Brake clamp housing and method of manufacturing the same

Abstract

The invention relates to a brake clamp housing and a method of manufacturing the same. A method of manufacturing a brake clamp housing is disclosed that includes providing a first mold and a second mold that cooperate to define a cavity when arranged to abut one another along a mating plane. The method further includes introducing a molten material into the cavity to cast the brake clamp housing. One or more surfaces of the brake clamp housing may be machined.

Description

[0001] This application is a divisional application of an application filed on October 15, 2018, with application number 201811196377.3 and invention name “Brake caliper housing and manufacturing method thereof”. Technical Field

[0002] The present disclosure relates to a brake caliper housing and a method of manufacturing the same. Background Art

[0003] A brake caliper housing is disclosed in U.S. Patent Publication No. 2017 / 0023082. Summary of the invention

[0004] 1) In at least one solution, a method of making a brake caliper housing is provided. The method may include providing a first mold and a second mold, the first mold and the second mold cooperating to define a cavity when arranged to abut each other along a matching plane. The method may further include introducing molten material into the cavity to cast the brake caliper housing. The brake caliper housing may include an actuator mounting flange, the actuator mounting flange being adapted to mount a brake caliper actuator. The actuator mounting flange may be at least partially arranged in the first mold. The actuator mounting flange may include a first surface, a first mounting boss, a second mounting boss, and an actuator nose. The first mounting boss may have a first boss surface arranged opposite to the first surface. The second mounting boss may have a second boss surface arranged opposite to the first surface. The actuator nose may be arranged between the first mounting boss and the second mounting boss and may extend away from the first surface. The first boss surface and the second boss surface may be arranged perpendicular to the matching plane.

[0005] 2) The method according to 1), wherein the actuator mounting flange is completely arranged in the first mold.

[0006] 3) The method according to 1), wherein the first boss surface is coplanar with the second boss surface.

[0007] 4) The method of 1), further comprising removing the brake caliper housing from the first mold and the second mold, and removing material from the first surface but not from the first boss surface to reduce a thickness of the first mounting boss.

[0008] 5) The method of 4) further comprising removing the brake caliper housing from the first mold and the second mold, and removing material from the first surface but not from the second boss surface to reduce the thickness of the second mounting boss.

[0009] 6) The method according to 5), further comprising drilling a first through hole through the first mounting boss.

[0010] 7) The method according to 6), further comprising drilling a second through hole through the second mounting boss.

[0011] 8) The method of 5) wherein removing material from the first surface comprises rendering the first surface substantially flat.

[0012] 9) The method of 8) wherein the substantially flat first surface is arranged in parallel relationship with the first boss surface.

[0013] 10) The method of 8) wherein the substantially flat first surface is arranged in parallel relationship with the second boss surface.

[0014] 11) The method according to 8), wherein the brake caliper housing includes a rear surface extending from the first surface to a lower surface of the brake caliper housing, wherein the first surface is arranged in a non-parallel relationship with the rear surface.

[0015] 12) The method according to 11), wherein the lower surface is arranged perpendicular to the rear surface.

[0016] 13) The method according to 11), wherein the brake caliper housing includes a first upper surface arranged opposite to the lower surface, the first upper surface being arranged at an acute angle relative to the first boss surface.

[0017] 14) The method according to 13), wherein the brake caliper housing includes a second upper surface arranged opposite to the lower surface, and the second upper surface is arranged at an acute angle relative to the second boss surface.

[0018] 15) The method according to 14), wherein the actuator nose is arranged between the first upper surface and the second upper surface.

[0019] 16) A method according to 7), wherein the method further comprises removing material from a front surface, the front surface being arranged opposite to the rear surface and defining a main opening, wherein the front surface is arranged in a non-parallel relationship with the first boss surface.

[0020] 17) The method of 16) wherein the front surface is arranged in a non-parallel relationship with the second boss surface.

[0021] 18) A method according to 16), wherein the front surface is arranged in a substantially parallel relationship with the rear surface.

[0022] 19) The method according to 1), wherein at least one of the first mold and the second mold is movable along an axis arranged perpendicular to the matching plane.

