Brake assembly with guide pin assembly

Abstract

A brake assembly includes a brake carrier, a brake clamp, and a guide pin assembly. The guide pin assembly slidably couples the brake clamp to the brake carrier. The guide pin assembly includes an integral capped bushing, a sleeve, and a fastener. The fastener couples the sleeve to the brake bracket. The integral capped bushing is movable relative to the sleeve.

Description

Technical Field

[0001] The present invention relates to a brake assembly and a guide pin assembly. background

[0002] U.S. Patent No. 9,845,837 discloses a guide assembly for a disc brake. Overview

[0003] This invention relates to a brake assembly. The brake assembly includes a brake bracket, a brake caliper, and a guide pin assembly. The brake caliper defines a bore. The bore extends along an axis. The guide pin assembly slidably connects the brake caliper to the brake bracket. The guide pin assembly includes an integral capped bushing, a sleeve, and a fastener. The integral capped bushing is at least partially received in the bore. The integral capped bushing is secured to the brake caliper. The integral capped bushing is a one-piece component including a tubular wall and a cap. The tubular wall surrounds and at least partially defines a cavity. The cavity extends along an axis. The tubular wall includes an end surface. The end surface is configured opposite to the cap. The cap extends from the tubular wall. The cap surrounds the end of the integral capped bushing. The sleeve is received in the cavity. The sleeve engages with the tubular wall such that the integral capped bushing is movable relative to the sleeve along an axis. The fastener is disposed in the sleeve. The fastener connects the sleeve to the brake bracket.

[0004] The tubular wall may further include an outer side. This outer side may be opposite to the axis. The outer side may engage a brake caliper in the bore. The cap may further include a cap outer side. This cap outer side may be opposite to the axis. The cap outer side may engage a brake caliper in the bore. The cap outer side may be positioned further from the axis than the outer side of the tubular wall. The cap outer side and the outer side of the tubular wall may be positioned at a common radial distance from the axis.

[0005] The brake caliper may further include a threaded area. The threaded area may be disposed within a hole. The integral capped bushing may further include a threaded portion. The threaded portion may mate with the threaded area and secure the integral capped bushing to the brake caliper. The threaded portion of the integral capped bushing may be disposed on a cap. The threaded portion of the integral capped bushing may be disposed on a tubular wall.

[0006] The integral capped bushing can be secured to the brake caliper using fasteners. The fasteners can be installed in the holes.

[0007] The brake caliper may further include a brake caliper recess. The brake caliper recess may surround the bore. The brake caliper recess may extend away from the axis. The brake caliper recess may extend from the bore. The cap may further include a cap outer side. The cap outer side may be away from the axis. The cap may further include a cap recess. The cap recess may extend from the cap outer side toward the axis. Fasteners may be received in the brake caliper recess and the cap recess.

[0008] The integral capped bushing can be secured to the brake caliper using fasteners positioned outside the bore. The cap may further include a cap flange. The cap flange may be positioned outside the bore. The cap flange may extend away from the axis. Fasteners can secure the cap flange to the brake caliper.

[0009] The brake caliper may further include a recess. The recess may extend away from the axis. The recess may extend from a bore. The integral capped bushing may further include a protrusion. The protrusion may extend away from the axis. The protrusion may be received within the recess. The protrusion may secure the integral capped bushing to the brake caliper.

[0010] Fasteners, sleeves, and integral capped bushings can be fitted together to define a chamber. The chamber can be positioned along the axis between the fastener and the cap. The chamber can contain lubricant.

[0011] An integral capped bushing can be spaced apart from the brake bracket. An integral capped bushing can also be non-contact with the brake bracket. A sleeve can engage with the brake bracket.

[0012] The brake assembly may further include a flexible shoe-shaped member. The flexible shoe-shaped member may extend between the brake bracket and the brake caliper. The flexible shoe-shaped member may further include a mounting edge. The mounting edge of the flexible shoe-shaped member may be disposed in a bore. The mounting edge may be secured between the integral capped bushing and the brake caliper.

[0013] The brake caliper may further include a brake caliper shoe-shaped groove. The brake caliper shoe-shaped groove may surround the bore. The brake caliper shoe-shaped groove may extend from the bore. The brake caliper shoe-shaped groove may extend away from the axis. The mounting edge of the flexible shoe-shaped member may be positioned within the brake caliper shoe-shaped groove.

[0014] The tubular wall may further include a guiding surface. This guiding surface extends from the end surface of the tubular wall toward the outer side of the tubular wall. A flexible boot-shaped member may engage the guiding surface. The guiding surface may be positioned at an angle relative to the end surface. The guiding surface may be positioned at an angle relative to the outer side. When the guiding surface extends away from the end surface, it may extend further away from the axis.

