Brake caliper, and motor vehicle disc brake with the same

Abstract

The invention relates to a brake caliper (1) for a motor vehicle disc brake, in particular for a commercial vehicle disc brake with a brake disc moved around a rotational axis (R), with a caliper housing (3) for receiving an application mechanism, and a caliper cover (5) which covers the top of the caliper housing (3) and engages over the brake disc from an application side (19) of the brake disc to a reaction side (21) of the brake disc, and a hold-down bracket (31) which is reversibly detachably fastened to a holder (11) on the reaction side of the caliper cover (5) and spans the brake disc from the application side (19) to the reaction side (21).It is proposed that the brake caliper (1) has a reaction-side support plate (9) which is materially connected to the caliper cover (5), and that the holder (11) is formed in one piece on the support plate (9), and / or that the holder (11) is a first holder, and the caliper housing (3) has a brake disc-side housing wall (17), on which a second holder (27) is formed, and on which the hold-down bracket (31) is reversibly detachably fastened on the application side, wherein the second holder (27) protrudes in the direction of the reaction side (21) from the brake disc-side housing wall (17).

Description

The present invention relates to a brake caliper for a motor vehicle disc brake, in particular for a commercial vehicle disc brake, having a brake disc moved about a rotational axis, having a caliper housing for receiving a brake application mechanism, and a caliper cover which is preferably formed partially or completely from sheet metal and which covers the caliper housing on the top side and engages over the brake disc from a brake application side of the brake disc as far as a reaction side of the brake disc, and having a hold-down clip which is fastened on the caliper cover on the reaction side to a holder and engages over the brake disc from the brake application side as far as the reaction side.Brake calipers of the above-mentioned type are well known. Brake calipers are quite common in which the caliper housing and / or the brake caliper are designed as cast parts. Those functional elements of the brake caliper and of the caliper housing in particular which require very precise alignment and surface machining because they movably support or hold functionally critical components are mechanically remachined in these cast parts in order to be able to fulfil the required functions.While the production of these elements from cast metal is basically authorized, because cast parts can be produced easily in a large number of pieces and have mechanically outstanding stability. Disadvantages are generally the high dead weight of the cast parts. The economics of using castings are sometimes limited depending on the molds used, particularly when using lost molds.There is therefore in principle the tendency, in particular for the caliper housing but also for the caliper, to find alternatives which allow economic production and make possible a reduction in the dead weight of the motor vehicle disc brake without compromising the stability of the brakes.From WO 2016 / 135316 A1 a brake caliper for a disc brake is known, in which the caliper housing is formed from an outer segment, an inner segment running substantially parallel to the outer segment, and two bases extending between the outer and inner segments with corresponding cover elements, which are each made of sheet metal. There, it is proposed to form at least two of these segments by a uniform sheet metal element.In an effort to form the brake caliper and above all the caliper cover from a sheet metal part, WO 2016 / 135316 A1 proposes, for fastening the hold-down bracket, fastening it on the reaction side to the caliper cover by means of a small metal sleeve and fastening it to the caliper cover by means of a splint or the like. However, it has been found that the strength of the sleeve-like fastening element is unsatisfactory and the attachment by means of a material-bonded connection and the alignment for this purpose are possible only with increased outlay on account of the small size of the holding element.Against this background, the invention was based on the object of further developing the brake caliper of the type specified at the beginning to the extent that the disadvantages described above are overcome as far as possible. The invention was based in particular on the object of improving the brake caliper designated at the beginning to the effect that improved mounting and dismantling of the hold-down level can be achieved.The invention achieves the object on which it is based by proposing a brake caliper according to claim 1. In particular, the invention proposes that the brake caliper has a reaction-side support plate which is connected to the caliper cover in a materially integral manner, wherein the holder is formed in one piece on the support plate. In other words, the invention proposes to displace the mounting location of the holder for the hold-down clip on the reaction side of the brake disc on the caliper housing from the caliper cover towards the support plate for the reaction-side brake pad. The support plate is in turn also connected to the saddle cover by a material bond, but because of its significantly larger dimensions compared to the holder it is much easier to position on the saddle cover than was the case with the small sleeve from the prior art.The holder can be attached to the support plate already in advance, so that an