodiment, the first hook portion 23 has a substantially corresponding shape relative to the first tooth portion 119, the second hook portion 24 has a substantially corresponding shape relative to the second tooth portion 120, and the third hook portion 25 has a substantially corresponding shape relative to the third tooth portion 121, so that the hook portion 6 is at least partially connected to the tooth portion 107 in shape.

[0081] According to an embodiment, said first toothed portion 119 and said third toothed portion 120 at least partially face in diametrically opposite directions in radial direction RR.

[0082] According to an embodiment, the first toothed portion 119 and the second toothed portion 120 are connected at the caliper body separation line 117 .

[0083] With the proposed solution it is possible to ensure that the electrical connector is reliably connected to the caliper body, wherein the hook portion 6 is tensioned against the toothed portion 107 of the caliper body through which the dividing line passes, thereby ensuring the presence of irregularities in the caliper body, thereby enhancing the coupling between the electrical connector and the caliper body.

[0084] According to an embodiment, the sharp-edged molding burr 122 protrudes between the first toothed portion 119 and the second toothed portion 120 along the caliper body separation line 117 .

[0085] By means of the proposed solution, the coupling between the electrical connector and the caliper body can be enhanced, since the sharp-edged burr bites into the connector body at the hook-shaped portion directly facing the toothing surface.

[0086] According to an embodiment, the electrical connector 2 is directly and irreversibly connected to the caliper body 102 due to interference. In other words, when the electrical connector is connected to the caliper body 102 by the interference of the elastic interference part that is elastically bent against the surface of the caliper body and by connecting the hook part to the toothed part, the electrical connector cannot be separated except by breaking the end part of the hook part.

[0087] According to an embodiment, the caliper body 102 includes at least one caliper body support surface 113, 114, which is arranged on the side opposite to the toothed portion 107 and on the same side as the caliper body surfaces 108, 109, thereby leaving an unobstructed space directly facing at least the end portion of the caliper body surfaces 108, 109. Therefore, when the connector body 4 is supported on the caliper body support surfaces 113, 114 with the at least one elastic interference portion 7, 8 in the maximum interference configuration and the hook portion 6 is connected to the toothed portion 107, the electrical connector 1 is correctly and firmly connected to the caliper body 102.

[0088] According to an embodiment, the caliper body wall 106 extends from the caliper body 102 mainly along a radial direction RR, wherein the radial direction RR is orthogonal to or intersecting the axial direction AA, and wherein the radial direction RR is orthogonal to or intersecting the lateral direction ZZ, which is orthogonal to or intersecting the axial direction AA.

[0089] According to an embodiment, the toothing 107 can be coupled to the hook portion 6 in a radially inner position like an undercut. According to an embodiment, each caliper body 108, 109 is configured to interfere with the respective elastic interference portion 7, 8 in a radially outer position. According to an embodiment, the at least one support surface 113, 114 is configured to carry the connector body 4 in a supporting manner in an intermediate position.

[0090] According to an embodiment, the intermediate position is arranged between the inner position and the outer position in the radial direction RR or in a direction parallel to the radial direction RR.

[0091] According to an embodiment, said caliper body wall 102 is tapered from a free edge of said caliper body wall 106 in said radial direction RR by increasing thickness in said axial direction AA or in a direction parallel to said axial direction AA.

[0092] According to an embodiment, along the radial direction RR from the corresponding upper edges of the first wall portion 110 and the second wall portion 112 toward the toothed portion 107, the first wall portion 110 and the second wall portion 112 are tapered in a manner of increasing thickness at least from the side opposite to the toothed portion 107 in the axial direction, so that by inserting the hook portion 6 into the self-centering seating portion and rotating the connector body 4 in a direction opposite to the toothed portion 107, each elastic interference portion 7, 8 is pushed against the corresponding wall portion 110, 112, and each elastic interference portion 7, 8 is bent by sliding on the corresponding caliper body surface 108, 109 until when the connector body 4 abuts by resting on at least one support surface 113, 114, each elastic interference portion 7, 8 is blocked between the corresponding caliper body surface 108, 109 and the connector body 4 due to interference.