[0015] The tubular wall may further include a stepped surface. This stepped surface may extend from the end of the guide surface to the outside of the tubular wall. A mounting edge may engage the stepped surface.

[0016] The present invention also relates to an integral capped bushing for a brake caliper. The integral capped bushing includes a tubular wall and a cap. The tubular wall surrounds and at least partially defines a cavity. The tubular wall includes an end surface. The cap is positioned opposite to the end surface. The cap extends from the tubular wall. The cap surrounds the end of the tubular wall. The integral capped bushing is a one-piece component. Attached Figure Description

[0017] Figure 1 This is a perspective view of an example of a brake assembly and a brake rotor.

[0018] Figure 2 This is a cross-sectional view along section line 2-2.

[0019] Figure 3 yes Figure 2 A magnified view of a portion of the image shows an example of a guide pin component.

[0020] Figure 4 This is a magnified view showing a second example of a guide pin component.

[0021] Figure 5 This is a magnified view showing a third example of a guide pin assembly.

[0022] Figure 6 This is a magnified view showing a fourth example of a guide pin assembly.

[0023] Figure 7 This is a magnified view showing the fifth example of a guide pin assembly.

[0024] Figure 8 This is a magnified view showing the sixth example of a guide pin assembly. Detailed Implementation

[0025] As requested, detailed embodiments of the invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely illustrative of how the invention can be practiced in various forms and alternative forms. The drawings are not necessarily to scale; some features may be exaggerated or minimized to show details of specific components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but merely as a representative basis for teaching those skilled in the art to employ the invention in various ways.

[0026] It should also be understood that although the terms first, second, etc., are used in some instances herein to describe various elements, these elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, without departing from the scope of the various embodiments described, a first element may be referred to as a second element, and similarly, a second element may be referred to as a first element. Both the first element and the second element are elements, but they are not the same element.

[0027] The terminology used in the description of the various embodiments described is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various embodiments described and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that, as used herein, the term “and / or” refers to and covers any and all possible combinations of one or more of the listed related items. It should be further understood that, when used in this specification, the terms “comprising,” “including,” “including,” and / or “comprising” indicate the presence of the recited features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0028] refer to Figure 1 An example of brake assembly 10 is shown. Brake assembly 10 can be incorporated into a vehicle, such as a motor vehicle like a truck, bus, agricultural machinery, military transport or armament vehicle, or a cargo loading device for land, air, or sea vessels. Brake assembly 10 is configured as a disc brake. Brake assembly 10 includes a brake bracket 20 and a brake caliper 22. Brake assembly 10 may also include a pair of brake pad assemblies 24 and a retaining bracket 26. (Main Reference) Figure 2 The brake assembly 10 also includes at least one guide pin assembly 28 and may include a flexible boot-shaped member 30.

[0029] refer to Figure 1 and Figure 2 The brake bracket 20 is configured to be mounted to a vehicle. For example, the brake bracket 20 may be mounted directly or indirectly to an axle assembly or steering knuckle. The brake bracket 20 may be stationary and may not move relative to the vehicle component to which it is mounted. In some configurations, the brake bracket 20 is configured to receive and support the brake pad assembly 24 such that it allows the brake pad assembly 24 to move toward and away from the brake rotor 40 while inhibiting rotation of the brake pad assembly 24.

[0030] The brake support 20 may include a rotor opening through which the brake rotor 40 may extend. The brake rotor 40 is rotatable about a brake rotor axis 42 and spaced apart from the brake support 20. For example, the brake support 20 may straddle the brake rotor 40 and help position the brake pad assembly 24 on opposite sides of the brake rotor 40.

[0031] refer to Figure 2The brake bracket 20 may include one or more fastener holes 50. The fastener holes 50 can facilitate the installation of the corresponding guide pin assembly 28. The fastener holes 50 can have any suitable configuration. In some configurations, the fastener holes 50 are threaded. The fastener holes 50 can be configured as through holes.

[0032] refer to Figure 1 and Figure 2 The brake caliper 22 is movably or slidably mounted on the brake support 20. The brake caliper 22 facilitates positioning the brake pad assembly 24 relative to the brake rotor 40. For example, the brake caliper 22 can be configured to position the brake pad assembly 24 into engagement with opposite sides of the brake rotor 40 to facilitate braking of the brake rotor 40 and to facilitate retraction of the brake pad assembly or disengagement of the brake rotor 40. In some configurations, the brake caliper 22 includes a caliper housing 60 and a caliper bridge 62.

[0033] The caliper housing 60 may be movably disposed on the brake bracket 20. For example, the caliper housing 60 may be slidably disposed on a pair of guide pin assemblies 28, which may be fixedly disposed on the brake bracket 20. The caliper housing 60 may facilitate the mounting of the brake actuator and may define an internal cavity that may receive or partially receive various components that facilitate the movement of the brake pad assembly 24, such as an operating shaft, yoke, tappet, piston, and wear adjuster mechanism. Examples of such components are described in U.S. Patent No. 11,718,283, which is incorporated herein by reference in its entirety. It should be further noted that the invention is not limited to the configuration described in U.S. Patent No. 11,718,283.