exact positioning in the alignment of the holder takes place implicitly by attaching the support plate to the saddle cover. This saves at least one working step, improves the positioning of the support plate and at the same time does not impair the dismantling and assembly of the hold-down clip in any way.According to the invention, the application mechanism is understood to mean the mechanism which transmits the actuating force of the brake actuator, usually transmitted via a piston, to the brake pads. The application mechanism usually comprises a brake lever, the corresponding bearing of the brake lever, and an application unit comprising a pressure piece and an adjusting device for wear compensation of the brake pads.The reaction-side holder preferably protrudes radially from the support plate, wherein it is intended to mean radially with respect to the axis of rotation of the brake disc. The retainer preferably projects radially outward from the support plate.In a preferred development, the caliper cover has an inner side facing the disc brake, and the support plate is formed from sheet metal and has a positioning collar which bears against the inner side of the caliper cover. The positioning collar is preferably configured to uniquely align and abut the support plate relative to the seat cover. This further simplifies the correct orientation and positioning of the reaction-side holder.In a further preferred embodiment, the positioning collar is designed as a bent sheet metal section which extends along a bending edge, wherein the bending edge is preferably designed in the shape of a circular arc. The bending edge can alternatively also be polygonal, elliptical or rectilinear. It is important that the bending edge, in relation to the positioning collar, can be produced very easily by bending the support plate, and in addition to the positioning of the support plate, also simultaneously improves the mechanical integrity of a support plate formed from sheet metal.In a further preferred embodiment, the positioning collar is connected to the saddle cover in a materially integral manner. According to the invention, the materially bonded connection is understood to mean in particular welding or soldering, in particular brazing. Particularly preferably, the positioning collar is connected to the saddle cover by means of welding.In a further preferred embodiment, the holder is designed as a hook on the support plate bent away from the application side, preferably opposite the positioning collar, wherein the hold-down clip is hooked into the hook. The hook shape can be straight or curved. By bending the hook away from the application side, i.e. also away from the brake disc, the holding and hooking function of the hold-down clip is improved.In a further preferred embodiment, the saddle cover has a contour on its inner side which abuts against the positioning collar and aligns the positioning collar relative to the saddle cover. The inner side of the caliper cover is understood to mean the radially inner side of the caliper cover facing the axis of rotation of the brake disc.In a further preferred embodiment, the holder is a first holder, and the caliper housing further has a brake-disc-side housing wall, on which a second holder is formed, and on which the hold-down clip is reversibly releasably fastened on the application side, wherein the second holder protrudes from the brake-disc-side housing wall in the direction of the reaction side. The second holder is accordingly arranged on the application side of the brake disc. The second holder protrudes from the housing wall in the direction of the brake disc, i.e. in the direction of the reaction side, and is thus spaced apart from the housing wall, and preferably also from a vehicle-side section of the caliper cover, which contains the cavity defined by the caliper housing, in the direction of the axis of rotation, i.e. in the direction parallel to the axis of rotation. This facilitates the suspension of the hold-down clip into the second holder, and the length of the hold-down clip can be shortened compared to the prior art, in which the holder is arranged completely in the plane of the housing wall.This aspect is at the same time an independent second aspect of the invention, accordingly the object indicated at the beginning is achieved by a brake caliper for a motor vehicle disc brake being proposed, in particular for a commercial vehicle disc brake, having a brake disc moved about an axis of rotation, having a caliper housing for receiving a brake application mechanism, and having a caliper cover which is preferably formed partly or completely from sheet metal and covers the caliper housing at the top and engages over the brake disc from a brake application side of the brake disc as far as a reaction side of the brake disc, wherein the caliper housing has a brake-disc-side housing wall on which a preferably radially protruding holder is formed, and a hold-down clip which is fastened to the caliper cover at the brake application side in a reversibly detachable manner to the holder, and extends over the brake from the brake application side as far as the reaction side, wherein the holder protrudes in the direction of the reaction side from the brake disk-side housing wall.The invention takes advantage of the same advantages according to the second aspect as the brake caliper according to the first aspect.Preferred embodiments of the brake caliper of the first aspect are thus simultaneously preferred embodiments of the brake caliper of the second aspect, and vice versa, for