[0093] According to an embodiment, the caliper body 102 includes a first protrusion 115 and a second protrusion 116, which extend mainly in the radial direction RR from the caliper body 102, thereby being tapered and thus reducing its thickness. According to an embodiment, the first protrusion 115 includes a first caliper body support surface 113 located at the radial end of the first protrusion 115. According to an embodiment, the second protrusion 116 includes a second caliper body support surface 114 located at the radial end of the second protrusion 116. Since the connector body 4 includes a first support portion 9 and a second support portion 10, when the hook portion 6 is coupled to the toothed portion 107, the connector body 4 is supported by the corresponding connector support surfaces 11, 12, thereby blocking each elastic interference portion 7, 8 bent in the maximum interference configuration and placed between the corresponding caliper body surface 108, 109 and the corresponding connector support portion 9, 10.

[0094] The present invention also relates to a brake caliper assembly 100 , comprising an electrical connector 1 according to any of the aforementioned embodiments and a caliper body 102 according to any of the aforementioned embodiments, wherein the electrical connector 1 is coupled to the caliper body 102 .

[0095] According to an embodiment, the caliper body 102 is a caliper body of a floating brake caliper. According to an embodiment, the brake caliper comprises a support bracket 101 and a caliper body 102 according to one of the above embodiments, wherein the caliper body 102 is adapted to be arranged to straddle a brake disc, and wherein the caliper body 106 is adapted to float, i.e. translate or slide axially, relative to the support bracket 101 in an axial direction AA parallel to the direction of the brake disc axis. According to an embodiment, the caliper body 106 internally comprises pad seats 104 on opposite sides to accommodate corresponding relative brake pads 103, so that the thrust means accommodated in the caliper body directly acts on the first pad 103, and the floating movement of the caliper body 106 also exerts a corresponding thrust action on the second pad. According to an embodiment, the brake caliper comprises at least one pad return spring 105 to move the brake pad 103 away from the brake disc after the braking action is completed.

[0096] The invention also relates to a wear indicator comprising an electrical connection 1 according to any of the preceding embodiments and a wear sensor 2 electrically connected to the electrical connection 1 by means of a cable 3 , wherein the wear sensor can be connected to a brake pad 103 .

[0097] By means of the proposed solution, it is possible to reduce the number of elements required to connect the electrical connector to the caliper body, thereby avoiding the use of sheared and bent elastic metal sheets by directly coupling the connector body 4 to the caliper body 106 .

[0098] Reference numerals list

[0099] 1 Electrical connector

[0100] 2 Wear sensor

[0101] 3 Cables

[0102] 4 Insulating material body or connector body

[0103] 5 Seating area for plug or socket

[0104] 6 Hook

[0105] 7 First elastic interference part

[0106] 8 Second elastic interference part

[0107] 9 First support part

[0108] 10 Second support section

[0109] 11 First connecting member support surface

[0110] 12 Second connecting member support surface

[0111] 13 Distal part

[0112] 14 Proximal part

[0113] 15 Central part

[0114] 16 Abutment

[0115] 17 Opposing contact portion

[0116] 18 First sliding part

[0117] 19 Second sliding part

[0118] 20 Sharpening

[0119] 21 Wear sensor side connection end

[0120] 22 Joining Edges

[0121] 23 First hook

[0122] 24 Second hook portion

[0123] 25 Third hook

[0124] 26 Flat spring

[0125] 100 Caliper Assembly

[0126] 101 Support bracket

[0127] 102 Caliper body

[0128] 103 Brake pads

[0129] 104 Seating area

[0130] 105 Spring pad

[0131] 106 Caliper body wall

[0132] 107 Tooth

[0133] 108 first caliper body surface

[0134] 109 Second caliper body surface

[0135] 110 first wall portion

[0136] 111 Hollow part

[0137] 112 Second wall portion

[0138] 113 First caliper body support surface

[0139] 114 Second caliper body support surface

[0140] 115 First protrusion

[0141] 116 Second protrusion

[0142] 117 Divider

[0143] 118 Toothed part connecting edge

[0144] 119 first toothed portion

[0145] 120 second toothed portion

[0146] 121 Third tooth portion

[0147] 122 Sharp edge molding burrs

[0148] AA Axial direction

[0149] ZZ Side direction

[0150] RR Radial direction.