[0034] Main Reference Figure 3 The clamp housing 60 defines one or more holes 70. The holes 70 are configured to receive corresponding guide pin assemblies 28. In some configurations, a pair of holes 70 are provided, positioned near opposite lateral sides of the brake clamp 22. The holes 70 may be configured as through holes. Each hole 70 may extend along a corresponding axis 72. The axis 72 may extend parallel to or substantially parallel to the brake rotor axis 42. As used herein, the term "substantially parallel" means identical to or very close to parallel, and includes features or axes parallel to each other within ±3°. In some configurations, the holes 70 may have a cylindrical configuration, in which the holes 70 are defined by a hole surface 74 of the brake clamp 22 or the clamp housing 60. The hole surface 74 may extend about the axis 72. The hole surface 74 may be radially disposed relative to the axis 72 or disposed at a substantially constant radial distance from the axis 72.

[0035] Reference Figure 1 and Figure 2 The clamp bridge 62 extends from the clamp housing 60. The clamp bridge 62 may be integrally formed with the clamp housing 60 or may be fixedly disposed on the clamp housing 60. For example, the clamp bridge 62 may be provided as a separate component that can be attached to the clamp housing 60 with one or more fasteners (such as bolts). In at least one configuration, the clamp bridge 62 may cooperate with the clamp housing 60 to at least partially define an opening 64 that may facilitate the insertion and removal of the brake pad assembly 24.

[0036] Brake pad assembly 24 is configured to engage brake rotor 40 to facilitate braking of the hub and associated wheel on which brake rotor 40 is mounted. Brake pad assembly 24 can engage brake rotor 40 to slow rotation of brake rotor 40 and associated wheel about brake rotor axis 42. One brake pad assembly 24 can be positioned between caliper housing 60 and brake rotor 40 and can be referred to as inner brake pad assembly 24. Figure 2 From the viewpoint shown, the inner brake pad assembly 24 is located on the right side of the brake rotor 40. Another brake pad assembly 24 may be positioned on the opposite side of the brake rotor 40 between the clamp bridge 62 and the brake rotor 40, and may be referred to as the outer brake pad assembly 24. Figure 2 From the viewpoint shown, the outer brake pad assembly 24 is located on the left side of the brake rotor 40. Each brake pad assembly 24 may include a backing plate 80 and friction material 82.

[0037] The backplate 80 is a structural member of the brake pad assembly 24. The backplate 80 can be configured as a plate and can be made of any suitable material, such as metal or metal alloy. In at least one configuration, the side of the backplate 80 of the inner brake pad assembly 24 facing away from the friction material 82 can engage or contact a pushrod extending from the cavity of the caliper housing 60 to actuate the inner brake pad assembly 24 into engagement with the brake rotor 40. The side of the backplate 80 of the outer brake pad assembly 24 facing away from its friction material 82 can engage or contact the caliper bridge 62.

[0038] Friction material 82 is disposed on the side of the back plate 80 that faces the brake rotor 40. During vehicle braking, friction material 82 can contact the brake rotor 40.

[0039] refer to Figure 1 and Figure 2The retaining bracket 26 (if provided) can be coupled to the brake caliper 22. For example, the retaining bracket 26 can extend across the brake pad assembly 24 and the opening 64 in the brake caliper 22 to help retain the brake pad assembly 24 in the brake bracket 20 when the retaining bracket 26 is secured to the brake caliper 22. The retaining bracket 26 can be detached or removed from the brake caliper 22 to allow removal or installation of the brake pad assembly 24 via the opening 64.

[0040] refer to Figure 2 and Figure 3 An example of the guide pin assembly 28 is shown. The guide pin assembly 28 slidably connects the brake caliper 22 to the brake bracket 20, such that the brake caliper 22 can slide relative to the brake bracket 20 along axis 72. In some configurations and as shown in the reference... Figure 3 As best shown, the guide pin assembly 28 includes a fastener 90, a sleeve 92, and an integral capped bushing 94.

[0041] Fastener 90 is configured to secure or fix sleeve 92 to brake bracket 20. Fastener 90 can have any suitable configuration. For example, fastener 90 can be configured as a bolt, such as a body bolt, which can be received in fastener hole 50 of brake bracket 20. Fastener 90 can be partially received in hole 70 of caliper housing 60 and can extend along or about axis 72. Fastener 90 is disposed in sleeve 92.