which reason, in order to avoid repetitions, reference is made in this respect to the above explanations and to the following explanations.In a preferred development, the second holder has a recess for receiving the hold-down clip and a web which is radially adjacent to the recess on the outside, wherein the housing wall is preferably formed from sheet metal, and the web is integrally formed on the housing wall. The formation of the axially projecting part of the second holder can be brought about in this way very easily by means of embossing, and the mechanical integrity of the second holder or of the housing wall on the brake disc side is simultaneously improved.The hold-down clip is introduced into the recess on the application side, extends into it and preferably through it, and is prevented from lifting off by the radially outwardly arranged web.The invention is advantageously further developed in that the saddle cover is connected to the housing wall in a materially integral manner, wherein the housing wall has a joining edge which runs in the circumferential direction from an inlet side to an outlet side of the housing wall with respect to the axis of rotation, and the saddle cover is connected to the housing wall by means of a continuous joining seam along the joining edge, which joining edge extends past the second holder.In particular, the joint seam extends past the web of the second holder. This is accompanied by a further particular advantage of the second aspect of the invention. The axial advancement of the web of the second holder facilitates access to the joint edge and facilitates the production of the joint seam. In the prior art, for fastening the caliper cover to the housing wall on the brake disc side for a cohesive connection, it was necessary to interrupt the welding process during welding along the joint seam as soon as the welding tool came into the region of the second holder. The weld seam had to be either omitted in the region of the second holder or made opposite from the radially inner side. According to the invention, in which the second holder is now no longer in the way, the connection between the saddle cover and the housing wall can be produced continuously in a single joining process, in particular by means of welding, from the inlet side to the outlet side, which simplifies the production process and is also advantageous for the material structure.In a further preferred embodiment, the housing wall on the brake disk side has a material thickness m, and the web of the second holder is disengaged in the direction of the brake disk by a distance a relative to the housing wall. The recess itself can, but does not have to be, also disengaged. The material into which the recess is introduced can remain on a plane with the remaining housing wall.The distance a to the material thickness m preferably has a ratio a / m in a range of 0.5 or more, preferably in a range of 0.75-1.25, and particularly preferably in a range of 0.9-1.1.The invention has been presented in the first two aspects with respect to the caliper itself. In a third aspect, the invention further relates to a motor vehicle disc brake, in particular a utility vehicle disc brake, for decelerating a brake disc moved about an axis of rotation, having a brake caliper. The invention achieves the object indicated at the beginning in such a brake by the brake caliper being designed according to one of the above-described preferred embodiments according to the first and / or second aspect.The invention takes advantage of the same advantages as in the first two aspects with respect to the third aspect. Preferred embodiments of the brake caliper according to the first and / or the second aspect are at the same time preferred embodiments of the disc brake and vice versa, for which reason reference is made again to the above explanations in order to avoid repetitions.The invention is described in more detail below with reference to the attached figures on the basis of a preferred exemplary embodiment. The following are shown here: FIG. 1 shows a first spatial schematic view of a brake caliper, FIG. 2 shows a second spatial schematic view of the brake caliper according to FIG. 1, FIG. 3 shows a schematic three-dimensional detailed view of a support plate of the brake caliper of FIGS. 1 and 2, and FIGS. 4a-4c show different schematic three-dimensional detail views of a variant of the brake caliper of FIGS. 1 to 3.FIGS. 1 and 2 show a brake caliper 1 according to the invention in accordance with a preferred exemplary embodiment. With reference to FIG. 1, the first aspect of the invention can be illustrated in particular. The brake caliper 1 has a caliper housing 3 which is formed at least partially from sheet metal segments. The caliper housing 3 has a caliper cover 5 made of a bent metal sheet which is placed on the caliper housing 3 and is configured to engage over a brake disc (not shown) which rotates about its axis of rotation R.The brake caliper 1 has a first housing wall 7 on the vehicle side, which is designed as a bent sheet metal body. The vehicle-side housing wall 7 is preferably oriented at right angles with respect to the axis of rotation R when the brake caliper 1 is mounted in the operating state.The seat cover 5 has an outer side 6 and an inner side 8 with respect to the axis of rotation R. The caliper cover 5 is further configured to receive a hold-down clip (FIG. 2 ) 31 which extends from a brake disc application side 19 to a brake disc reaction side 21 and which prevents the brake pads from falling out of the brake in