Claims

1. An electrical connector (1) for a wear sensor (2), the electrical connector (1) comprising: - a connector body (4) made of an electrically insulating material and defining a seat (5) for a plug or a socket to electrically connect the wear sensor (2) to a wear detection circuit, Characterized in that the electrical connector (1) comprises: a hook portion (6) in the shape of a hook, wherein the hook portion (6) is configured to be coupled to a tooth (107) of a caliper body (102), wherein the hook portion (6) is made in one piece with the connector body (4), and - at least one elastic interference portion (7, 8) which projects in a cantilevered manner from the connector body (4), Wherein, each elastic interference portion (7, 8) is capable of elastically bending between a rest configuration and a maximum interference configuration so as to slide against a caliper body surface (108) opposite to the toothed portion (107) by bending from the rest configuration until each elastic interference portion (7, 8) is blocked in the maximum interference configuration due to interference against the caliper body surface (108) by tensioning the caliper body wall (106) of the caliper body (102) between the hook portion (6) and each elastic interference portion (7, 8) from the opposite side.

2. The electrical connector (1) according to the preceding claim, comprising at least one of the following features or a combination of the following features: - at least one supporting part (9, 10) made in one piece with the connector body (4), wherein: At least one of the elastic interference portions (7, 8) protrudes from at least one of the support portions (9, 10) in a cantilevered manner, wherein the support portion (9, 10) comprises a connector support surface (11, 12), preferably, the support portion (9, 10) comprises a flat connector support surface (11, 12), the connector support surface (11, 12) being supported against the caliper body (102) to block each elastic interference portion (7, 8) bent in the maximum interference configuration and disposed between the caliper body surface (108, 109) and the support portion (9, 10), And / or wherein each elastic interference portion (7, 8) is made in one piece with the connector body (4), and / or wherein each elastic interference portion (7, 8) is made by molding a polymer material, and / or wherein the connector body (4) is made of polyamide, preferably, the connector body (4) is made of nylon 66 or polyamide 66.

3. The electrical connector (1) according to any one of the preceding claims, in, Each elastic interference portion (7, 8) comprises: a distal portion (13) adapted to slide on the caliper body surface (108, 109) until it is blocked on the caliper body surface (108, 109) when the elastic interference portions (7, 8) are in the maximum interference configuration, - a proximal portion (14) connected to the connector body (4), - a central portion (15) connected to the distal portion (13) and the proximal portion (14), wherein the central portion (15) is U-shaped or V-shaped, thereby defining a fulcrum, and the distal portion (13) elastically rotates relative to the proximal portion (14) between the rest configuration and the maximum interference configuration around the fulcrum.

4. The electrical connector (1) according to the preceding claim, comprising at least one of the following features or a combination of the following features: in, Each elastic interference portion (7, 8) comprises: an abutment portion (16) connecting the central portion (15) and the distal portion (13), and an opposing abutment portion (17) connecting the central portion (15) and the proximal portion (14), wherein the abutting portion (16) faces the opposing abutting portion (17), wherein the distal portion (13) is configured such that: the distal portion (13) elastically rotates around the central portion (15) until the abutment portion (16) abuts against the opposing abutment portion (17), thereby preventing the distal portion (13) from further elastically rotating relative to the proximal portion (14), and / or wherein the abutting portion (16) and the opposing abutting portion (17) respectively comprise an abutting surface and an opposing abutting surface, wherein, in the rest configuration, the abutment surface and the counter-abutment surface are oriented at an angle of between 45° and 20° relative to each other, preferably, the abutment surface and the counter-abutment surface are oriented at an angle of between 40° and 35° relative to each other, and wherein In the maximum interference configuration, the abutment surface and the opposing abutment surface are in contact in at least one point and / or the abutment surface and the opposing abutment surface are oriented parallel to each other, and / or wherein, between the rest configuration and the maximum interference configuration, each distal portion (13) is rotated relative to the corresponding proximal portion (14) by an interference angle between 45 and 20 degrees, preferably, each distal portion (13) is rotated relative to the corresponding proximal portion (14) by an interference angle between 40 and 35 degrees, and / or wherein each distal portion (13) has a convex profile to facilitate sliding against the caliper body surface (108, 109) by rotating the distal portion (13) about the central portion (15), And / or wherein each distal portion (13) has at least a first sliding portion (18), the first sliding portion (18) being connected to a second sliding portion (19) by a sharpened portion (20), the sharpened portion (20) being configured to be tensioned due to interference on the caliper body surface (108, 109).