[0042] The sleeve 92 is at least partially received in the bore 70 of the clamp housing 60 and in the integral capped bushing 94. The sleeve 92 receives the fastener 90. For example, the sleeve 92 can be configured as a hollow tube that can surround the fastener 90. The size of the hollow portion of the sleeve 92 that receives the fastener 90 can be determined to be slightly larger than the fastener 90 to allow insertion and rotation of the fastener 90 for assembly purposes, but alternatively, the sleeve 92 can be made substantially centered about the axis 72.

[0043] The sleeve 92 may have a first end and a second end. The first end may engage or contact the brake bracket 20. The second end may be configured opposite to the first end. In some configurations, the diameter of the hollow portion of the sleeve 92 at the second end may be larger than the diameter at the first end. For example, the head of the fastener 90 may be received in the larger diameter region of the hollow portion and engage a stepped surface extending into the smaller diameter region of the hollow portion to inhibit axial movement of the sleeve 92 away from the brake bracket 20. Thus, when the sleeve 92 is secured to the brake bracket 20 with the fastener 90, the sleeve may be fixedly positioned or stationary relative to the brake bracket 20. In some configurations, the sleeve 92 has an outer surface 100.

[0044] The outer surface 100 is opposite to the axis 72. The outer surface 100 may be at least partially received in the bore 70 of the clamp housing 60. The outer surface 100 may be the outer circumferential surface of the sleeve 92 and may be spaced apart from the bore surface 74. For example, the outer surface 100 may be positioned at a substantially constant radial distance from the axis 72. The outer surface 100 may engage or contact the integral capped bushing 94.

[0045] An integral capped bushing 94 is at least partially received in a bore 70 of the caliper housing 60. The integral capped bushing 94 can engage the brake caliper 22, but can be spaced apart from the brake support 20 and may not contact or engage the brake support. The integral capped bushing 94 is a one-piece component, which can be made of any suitable one or more materials, such as polymer materials or metal alloys. In some configurations, the integral capped bushing 94 includes a tubular wall 120, a cap 122, and a cavity 124.

[0046] The tubular wall 120 is at least partially received in the aperture 70. For example, the tubular wall 120 may surround and be spaced apart from the axis 72. The tubular wall 120 engages and surrounds the sleeve 92. The tubular wall 120 at least partially defines a cavity 124. In some configurations, the tubular wall 120 includes an end surface 130, an outer side 132, an inner side 134, a guide surface 136, and a stepped surface 138.

[0047] End surface 130 is disposed at the end of tubular wall 120 opposite to the end where cap 122 is disposed. Thus, end surface 130 faces brake bracket 20 and can be spaced apart from brake bracket 20. In one or more configurations, end surface 130 may be disposed substantially perpendicular to axis 72. The term "substantially perpendicular" is used herein to refer to features or axes that are the same as or very close to perpendicular, and includes features perpendicular to each other within ±3°. End surface 130 may or may not be received in bore 70.

[0048] The outer side 132 is opposite to the axis 72. In some configurations, the outer side is the outer circumferential surface of the tubular wall 120 and may be positioned at a substantially constant radial distance from the axis 72. At least a portion of the outer side 132 is received in the bore 70 and contacts or engages the brake caliper 22.

[0049] The inner side 134 is configured opposite to the outer side 132. Thus, the inner side 134 faces the axis 72. The inner side 134 can engage or contact the sleeve 92.

[0050] The guide surface 136 (if provided) may facilitate insertion of the integral capped bushing 94 into the bore 70, facilitate mounting of the flexible boot-shaped member 30, or both. In some configurations, the guide surface 136 extends from the end surface 130 toward the cap 122. In some configurations, the guide surface 136 extends toward or to the outside of the outer surface 132. The guide surface 136 may be positioned at an angle relative to the end surface 130, the outer surface 132, or both. In some configurations, when the guide surface 136 extends away from the end surface 130, the guide surface 136 extends further away from the axis 72.

[0051] A stepped surface 138 (if provided) may extend from the guide surface 136 to the outer side 132. For example, the stepped surface 138 may extend from the end of the guide surface 136 away from the axis 72 to the outer side 132. In some configurations, the stepped surface 138 is positioned substantially perpendicular to the axis 72, the outer side 132, or both.

[0052] The cap 122 surrounds the end of the integral capped bushing 94 that is positioned opposite to the end surface 130. In some configurations, the cap 122 extends from the axis 72 to the tubular wall 120. The cap 122 is disposed in the orifice 70, partially disposed in the orifice 70, or may not be disposed in the orifice 70. The cap 122 is integrally formed with the tubular wall 120, which eliminates potential leakage paths between the cap 122 and the tubular wall 120. In some configurations, the cap 122 includes a cap end wall 140 and a cap outer side 142.

[0053] The cap end wall 140 is provided at the end of the integral cap bushing 94 that is positioned opposite to the end surface 130. The cap end wall 140 may be spaced apart from the fastener 90, the sleeve 92, or both. The cap end wall 140 may intersect the axis 72 and extend to the outer side 142 of the cap.