a generally known manner.On a side of the brake caliper 1 opposite the vehicle-side housing wall 7, a support plate 9 for supporting a reaction-side brake pad (not shown) is provided, preferably likewise made of a metal sheet. On the reaction side ( 21) of the saddle housing 1, there is also a (first) reaction-side holder 11 for receiving the hold-down clip 31, cf. FIG. 2.Between the caliper housing 3 and the caliper cover 5 there are arranged a plurality of sliding sleeves 13 for receiving guide bolts of the disc brake. The construction of the brake caliper 1 is preferably designed completely without cast parts, but can have one or more forged parts or parts produced by machining according to the invention.The brake caliper 1 has a mounting interface 15 configured to mount a brake actuator and having a number of fastener through holes 29. The caliper housing 3 includes therein a cavity 23 for receiving a clamping mechanism which is accessible from the vehicle side by means of a through-opening 25. In the operating state, a tappet of a brake cylinder extends through this through-opening 25, which tappet is fastened to the mounting interface 15.As can be seen from FIG. 1, but better still from FIG. 2, the caliper housing 3 has, opposite the vehicle-side housing wall 7, a second, brake-disc-side housing wall 17, on which a second holder 27 is provided. The second holder 27 is initially illustrated in a simplified variant in FIG. 2. It will be discussed in more detail with respect to the second aspect of the invention in FIGS. 4a-4c.The hold-down clip 31 is in engagement with the second bracket 27 on the application side 19 and in engagement with the first bracket 11 on the reaction side 21.The first holder 11 has a hook 14 bent away from the application side 19, which is integrally formed on the support plate 9, preferably by bending. Once the hold-down clip is suspended in the manner shown in FIG. 2, the hold-down clip 31 can be fixed to the saddle cover 5 by a fastening means, for example in the form of a screw, being introduced into a fastening opening 12 of the saddle cover 5 provided for this purpose.The support plate 9, which is also shown in isolation in FIG. 3, abuts against a corresponding contour 33 on the inner side 8 of the saddle cover 5 and is positionally aligned by said contour. The support plate 9 is preferably connected to the saddle cover 5 in a materially integral manner, preferably by means of welding.The alignment of the support plate 9 on the saddle cover 5 is preferably effected on the basis of a positioning collar 35 which is illustrated in FIG. 3 and which is formed on the support plate 9 by bending along a bending edge 37. The positioning collar 35 preferably extends in the same direction, namely away from the application side 19, on the support plate 9. The contour 33 can be designed for point-by-point contact of the positioning collar 35, or for linear or flat contact. For the basic positioning, however, a two-point system will be sufficient.While FIGS. 1-3 focus on the first aspect of the invention with respect to the reaction-side attachment of the hold-down clip 31, FIGS. 4a-4c show a second aspect of the invention focus on the application-side attachment of the hold-down clip 31. It should be understood that the features shown in FIGS. 4 ato 4 cmay be incorporated into the caliper of FIGS. 1 and 2 to combine the first and second aspects with each other.The second holder 27 indicated in FIGS. 1 and 2 is shown in a three-dimensional oblique view in FIG. 4 a, in a lateral oblique view in FIG. 4 band in a plan view from above in FIG. 4 c. The second mounting 27 on the application side has a recess 39 for receiving an end of the hold-down clip 31 on the application side, preferably as a slot formed corresponding to the cross section of the hold-down clip. Radially outside the recess 39, the second holder 27 is delimited by a web 41 which projects from the brake-disc-side housing wall 17 in the direction of the arrow P 1, which runs parallel to the axis of rotation R. The housing wall 17 on the brake disc side has a material thickness m.The web 41 is, as can be clearly seen in particular from FIGS. 4 band 4 c, advanced in particular in that region by the distance a from the plane of the brake-disc-side housing wall 17 in which, on the one hand, the holder 27 is formed and, on the other hand, a dome portion 10 of the caliper cover 5 is formed. The dome portion 10 is provided to enlarge the cavity 23 to enable pivotal movement of a lever of the application mechanism (not shown) in a well known manner.By advancing the web 41, it is possible, as shown in particular in FIG. 4 c, to produce a joint seam 43 continuously along a joint edge 42 from an inlet side 45 of the housing wall 17 to an outlet side 47 of the housing wall 17. A stable, continuous, material-bonded connection can thus be produced between the caliper cover 5 and the brake-disc-side housing wall 17 of the caliper housing 3 by means of welding, since the web 41 has deviated somewhat in the direction of the arrow P 1 to the protrusion which the dome portion 10 represents, so that space is created for the joining tool. By projecting the web 41 by the distance a, a slightly shorter holding-down clip can also be used.The extent of the protrusion by the predetermined distance a is preferably relative to the material thickness m of the brake-disc-side housing wall 17 in the region of the second holder 27 in a ratio a / m of 0.75 to 1.25, particularly preferably in a range of 0.9 to 1.1.Reference Sign (Part of Description)1 Brake caliper 3 