[0023] 20) The method according to 19), wherein the brake caliper housing has a top surface and a bottom surface, the top surface is facing away from the cavity, the bottom surface is arranged opposite to the top surface and faces away from the cavity, and wherein the top surface and the bottom surface are arranged in a non-parallel and non-perpendicular relationship with the matching plane and the axis. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 is a partial exploded view of the brake assembly.

[0025] Figure 2 is a cross-sectional view of a mold assembly for casting a brake caliper housing.

[0026] Figure 3 is a front perspective view of the brake caliper housing.

[0027] Figure 4 is a rear perspective view of the brake caliper housing.

[0028] Figure 5 is a side elevation view of the brake caliper housing.

[0029] Figure 6 is a front elevation view of the brake caliper housing.

[0030] Figure 7 is a cross-sectional view of the brake caliper housing.

[0031] Figure 8 is an enlarged view of a protrusion formed within the cavity of the brake caliper housing. DETAILED DESCRIPTION

[0032] Embodiments of the present disclosure are described herein. However, it should be understood that the disclosed embodiments are merely examples and that other embodiments may take different and alternative forms. These drawings are not necessarily to scale; some features may be exaggerated or minimized to show the details of specific components. Therefore, the specific structural and functional details disclosed herein should not be interpreted as restrictive, but only as a representative basis for teaching those skilled in the art to adopt the present invention in different ways. It should be understood by those of ordinary skill in the art that the different features shown and described with reference to any of the accompanying drawings can be combined with the features shown in one or more other accompanying drawings to produce embodiments that are not explicitly shown or described. The combination of the features shown provides representative embodiments for typical applications. However, different combinations and modifications of features consistent with the content taught by the present disclosure may be desired for specific applications or implementations.

[0033] See also Figure 1 , a brake assembly 10 is shown. The brake assembly 10 may be provided for a vehicle, such as a motor vehicle, like a truck, a bus, agricultural equipment, a military transport or armament vehicle, or a cargo loading device for a land, air, or marine vessel. In at least one solution, the brake assembly 10 may include a housing assembly 20, a first brake pad assembly 22, a second brake pad assembly 24, and at least one brake pad spring 26. In another solution, the brake assembly 10 may include a pad shield instead of or in addition to the brake pad spring 26.

[0034] The housing assembly 20 may receive a number of different components of the brake assembly 10. Among other things, the housing assembly 20 may facilitate positioning of the first brake pad assembly 22 and the second brake pad assembly 24 relative to a rotor 28 (also referred to as a brake disc) to facilitate vehicle braking. The rotor 28 may define a central axis 12 extending therethrough.

[0035] In at least one solution, the housing assembly 20 may include a brake bracket 30, a brake caliper housing (referred to herein as a caliper housing 32), and a brake caliper bridge 34. The brake bracket 30 may be fixedly mounted to the vehicle. For example, in one or more embodiments, the brake bracket 30 may be connected to an axle assembly or a steering knuckle, for example, via an intermediate component such as a torque plate. The brake bracket 30 may receive and / or support the first brake pad assembly 22 and the second brake pad assembly 24, and may include a rotor opening that may be configured to receive the rotor 28. In this way, the brake bracket 30 may straddle the rotor 28 and help position the first brake pad assembly 22 and the second brake pad assembly 24 on opposite sides of the rotor 28.

[0036] The housing assembly 20 may further include a retainer bracket 36. The retainer bracket 36 may have a first end that may engage or be received in a recess in the clamp housing 32 and a second end that may be fixedly disposed on the clamp bridge 34. For example, the second end may receive a fastener 38 (e.g., a bolt) that may couple the retainer bracket 36 to the clamp bridge 34.

[0037] The caliper housing 32 may be movably disposed on the brake bracket 30. For example, the caliper housing 32 may be slidably disposed on a pair of guide pins that may be fixedly disposed on the brake bracket 30. The caliper housing 32 may be associated with or may receive at least one actuator 42 that may actuate the first brake pad assembly 22 and the second brake pad assembly 24 into engagement with the rotor 28. More specifically, the actuator 42 may actuate the first brake pad assembly 22 into engagement with the rotor 28 and then move the caliper housing 32 and the bridge 34 to actuate the second brake pad assembly 24 toward the rotor 28. The actuator 42 may have any suitable configuration. For example, in one or more embodiments, the actuator may include a piston assembly that may be pneumatically, hydraulically, mechanically, electrically, or electromechanically actuated. The piston assembly may be movable along an axis toward or away from the rotor 28 such that the piston assembly may apply a force against the back side of the first brake pad assembly 22 .