5. Electrical connector (1) according to any one of the preceding claims, in, The connector body (4) extends mainly along an extension axis defining an axial direction (AA) between a connection end (21) on the wear sensor side and a seat (5) of a plug or socket for connecting the wear sensor (2) to a wear detection circuit, wherein each elastic interference portion (7, 8) extends mainly in a direction parallel to the axial direction (AA), wherein at least one of the elastic interference portions (7, 8) comprises a first elastic interference portion (7) and a second elastic interference portion (8), wherein the first elastic interference portion (7) and the second elastic interference portion (8) are laterally connected to the connector body (4) through two completely opposite portions of the connector body (4) along a lateral direction (ZZ), wherein the lateral direction (ZZ) is orthogonal to and / or intersecting with the axial direction (AA), Wherein, the first elastic interference portion (9) and the second elastic interference portion (10) protrude from the connector body (4) in a cantilevered manner along a direction parallel to the extension axis (AA) in the following manner: elastically bending around a bending axis parallel to the lateral direction (ZZ).

6. Electrical connector (1) according to the preceding claim, The electrical connector (1) comprises at least one supporting portion (9, 10), the supporting portion (9, 10) being made in one piece with the connector body (4), the supporting portion (9, 10) comprising a first supporting portion (9) and a second supporting portion (10), wherein: The first supporting portion (9) and the second supporting portion (10) are integrally connected to the connector body (4) in the lateral direction via diametrically opposite portions along the lateral direction (ZZ), wherein each support portion (9, 10) comprises a corresponding connector support surface (11, 12) supported against the caliper body (102) to block each elastic interference portion (7, 8) bent in the maximum interference configuration and disposed between the corresponding caliper body surface (108, 109) and the corresponding support portion (9, 10) when the hook portion (6) is coupled to the toothed portion (107), Each connecting element support surface (11, 12) comprises at least one support plane intersecting a support direction (XX) transverse to the lateral direction (ZZ) and transverse to a direction parallel to the axial direction (AA), Wherein, the first elastic interference portion (7) and the second elastic interference portion (8) protrude from the first supporting portion (9) and the second supporting portion (10) respectively in a cantilevered manner along a direction parallel to the axial direction (AA) in the following manner: elastically bending around a bending axis parallel to the lateral direction (ZZ).

7. An electrical connector (1) according to any one of the preceding claims, wherein The hook-shaped portion (6) extends in the axial direction (AA) at least partially beyond the wear sensor-side end (21) of the connector body (4), wherein the hook-shaped portion (6) is rigid, and / or wherein the hook portion (6) has a coupling edge (22), the coupling edge (22) being configured to couple to the toothed portion (107), and / or wherein the hook-shaped portion (6) has a coupling edge (22), the coupling edge (22) having a profile of a corresponding shape relative to the profile of the toothed portion (107), and / or wherein the hook-shaped portion (6) has a coupling edge (22), the coupling edge (22) comprising at least a first hook-shaped portion (23), a second hook-shaped portion (24) and a third hook-shaped portion (25) away from the connector body (4), the first hook-shaped portion (23), the second hook-shaped portion (24) and the third hook-shaped portion (25) being connected to each other to form a concave hook-shaped profile, and / or where The hook-shaped portion (6) has a coupling edge (22), the coupling edge (22) comprising: a first hook-shaped portion (23), the first hook-shaped portion (23) being inclined at a first angle between 10° and 35° relative to a direction parallel to the axial direction (AA); a second hook-shaped portion (24), the second hook-shaped portion (24) being inclined at a second angle between 80° and 120° relative to the axial direction (AA) or a direction parallel to the axial direction (AA); and a third hook-shaped portion (25), the third hook-shaped portion (25) being inclined at a third angle of at least 130° relative to the axial direction (AA) or a direction parallel to the axial direction (AA), and / or wherein at least the third hook portion (25) faces the distal portion (13) of each elastic interference portion (7, 8), wherein each elastic interference portion (7, 8) rotates toward the third portion (25) when each elastic interference portion (7, 8) switches from the maximum interference configuration toward the rest configuration, And / or wherein the third hook portion (25) is configured to abut against the tooth portion like an undercut.