Caliper housing 5 Caliper cover 6 Outer side, Caliper cover 7 Housing wall, 8 Inner side on the vehicle side, Caliper cover 9 Support plate, 10 Dome portion 11 (first) Holder on the reaction side, 12 Fastening opening, Caliper cover 13 Sliding sleeves for guide bolts 14 Hooks 15 Mounting interface 17 Housing wall, 19 Application side on the brake disk side, Brake disk 21 Reaction side, Brake disk 23 Cavity 25 Through opening, Mounting interface 27 (second) Holder, 29 (first) Through hole on the application side, Mounting interface 31 Hold-down clip 33 Contour, Caliper cover 35 Positioning collar, Support plate 37 Bending edge 39 Recess, (second) Holder 41 Web, (second) holder 42 joining edge 43 joining seam 45 inlet side 47 outlet side P 1 arrow R axis of rotation a distance m material thickness, housing wallReferences included in the specificationThis list of documents cited by the applicant has been produced in an automated manner and is only included for the better information of the reader. The list is not part of the German patent application or utility model application. The DPMA does not take any adhesion for any faults or omissions.Patent Literature citedWO 2016 / 135316 A1 [0005, 0006]

Claims

Brake caliper (1) for a motor vehicle disc brake, in particular for a utility vehicle disc brake having a brake disc moved about an axis of rotation (R), having a caliper housing (3) for receiving a brake application mechanism, and a caliper cover (5) which covers the caliper housing (3) on the top side and engages over the brake disc from a brake application side (19) of the brake disc as far as a reaction side (21) of the brake disc, and having a hold-down clip (31) which is fastened on the caliper cover (5) on the reaction side to a holder (11) in a reversibly detachable manner and extends over the brake disc from the brake application side (19) as far as the reaction side (21), characterized in that the brake caliper (1) has a reaction-side support plate (9) which is connected in a materially integral manner to the caliper cover (5), and the holder (11) is formed in one piece on the support plate (9).Brake caliper (1) according to claim 1, characterised in that the caliper cover (5) has an inner side (8) facing the disc brake, and in that the support plate (9) is formed from sheet metal and has a positioning collar (35) which bears against the inner side (8).Brake caliper (1) according to Claim 2, characterized in that the positioning collar (35) is designed as a bent sheet-metal section which extends along a bending edge (37), the bending edge (37) preferably being designed in the form of a circular arc.Brake caliper (1) according to Claim 2 or 3, characterized in that the positioning collar (35) is connected to the caliper cover (5) in a materially integral manner.Brake caliper (1) according to one of the preceding claims, characterized in that the holder (11) is designed as a hook (14) on the support plate (9) which is bent away from the application side (19), preferably opposite the positioning collar (35), wherein the hold-down clip (31) is hooked into the hook (14).Brake caliper (1) according to one of Claims 2 to 5, characterized in that the caliper cover (5) has, on its inner side (8), a contour (33) which bears against the positioning collar (35) and aligns the positioning collar (35) relative to the caliper cover (5).Brake caliper (1) according to one of the preceding claims, characterized in that the holder (11) is a first holder, and the caliper housing (3) has a housing wall (17) on the brake disc side, on which a second holder (27) is formed, and on which the hold-down clip (31) is fastened in a reversibly releasable manner on the application side, wherein the second holder (27) protrudes from the housing wall (17) on the brake disc side in the direction of the reaction side (21).Brake caliper (1) according to Claim 7, characterized in that the second holder (27) has a recess (39) for receiving the hold-down clip (31) and a web (41) which is radially adjacent to the outside of the recess (39), wherein the housing wall (17) is preferably formed from sheet metal and the web (41) is integrally formed on the housing wall (17).Brake caliper (1) according to Claim 7 or 8, characterized in that the caliper cover (5) is connected to the housing wall (17) in a materially integral manner, wherein the housing wall (17) has a joining edge (42) which runs in the circumferential direction from an inlet side (45) to an outlet side (47) of the housing wall (17) with respect to the axis of rotation (R), and the caliper cover (5) is connected to the housing wall (17) by means of a continuous joining seam (43) along the joining edge (42), which joining edge extends past the second holder (27).Brake caliper (1) according to Claim 8 or 9, characterized in that the housing wall (17) on the brake disc side has a material thickness (m), and the web (41) of the second holder (27) is disengaged in the direction of the brake disc by a distance (a) relative to the housing wall (17).Brake caliper (1) according to claim 10, characterised in that the distance (a) to the material thickness (m) has a ratio (a / m) in a range of 0.5 or more, preferably in a range of 0.75 to 1.25, particularly preferably in a range of 0.9 to 1.1.Motor vehicle disc brake, in particular a commercial vehicle disc brake, for delaying a brake disc moved about an axis of rotation (R), having a brake caliper (1), characterized in that the brake caliper (1) is designed according to one of Claims 1 to 11.

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