[0054] The outer side 142 of the cap is opposite to the axis 72 and can surround the axis 72. In some configurations, the outer side 142 of the cap is positioned further from the axis 72 than the outer side 132 of the tubular wall 120. The outer side 142 of the cap can engage the brake caliper 22 in the bore 70. In other configurations, such as... Figure 8 As shown, the extension distance of the outer side 142 of the cap from the axis 72 does not exceed the extension distance of the outer side 132 of the tubular wall 120 from the axis. For example, in Figure 8 In this configuration, the outer side 132 of the tubular wall 120 and the outer side 142 of the cap are positioned at a common radial distance from the axis 72. It is conceivable that, in... Figures 3 to 7 In the configuration shown, the outer side 132 and the outer side of the cap 142 can be positioned at a common radial distance from the axis 72. Similarly, it is conceivable that in Figure 8 In the configuration shown, the outer side 142 of the cap can extend further from the axis 72 than the outer side 132.

[0055] A cavity 124 is disposed within an integral capped bushing 94. The cavity 124 extends along axis 72. For example, the cavity 124 may extend from end surface 130 to cap end wall 140. In some configurations, the cavity 124 has a cylindrical shape. Fasteners 90 and sleeves 92 are received within the cavity 124.

[0056] Fastener 90, sleeve 92, and integral capped bushing 94 can cooperate to define chamber 150. Chamber 150 can be part of cavity 124. Chamber 150 can be positioned between fastener 90 and cap 122 along axis 72. For example, chamber 150 can be positioned between fastener 90 and cap end wall 140 along axis 72 and can be surrounded by tubular wall 120, cap 122, or both. Chamber 150 is configured to receive or contain lubricant 152, such as grease. Lubricant 152 can fill or partially fill chamber 150 and can facilitate sliding movement of integral capped bushing 94 along sleeve 92. For example, some lubricant 152 can enter a small gap between outer surface 100 of sleeve 92 and inner side 134 of tubular wall 120 and facilitate sliding movement between them.

[0057] The integral capped bushing 94 is fixed to the brake caliper 22. Thus, the integral capped bushing 94 is fixedly or statically positioned relative to the brake caliper 22 when installed, and therefore the brake caliper 22 and the integral capped bushing 94 can move together along axis 72 relative to the brake bracket 20, the fastener 90 and the sleeve 92.

[0058] The brake caliper 22 and the integral capped bushing 94 are movable relative to the brake bracket 20, fastener 90, and sleeve 92 between a retracted position and an extended position. When braking, or when braking force is applied, for example, by means of a brake actuator, the brake caliper 22 and the integral capped bushing 94 can move from the retracted position to the extended position. For example, the inner brake pad assembly 24 can move from the retracted position to contact the brake rotor 40, in which position it is spaced apart from the brake rotor 40. Once the inner brake pad assembly 24 contacts the brake rotor 40, a reaction force can cause the brake caliper 22 and the integral capped bushing 94 to move along axis 72 in a first direction relative to the brake bracket 20, fastener 90, and sleeve 92, actuating the outer brake pad assembly 24 to engage the opposite side of the brake rotor 40, thereby helping to slow the rotation of the brake rotor 40 and the associated wheel. When braking or braking force is reduced or no longer applied, the brake caliper 22 and the integral capped bushing 94 can move from the extended position to the retracted position.

[0059] The integral capped bushing 94 can be secured to the brake caliper 22 in a variety of ways.

[0060] exist Figure 3 In the configuration shown, the integral capped bushing 94 is fixed to the brake caliper 22 by an interference fit. The interference fit can be provided between the brake caliper 22 and the tubular wall 120, between the brake caliper 22 and the cap 122, or a combination thereof.

[0061] refer to Figure 4 and Figure 5 This illustrates the configuration of the integral capped bushing 94, which is secured to the brake caliper 22 via mating threads. The mating threads can be positioned in any suitable location.

[0062] exist Figure 4 In the illustrated configuration, a mating thread is associated with cap 122. Brake caliper 22 may include a threaded region 160. The threaded region 160 may be disposed in bore 70 and may include one or more threads helical about axis 72 and facing axis 72. Integral cap bushing 94 may include a threaded portion 162 compatible with the threaded region 160. The threaded portion 162 may include one or more threads helical about axis 72 and facing away from axis 72. The threaded portion 162 of the integral cap bushing 94 mates with the threaded region 160 of brake caliper 22 and secures the integral cap bushing 94 to brake caliper 22. When the integral cap bushing 94 is installed, the threaded portion 162 may be at least partially disposed in bore 70.