8. The electrical connector (1) according to claim 1, comprising a flat spring (26), wherein: The flat spring (26) includes at least one of the elastic interference portions (7, 8), wherein the flat spring (26) is connected to the connector body (4) so ​​that at least one of the elastic interference portions (7, 8) protrudes from the connector body (4) in a cantilevered manner to tension the caliper body wall (106) of the caliper body (102) between the hook portion (6) and each of the elastic interference portions (7, 8) from the opposite side, for example, the flat spring (26) is connected to the connector body (4) by interlocking or common molding.

9. A caliper body (102) for a brake caliper, the caliper body (102) comprising: at least one caliper body wall (106), the caliper body wall (106) comprising a toothed portion (107) protruding from the caliper body wall (106) and at least one caliper body surface (108, 109), the toothed portion (107) protruding from the caliper body wall (106), the caliper body surface (108, 109) delimiting the caliper body wall (106) on the opposite side of the toothed portion (107), So that: An electrical connector (1) comprising a hook-shaped portion (6) and at least one elastic interference portion (7, 8) is connected to a caliper body wall (106) located between the hook-shaped portion (6) and each elastic interference portion (7, 8), thereby avoiding the use of a screw fastening system and / or a fixing hole in the caliper body (102), the hook-shaped portion (6) being able to be connected to the toothed portion (107), and at least one of the elastic interference portions (7, 8) being able to be elastically bent and blocked in a manner of interfering against the caliper body surface (108, 109).

10. The caliper body (102) according to the preceding claim, in, The caliper wall (106) defines a self-centering seat having a U-shaped profile, the self-centering seat being bounded by a first wall portion (110), a hollow portion (111) and a second wall portion (112), The toothed portion (107) protrudes from the hollow portion (111), and the caliper body surfaces (108, 109) include a first caliper body surface (108) and a second caliper body surface (109), wherein the first caliper body surface (108) defines the first wall portion (110) located on the opposite side of the toothed portion (107), and the second caliper body surface (109) defines the second wall portion (112) located on the opposite side of the toothed portion (107), So that: The hook portion (6) can be inserted into the self-centering seat to couple to the toothed portion (107), And the elastic interference part (7, 8) comprises: a first elastic interference portion (7) and a second elastic interference portion (8), wherein the first elastic interference portion (7) and the second elastic interference portion (8) are connected to the connector body (4) in a lateral direction through two diametrically opposite portions of the connector body (4), In which, the first elastic interference portion (7) and the second elastic interference portion (8) slide on the first caliper body surface (108) and the second caliper body surface (109), and the first elastic interference portion (7) and the second elastic interference portion (8) are bent from the static configuration to the maximum interference configuration by elastically tensioning the caliper body wall (106) between the hook portion (6) on the one hand and the first elastic interference portion (7) and the second elastic interference portion (8) on the other hand in an interference manner from completely opposite sides of the axial direction (AA) mainly related to the extension of the connecting member body (4).

11. The caliper body (102) according to any one of the preceding claims 9 to 10, comprising at least one of the following features or a combination of the following features: in, The caliper body (102) is made by molding cast iron or aluminum metal material, wherein the toothed portion (107) is passed through a caliper body separation line (117) defined by two half molds on the caliper body (102) during melt molding, And / or wherein the caliper body (102) includes a sharp-edged molded burr (122) on the toothed portion (107) along the caliper body dividing line (117), and the sharp-edged molded burr (122) is configured to be inserted into the hook-shaped portion (6) by plastically deforming a portion of the hook-shaped portion (6) directly facing the sharp-edged molded burr (122), thereby enhancing the connection between the electrical connector (1) and the caliper body (102).