[0038] See also Figure 2 , the clamp housing can be formed of an integral ("one-piece") cast clamp housing 32. The cast clamp housing 32 can be formed within a casting assembly 52. ​​The casting assembly 52 can include a first mold 54 and a second mold 56. At least one of the first mold 54 and the second mold 56 can be moved along an axis 58, which can be arranged perpendicular to a matching plane 60. The first mold 54 and the second mold 56 can cooperate to define a cavity 62 when arranged against each other along the matching plane 60. The matching plane 60 can extend generally perpendicular to the axis 58. In a closed configuration, the first mold 54 can continuously engage the second mold 56 in the matching plane 60 around the cavity 62. To cast the clamp housing 32, molten material can be introduced into the cavity 62. One or more inserts and / or cores 64 can be provided in the cavity 62 to form the interior of the cast clamp housing 32.

[0039] Once cast, the clamp housing 32 may be removed from the first and second dies 54, 56. One or more surfaces (e.g., surface 72 and surface 74) may be altered (e.g., machined) such that material is removed from the cast clamp housing 32. For example, and as discussed in greater detail, material may be removed from surface 72 but not from a boss surface disposed opposite surface 72 in order to reduce the thickness of the mounting boss.

[0040] See also Figures 3 to 6 , the caliper housing 32 may include an actuator mounting flange 70. The actuator mounting flange 70 may be adapted so that a brake caliper actuator (e.g., Figure 1 The actuator 42 of the embodiment is mounted to the clamp housing 32. The actuator mounting flange 70 may include a first surface 80.

[0041] The actuator mounting flange 70 may also include a first mounting boss 82, a second mounting boss 84, and an actuator nose 86 disposed between the first mounting boss 82 and the second mounting boss 84. The actuator nose 86 may extend from the first surface 80. The first mounting boss 82 may have a first boss surface 92 disposed opposite the first surface 80. The second mounting boss 84 may have a second boss surface 94, which may also be disposed opposite the first surface 80. In at least one solution, the first boss surface 92 and the second boss surface 94 are coplanar.

[0042] The first mounting boss 82 can define a first hole 102. The first hole 102 can extend from the first surface 80 to the first boss surface 92, so that the first hole 102 can be referred to as a first through hole. The second mounting boss 84 can similarly define a second hole 104. The second hole 104 can extend from the first surface 80 to the second boss surface 94, so that the second hole can be referred to as a second through hole. The first hole 102 and the second hole 104 can be formed by drilling the first mounting boss 82 and the second mounting boss 84, respectively. In yet another solution, the first hole 102 and the second hole 104 can be formed during the casting process (e.g., using an insert, a core, or other suitable approach).

[0043] See you again for now Figure 2 During casting of the caliper housing 32, the actuator mounting flange 70 may be at least partially disposed in the first mold 54. In at least one approach, the actuator mounting flange 70 may be completely disposed in the first mold 54. The first boss surface 92 and the second boss surface 94 may be disposed perpendicular to the mating plane 60, as indicated at 96.

[0044] The clamp housing 32 can have a top surface 120 that can face away from the cavity 62. The clamp housing 32 can also have a bottom surface 112 that is disposed opposite the top surface 120 and also faces away from the cavity 62. In at least one approach, the top surface 120 and the bottom surface 112 can be disposed in a non-parallel and non-perpendicular relationship to the mating plane 60 and the axis 58.

[0045] As discussed, once the clamp housing 32 is removed from the casting assembly 52, material may be removed from one or more surfaces. In at least one approach, a method of making the clamp housing 32 may include removing material from the clamp housing 32 to form the first surface 80. Removing material from the first surface 80 may reduce the thickness of at least a portion of the actuator mounting flange 70. In one example, at the first mounting boss 82, material may be removed from the first surface 80 but not from the first boss surface 92. In this way, the thickness of the first mounting boss 82 may be reduced. Similarly, at the second mounting boss 84, material may be removed from the first surface 80 but not from the second boss surface 94. In this way, the thickness of the second mounting boss 84 may be reduced.