[0063] exist Figure 5 In the configuration shown, the mating threads are associated with the tubular wall 120. For example, the integral capped bushing 94 may include a threaded portion 162 disposed together with the tubular wall 120. The threaded portion 162 may include one or more threads that are helical about axis 72 and opposite to axis 72. The threaded portion 162 mates with the threaded region 160 of the brake caliper 22 and secures the integral capped bushing 94 to the brake caliper 22. The threaded region 160, the threaded portion 162, or both may extend along axis 72 by a length greater or less than the length shown, and may be positioned along axis 72 at locations different from those shown. For example, the threaded region 160 and the threaded portion 162 may be disposed adjacent to the cap 122 or near the end surface 130. Providing a threaded area 160 and a threaded portion 162 along a shorter axial distance allows the majority of the integral capped bushing 94 to be inserted into the bore 70 before the threaded engagement, and the integral capped bushing 94 to be rotated to tighten and secure it to the brake caliper 22.

[0064] The integral capped bushing 94 can be secured to the brake caliper 22 using fasteners or fastening features. Figure 6 and Figure 7 The diagram shows some examples of configurations that employ fasteners.

[0065] exist Figure 6 In the illustrated configuration, an integral capped bushing 94 is secured to a brake caliper 22 using a fastener 170 disposed in a bore 70. The brake caliper 22 may include a brake caliper recess 172. The brake caliper recess 172 may surround an axis 72 and a bore 70. The brake caliper recess 172 may extend from the bore 70 in a direction away from the axis 72. The integral capped bushing 94 may include an integral capped bushing recess 174. The integral capped bushing recess 174 may surround an axis 72. The integral capped bushing recess 174 may be provided with the tubular wall 120, the cap 122, or both. In the illustrated configuration, the integral capped bushing recess 174 is provided with the cap 122 and extends from the outer side 142 of the cap toward the axis 72. The fastener 170 may be received in both the brake caliper recess 172 and the integral capped bushing recess 174. The fastener 170 may have any suitable configuration. For example, fastener 170 can be configured as a clamp, snap ring, etc.

[0066] exist Figure 7 The illustrated configuration shows another example of an integral capped bushing 94, which is attached to a brake caliper 22 and disposed within a bore 70. In the illustrated example, the brake caliper 22 includes a recess 180. The recess 180 extends from the bore 70 in a direction extending away from the axis 72. The recess 180 may or may not surround the axis 72. The integral capped bushing 94 includes a protrusion 182. The protrusion 182 may extend away from the axis 72 and may be received in the recess 180 to secure the integral capped bushing 94 to the brake caliper 22. The recess 180 and the protrusion 182 may be disposed in any suitable location. For example, the protrusion 182 may be disposed together with a cap 122, as shown, or it may be disposed together with a tubular wall 120. It is also conceivable that... Figure 7 The configuration shown can be reversed, in which case the protrusion 182 can be provided together with the brake caliper 22, and the recess 180 can be provided together with the integral cap bushing 94.

[0067] exist Figure 8In the illustrated configuration, the integral capped bushing 94 is secured to the brake caliper 22 using a fastener not disposed in the bore 70. Thus, the fastener 190 is disposed outside the bore 70 in the brake caliper 22. As an example, the cap 122 may include a cap flange 192. The cap flange 192 may be disposed outside the bore 70 and extend away from axis 72. In some configurations, the cap flange 192 may protrude away from axis 72 and / or overlap a portion of the brake caliper 22. The fastener 190 secures the cap flange 192 to the brake caliper 22. The fastener 190 may be a separate component from the cap flange 192 or may be integral with the cap flange 192. For example, the fastener 190 may be a threaded fastener, such as a bolt or screw, or an unthreaded fastener, such as a pin or clip, extending through a hole or slot in the cap flange 192 and into a corresponding fastener receiving hole 194 in the brake caliper 22. As another example, the fastener 190 may be integrally formed with the cap flange 192. For instance, the fastener 190 may be a protrusion, such as a clip or pin, that extends from the cap flange 192 into a fastener receiving hole 194 in the brake caliper 22. Such a fastener 190 can be secured in any suitable manner, such as by interference fit, mating features (e.g., barbs, hooks, splines, protrusions, recesses, etc.). It is conceivable that multiple cap flanges 192 and fasteners 190 may be provided, and the fasteners 190 may have the same or different configurations.

[0068] Main Reference Figure 3 The flexible boot-shaped member 30 may extend between the brake bracket 20 and the brake caliper 22, or between the guide pin assembly 28 and the brake caliper 22. The flexible boot-shaped member 30 is configured to flex in response to movement of the brake caliper 22. For example, the flexible boot-shaped member 30 may expand or unfold when the brake caliper 22 moves relative to the brake bracket 20 in a first direction along axis 72, and may retract or fold when the brake caliper 22 moves relative to the brake bracket 20 in a second or opposite direction. The flexible boot-shaped member 30 may include one or more mounting edges 200. One mounting edge 200 may be secured to the brake bracket 20, and another mounting edge 200 may be secured to the brake caliper 22. For clarity, only the mounting edges 200 engaging the brake caliper 22 are numbered.