12. The caliper body (102) according to any one of the preceding claims 9 to 11, comprising at least one of the following features or a combination of the following features: in, The tooth (107) includes a tooth coupling edge (118) configured to be coupled by the hook portion (6), The toothed portion coupling edge (118) includes at least a first toothed portion (119), at least a second toothed portion (120) and a third toothed portion (121) protruding on opposite sides of the caliper body surfaces (113, 114), and / or wherein the first hook portion (23) has a substantially corresponding shape relative to the first tooth portion (119), the second hook portion (24) has a substantially corresponding shape relative to the second tooth portion (120), and the third hook portion (25) has a substantially corresponding shape relative to the third tooth portion (121), so that the hook portion (6) is at least partially shaped to be coupled to the tooth portion (107), and / or wherein the first toothed portion (119) and the third toothed portion (120) at least partially face in completely opposite directions along the radial direction (RR), and / or wherein the first toothed portion (119) and the second toothed portion (120) are connected at the caliper body separation line (117), And / or wherein a sharp-edged molded burr (122) protrudes along the caliper body separation line (117) between the first toothed portion (119) and the second toothed portion (120).

13. The caliper body (102) according to any one of the preceding claims 9 to 12, comprising at least one of the following features or a combination of the following features: in, The caliper body (102) comprises at least one caliper body support surface (113, 114), which is arranged on the opposite side of the toothed portion (107) and on the same side as the caliper body surfaces (108, 109), so that when at least one of the elastic interference portions (7, 8) is in the maximum interference configuration and the hook portion (6) is connected to the toothed portion (107), the connector body (4) is supported on the caliper body support surface (113, 114), in, The caliper body wall (106) extends from the caliper body (102) primarily in a radial direction (RR), wherein the radial direction (RR) is orthogonal to or intersecting the axial direction (AA), and wherein the radial direction (RR) is orthogonal to or intersecting a lateral direction (ZZ), wherein the lateral direction (ZZ) is orthogonal to or intersecting the axial direction (AA), wherein the toothed portion (107) can be coupled to the hook-shaped portion (6) like an undercut in a radially inner position, wherein each caliper body surface (108, 109) is configured to interfere with the corresponding elastic interference portion (7, 8) in a radially outer position, wherein at least one of the support surfaces (113, 114) is configured to support the connector body (4) in a supporting manner at an intermediate position, wherein the intermediate position is arranged between the inner position and the outer position along the radial direction (RR) or along a direction parallel to the radial direction (RR), and / or wherein the caliper body (102) comprises a first protrusion (115) and a second protrusion (116), the first protrusion (115) and the second protrusion (116) mainly extending from the caliper body (102) along the radial direction (RR) so as to be tapered and thus reduce the thickness of the first protrusion (115) and the second protrusion (116), wherein the first protrusion (115) comprises a first caliper body support surface (113) located at a radial end of the first protrusion (115), wherein the second protrusion (116) includes a second caliper body support surface (114) located at a radial end of the second protrusion (116), When the hook-shaped portion (6) is connected to the tooth-shaped portion (107), the connector body (4) including the first support portion (9) and the second support portion (10) is supported by the corresponding connector support surfaces (11, 12), thereby blocking each elastic interference portion (7, 8) bent in the maximum interference configuration and placed between the corresponding caliper body surface (108, 109) and the corresponding connector support portion (9, 10).

14. A brake caliper assembly (100), the brake caliper assembly (100) comprising: The electrical connector (1) according to any one of claims 1 to 8 and the caliper body (102) according to any one of claims 9 to 13, Wherein, the electrical connector (1) is connected to the caliper body (102).

15. A wear indicator for a disc brake, the wear indicator comprising: An electrical connector (1) according to any one of the preceding claims 1 to 7, and a wear sensor (2), the wear sensor (2) being electrically connected to the electrical connector via at least one cable (3), wherein the wear sensor (2) is connectable to a brake pad (103).

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