[0046] Removing material from the first surface 80 can also include making the first surface 80 a substantially flat surface. For example, the first surface 80 can be machined so that it is parallel to the first boss surface 92, the second boss surface 94, or both the first boss surface 92 and the second boss surface 94.

[0047] Thus, one or both of the first mounting boss 82 and the second mounting boss 84 may be provided with a machined surface at the first surface 80, and a non-machined surface (e.g., the corresponding first boss surface 92 and the second boss surface 94). The non-machined surface may be a surface formed during a casting process (e.g., a sand casting process). The machined surface may be a surface that has been exposed, for example, due to a machining process performed after the casting process. The machining process may be any process that changes the surface size or surface treatment. Example machining processes may include, for example, boring, broaching, drilling, electrical discharge machining, electrochemical machining, electron beam machining, milling, photochemical machining, planing, reaming, sawing, shaping, tapping, turning, and ultrasonic machining.

[0048] Different surface treatments can be expressed as having different surface roughness values. Unmachined surfaces can have surface roughness values ​​greater than 10 microns. For example, unmachined surfaces can have surface roughness values ​​in the range of about 12 microns to about 25 microns. Machined surfaces can have surface roughness values ​​less than or equal to 10 microns. For example, machined surfaces can have surface roughness values ​​in the range of about 5 microns to about 7 microns.

[0049] like Figure 5 As shown, the clamp housing 32 may include a rear surface 110. The rear surface 110 may extend from the first surface 80 to a lower surface 112 of the clamp housing 32. In at least one approach, the rear surface 110 may be arranged in a non-parallel relationship with the first surface 80. The rear surface 110 may be arranged perpendicular to the lower surface 112, or substantially perpendicular (e.g., within + / - 5°).

[0050] The clamp housing 32 may include a first upper surface 120 and may include a second upper surface 122. The first upper surface 120 and the second upper surface 122 may be arranged opposite to the lower surface 112. Figure 5 As shown, the first upper surface 120 can be arranged at an acute angle (as indicated by 124) with respect to the first mounting boss 82. Similarly, the second upper surface 122 can be arranged at an acute angle with respect to the second mounting boss 84. Figure 4 As shown, the actuator nose 86 may be disposed between the first upper surface 120 and the second upper surface 122 .

[0051] The caliper housing 32 may further include an interface wall 130. The interface wall 130 may be disposed opposite the rear surface 110 and may be disposed in a parallel or substantially parallel (e.g., within + / - 5°) relationship with the rear surface 110. In at least one approach, the interface wall 130 may be disposed in a non-parallel relationship with the first boss surface 92, the second boss surface 94, or both the first boss surface 92 and the second boss surface 94. The interface wall 130 may define an opening 132 that may allow one or more internal components (e.g., a piston) to be disposed within the caliper housing 32 to interact with one or more brake pad assemblies.

[0052] like Figure 6 As shown, the clamp housing 32 may include a first end wall 140, a second end wall 142 that may be disposed opposite the first end wall 140, and a transverse wall 144 extending from the first end wall 140 to the second end wall 142. In at least one solution, the second end wall 142 may extend at least partially in a plane parallel to the first end wall 140. The first end wall 140 and the second end wall 142 may extend orthogonally to the transverse wall 144.

[0053] The interface wall 130 may extend from the first end wall 140, the second end wall 142, and the transverse wall 144. The interface wall 130 may cooperate with the first end wall 140, the second end wall 142, and the transverse wall 144 to at least partially define the cavity 150. The interface wall 130 may define an opening 132 of the cavity 150.

[0054] See now Figure 7 and Figure 8 , one or more support protrusions may be provided in the cavity 150. For example, a first support protrusion 160 may extend from the first end wall 140 and the transverse wall 144. The first support protrusion 160 may define a first lateral support surface 162, which may be arranged, for example, substantially parallel to the first end wall 140. The first support protrusion 160 may further define a first arcuate support surface 164, which may, for example, extend from the first lateral support surface 162. Figure 8 As indicated, the first lateral support surface 162 may intersect the first arcuate support surface 164 along a continuous curve 166 .