[0069] The flexible boot-shaped component 30 can be secured in various ways. In the illustrated configuration, the flexible boot-shaped component 30 is shown secured between the integral capped bushing 94 and the brake caliper 22; however, it is also conceivable that the flexible boot-shaped component 30 may not be secured between the integral capped bushing 94 and the brake caliper 22. For example, the mounting edge 200 of the flexible boot-shaped component 30 may not contact or engage the integral capped bushing 94 and may be secured with fasteners (such as rings that are press-fitted into the brake caliper 22 and hold the mounting edge 200 between the ring and the brake caliper 22).

[0070] A mounting edge 200 associated with the brake caliper 22 can be secured between the integral capped bushing 94 and the brake caliper 22. For example, the mounting edge 200 can be disposed in the bore 70 and can extend at least partially around or around the integral capped bushing 94, such that the mounting edge 200 is clamped or secured between the brake caliper 22 and the tubular wall 120. In some configurations, the mounting edge 200 is received in a brake caliper shoe recess 202. The brake caliper shoe recess 202 can surround the bore 70 and extend from the bore 70 in a direction remote from axis 72. In some configurations, the mounting edge 200 of the flexible shoe 30 engages a guide surface 136 and an optional stepped surface 138.

[0071] The brake assembly 10 can be assembled by mounting the sleeve 92 to the brake bracket 20 using fastener 90. Lubricant 152 can be injected into the cavity 124 of the integral capped bushing 94, which positions the lubricant 152 near the cap end wall 140. The amount of injected lubricant 152 can be metered or measured to provide a sufficient amount of lubricant 152 and to allow the cavity 150 to contain such an amount of lubricant. The integral capped bushing 94 can be inserted into the hole 70 in the brake caliper 22 before or after the lubricant 152 is injected.

[0072] Next, the integral capped bushing 94 and brake caliper 22 can then be aligned with the sleeve 92 so that the sleeve 92 can be inserted into the cavity 124 of the integral capped bushing 94. Relative movement along axis 72 between the sleeve 92 and the integral capped bushing 94 can be provided to insert or position the sleeve 92 within the integral capped bushing 94. Insertion of the sleeve 92 can facilitate the distribution of lubricant 152 between the sleeve 92 and the inner side 134 of the tubular wall 120 of the integral capped bushing 94. Alignment and insertion can be aided by the tapering shape of the guide surface 136 of the integral capped bushing 94.

[0073] In a configuration where the flexible boot 30 is positioned within the bore 70 of the brake caliper 22 and clamped between the integral cap bushing 94 and the brake caliper 22, the mounting edge 200 of the flexible boot 30 can be inserted into the bore 70 and the brake caliper boot recess 202 (if provided) before the integral cap bushing 94 is fully inserted or secured. This allows the integral cap bushing 94 to assist in securing the flexible boot 30, thereby reducing or eliminating the need for additional fasteners. The guide surface 136 can act as a wedge and can engage the mounting edge 200 and apply force against it. This force forces the mounting edge to move radially outward as the integral cap bushing 94 moves along axis 72 toward the brake bracket 20, thereby securing the mounting edge 200 in the brake caliper boot recess 202.

[0074] As described, the brake assembly and guide pin assembly utilize a cap that is integral with the tubular wall, rather than a cap provided as a separate component, such as a cap that is press-fitted into the end of a hole in the brake caliper and does not support or slide along the sleeve. The integral capped bushing has fewer potential lubricant leakage paths, better lubricant containment, better separation of lubricant from external contaminants, and helps prevent lubricant degradation. Furthermore, the integral capped bushing avoids problems associated with caps as separate individual parts, such as misalignment and improper installation during assembly or maintenance, which can lead to poor sealing, leakage, or damage. Preventing or reducing lubricant degradation and leakage can facilitate smooth axial movement of the brake caliper relative to the brake support, which in turn helps reduce or avoid brake pad drag and uneven wear of the friction material, thereby reducing drag and contributing to increased lifespan of the brake pad assembly. Integral capped bushings allow lubricant to be injected into the bushing prior to installation. This provides lubrication near the sliding surfaces of the sleeve and the bushing without removing the fasteners and sleeve from the brake support, reducing maintenance time and associated costs and labor. Furthermore, preventative maintenance or inspections can be performed more efficiently with integral capped bushings because they can be removed and reinstalled without disassembling the brake caliper, removing the brake caliper from the brake support, removing the sleeve and fasteners from the brake support, or any combination thereof.

[0075] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the invention. Rather, the terminology used herein is descriptive rather than restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, features of various implementations of the embodiments may be combined to form other embodiments of the invention.