[0055] Figure 7 It is schematically indicated that the first lateral support surface 162 and the first arcuate support surface 164 of the first support protrusion 160 may be adapted for rotatably supporting the operating shaft 170 .

[0056] In at least one approach, the first lateral support surface 162 can be spaced apart from the first end wall 140. The first arcuate support surface 164 can be spaced apart from the transverse wall 144. In this manner, the support surface of the first lateral support surface 162 and the support surface of the first arcuate support surface 164 can be offset from the first end wall 140 and the transverse wall 144, respectively.

[0057] See temporarily Figure 6 , the transverse axis 172 may intersect the first end wall 140 and the second end wall 142. The transverse axis 172 may be parallel to the central axis of the operating shaft 170. In another solution, the transverse axis 172 may be coaxial with the central axis of the operating shaft 170.

[0058] See again Figure 7 , the first arcuate support surface 164 can be arranged radially relative to the transverse axis 172. The first lateral support surface 162 can be arranged perpendicular to the transverse axis 172. In at least one solution, the first support protrusion 160 can be arranged completely below the transverse axis 172.

[0059] The clamp housing 32 may further include a second support protrusion 180. The second support protrusion 180 may extend from the first end wall 140. The second support protrusion 180 may be arranged opposite the first support protrusion 160 about the transverse axis 172 and may extend toward the first support protrusion 160. In at least one solution, the second support protrusion 180 may be arranged completely above the transverse axis 172. The second support protrusion 180 may define a second lateral support surface 182 and a second arcuate support surface 184. In at least one solution, the second lateral support surface 182 may be spaced apart from the first end wall 140. The second arcuate support surface 184 may be spaced apart from the transverse wall 144. The second lateral support surface 182 may be arranged substantially parallel to the first end wall 140. The second arcuate support surface 184 may extend from the second lateral support surface 182. The second lateral support surface 182 and the second arcuate support surface 184 may be adapted to support the operating shaft 170.

[0060] In at least one approach, the clamp housing 32 can further include an upper surface 190. The second support protrusion 180 can extend from the upper surface 190 toward the first support protrusion 160.

[0061] The first lateral support surface 162 can be parallel to the second lateral support surface 182. For example, the first lateral support surface 162 can be coplanar with the second lateral support surface 182.

[0062] The second arcuate support surface 184 can be disposed radially relative to the transverse axis 172. Thus, the first arcuate support surface 164 and the second arcuate support surface 184 can be disposed at a common radial distance R from the transverse axis 172.

[0063] In at least one solution, the clamp housing 32 includes at least one saddle-shaped support protrusion 192. The saddle-shaped support protrusion 192 can extend from the transverse wall 144. The first support protrusion 160 can be axially disposed between the saddle-shaped support protrusion 192 and the first end wall 140. The second support protrusion 180 can also be axially disposed between the saddle-shaped support protrusion 192 and the first end wall 140.

[0064] See again Figure 5 and Figure 6 , the clamp housing 32 may further include a first mounting block 200 and a second mounting block 202. The second mounting block 202 may be spaced apart from the first mounting block 200. The first mounting block 200 and the second mounting block 202 may extend perpendicularly relative to each other.

[0065] One or both of the first mounting block 200 and the second mounting block 202 may define a hole 204, a hole 206. The hole 204, the hole 206 may be a through hole that may extend through each of the first mounting block 200 and the second mounting block 202, respectively. The hole 204, the hole 206 may be adapted to receive a fastener that is used to attach a bridge member (e.g., Figure 1 A bridge member 34 is mounted to the clamp housing 32.

[0066] In at least one approach, the connection surface 210 can extend from the first mounting pad 200 to the second mounting pad 202. For example, the step surface 212 can extend from the connection surface 210 to the first mounting pad 200 and the second mounting pad 202. In this manner, the step surface 212 can define an offset between the connection surface 210 and the face surfaces of the first mounting pad 200 and the second mounting pad 202. In this way, the connection surface 210 can be spaced apart from the bridge 34; for example, when the bridge 34 is secured to the clamp housing 32 at the face surface.

[0067] Although multiple exemplary embodiments are described above, these embodiments are not intended to describe all possible forms covered by the claims. These words used in this specification are illustrative rather than restrictive words, and it should be understood that a variety of different changes can be made without departing from the spirit and scope of the present disclosure. As previously described, the features of multiple different embodiments can be combined to form other embodiments that the present invention may not explicitly describe or display. Although, multiple different embodiments may have been described as providing advantages or preferred over other embodiments or prior art implementations in terms of one or more desired features, it is recognized by those of ordinary skill in the art that to achieve the overall system properties desired depending on the specific application and implementation, it may be necessary to compromise on one or more features or characteristics. These properties may include, but are not limited to, cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, applicability, weight, manufacturability, ease of assembly, etc. In this way, embodiments described as less desirable than other embodiments or prior art implementations in terms of one or more features do not fall outside the scope of the present disclosure, and may be desirable for specific applications.

Claims

1. A method of manufacturing a brake caliper housing, the method comprising: providing a first mold and a second mold that cooperate to define a cavity when arranged against each other along a mating plane; as well as Introducing molten material into the cavity to cast the brake caliper housing, wherein the brake caliper housing includes an actuator mounting flange, the actuator mounting flange being at least partially disposed in the first mold, the actuator mounting flange comprising: a first surface adapted for mounting a brake caliper actuator; a first mounting boss having a first boss surface disposed opposite to the first surface; a second mounting boss having a second boss surface disposed opposite to the first surface; and an actuator nose disposed between the first mounting boss and the second mounting boss and extending away from the first surface, wherein the first boss surface and the second boss surface are disposed perpendicular to the mating plane; The brake caliper housing further comprises an interface wall, which is arranged opposite to a rear surface of the brake caliper housing, the rear surface extending from the first surface to a lower surface of the brake caliper housing, and the interface wall is arranged in a non-parallel relationship with the first boss surface.

2. The method according to claim 1, wherein: The actuator mounting flange is completely disposed in the first mold.

3. The method according to claim 1, wherein: The first boss surface is coplanar with the second boss surface.

4. The method according to claim 1, further comprising: The brake caliper housing is removed from the first and second dies, and material is removed from the first surface but not from the first boss surface to reduce a thickness of the first mounting boss. 5 . The method of claim 4 , further comprising removing the brake caliper housing from the first and second dies and removing material from the first surface but not from the second boss surface to reduce a thickness of the second mounting boss. The method of claim 5 , further comprising drilling a first through hole through the first mounting boss. 7 . The method of claim 6 , further comprising drilling a second through hole through the second mounting boss.

8. The method according to claim 5, wherein: Removing material from the first surface includes planarizing the first surface.

9. The method according to claim 8, wherein: The planar first surface is disposed in parallel relationship with the first boss surface.

10. The method according to claim 8, wherein: The planar first surface is disposed in parallel relationship with the second boss surface.

11. The method according to claim 8, wherein: The first surface is disposed in a non-parallel relationship with the rear surface.

12. The method according to claim 11, wherein: The lower surface is arranged perpendicular to the rear surface.

13. The method according to claim 11, wherein: The brake caliper housing includes a first upper surface disposed opposite the lower surface, the first upper surface being disposed at an acute angle relative to the first boss surface.

14. The method according to claim 13, wherein: The brake caliper housing includes a second upper surface disposed opposite the lower surface, the second upper surface being disposed at an acute angle relative to the second boss surface.

15. The method according to claim 14, wherein: The actuator nose is disposed between the first upper surface and the second upper surface.

16. The method according to claim 7, wherein: The interface wall defines an opening.

17. The method according to claim 16, wherein: The interface wall is disposed in a non-parallel relationship with the second boss surface.

18. The method according to claim 16, wherein: The interface wall is arranged in parallel relationship with the rear surface.

19. The method according to claim 1, wherein: At least one of the first mold and the second mold is movable along an axis arranged perpendicular to the matching plane.

20. The method according to claim 19, wherein: The brake caliper housing has a top surface facing away from the cavity and a bottom surface disposed opposite the top surface and facing away from the cavity, and wherein the top surface and the bottom surface are disposed in a non-parallel and non-perpendicular relationship to the mating plane and the axis.

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