Claims

1. A brake assembly, comprising: Brake bracket; A brake caliper that defines a hole extending along an axial direction; as well as A guide pin assembly that slidably connects the brake caliper to the brake bracket, the guide pin assembly comprising: An integral capped bushing, the integral capped bushing being at least partially received in the bore and secured to the brake caliper, wherein the integral capped bushing is a one-piece component comprising a tubular wall and a cap, wherein the tubular wall surrounds and at least partially defines a cavity extending along the axis and including an end surface configured opposite to the cap, and the cap extending from the tubular wall and surrounding an end of the integral capped bushing; A sleeve, the sleeve being received within the cavity, and the sleeve engaging with the tubular wall such that the integral capped bushing is movable relative to the sleeve along the axis; and Fasteners are disposed in the sleeve and the sleeve is connected to the brake bracket.

2. The brake assembly as claimed in claim 1, wherein, The tubular wall further includes an outer side opposite to the axis and engaging the brake caliper in the hole, and the cap further includes an outer side opposite to the axis and engaging the brake caliper in the hole, and the outer side of the cap is positioned further away from the axis than the outer side of the tubular wall.

3. The brake assembly as claimed in claim 1, wherein, The tubular wall further includes an outer side opposite to the axis and engaging the brake caliper in the hole, the cap further includes an outer side opposite to the axis and engaging the brake caliper in the hole, and the outer side of the cap and the outer side are positioned at a common radial distance from the axis.

4. The brake assembly as claimed in claim 1, wherein, The brake caliper further includes a threaded region disposed in the hole, and the integral capped bushing further includes a threaded portion that engages with the threaded region and secures the integral capped bushing to the brake caliper.

5. The brake assembly as claimed in claim 4, wherein, The threaded portion of the integral capped bushing is provided on the cap.

6. The brake assembly of claim 4, wherein, The threaded portion of the integral capped bushing is located on the tubular wall.

7. The brake assembly as claimed in claim 1, wherein, The integral capped bushing is secured to the brake caliper using fasteners provided in the hole.

8. The brake assembly of claim 7, wherein, The brake caliper further includes a brake caliper recess surrounding the hole and extending from the hole away from the axis, the cap further includes a cap outer side facing away from the axis and a cap recess extending from the cap outer side toward the axis, and the fastener is received in the brake caliper recess and the cap recess.

9. The brake assembly as claimed in claim 1, wherein, The integral capped bushing is secured to the brake caliper using fasteners located outside the hole.

10. The brake assembly of claim 9, wherein, The cap further includes a cap flange disposed outside the hole and extending away from the axis, wherein the fastener secures the cap flange to the brake clamp.

11. The brake assembly of claim 1, wherein, The brake caliper further includes a recess extending from the bore away from the axis, and the integral capped bushing further includes a protrusion extending away from the axis, the protrusion being received in the recess and securing the integral capped bushing to the brake caliper.

12. The brake assembly of claim 1, wherein, The fastener, the sleeve, and the integral capped bushing cooperate to define a chamber disposed along the axis between the fastener and the cap, wherein the chamber contains lubricant.

13. The brake assembly of claim 1, wherein, The sleeve engages with the brake bracket, and the integral capped bushing is spaced apart from the brake bracket and does not contact the brake bracket.

14. The brake assembly of claim 1, further comprising a flexible boot-shaped member extending between the brake bracket and the brake caliper, wherein, The mounting edge of the flexible boot-shaped component is disposed in the hole and fixed between the integral capped bushing and the brake caliper.

15. The brake assembly of claim 14, wherein, The brake caliper further includes a brake caliper boot-shaped groove surrounding the bore and extending from the bore away from the axis, wherein the mounting edge of the flexible boot-shaped member is disposed in the brake caliper boot-shaped groove.

16. The brake assembly of claim 15, wherein, The tubular wall further includes: an outer side, the outer side being opposite to the axis and engaging the brake caliper in the hole; and a guide surface, the guide surface extending from the end surface toward the outer side, wherein the flexible boot-shaped member engages the guide surface.

17. The brake assembly of claim 16, wherein, The guide surface is set at an inclined angle relative to the end surface and the outer side.

18. The brake assembly of claim 16, wherein, As the guide surface extends away from the end surface, the guide surface extends further away from the axis.

19. The brake assembly of claim 18, wherein, The tubular wall further includes a stepped surface extending from the end of the guide surface to the outer side.

20. The brake assembly of claim 19, wherein, The mounting edge engages with the step surface.

21. An integral capped bushing for a brake caliper, the integral capped bushing comprising: A tubular wall that surrounds and at least partially defines a cavity, the tubular wall including an end surface; as well as A cap, which is configured to be opposite to the end surface and extend from the tubular wall, wherein the cap surrounds the end of the tubular wall, and the integral capped bushing is a one-piece component.

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