Mounting interface of a cover for a motor vehicle disc brake housing

Abstract

Cover (20, 200) with an automotive disc brake caliper assembly comprising a disc brake floating caliper housing with an actuating section, a bridge section and a floating section, wherein the floating section comprises an abutment for supporting the cover (20, 200), wherein the brake caliper housing (10, 100) comprises an axial actuating axis 03 extending parallel to an axis of wheel rotation, wherein the assembly comprises a releasable fastening means cooperating with the abutment for the cover (20, 200), wherein the fastening means is at least one screw comprising an axis extending substantially radially, wherein the cover (20, 200) comprises a visible front with an invisible back behind the front, the back serving as the locking contact with the brake caliper housing (10, 100), together with the screw as a releasable fastening means being concealed behind the front of the cover (20, 200).wherein the fist section includes an interface opening for receiving an interface projection extending from the rear of the cover and interacting with the interface opening of the fist.

Description

[0001] The present invention relates to automotive disc brakes. Automotive disc brakes can be of the fixed caliper type or the floating caliper type and have a brake housing. Disc brakes are equipped with brake pads for relative interaction with a friction surface of a brake disc, and the space- and cost-efficient floating caliper includes a special holder or brake corner module for holding and guiding the brake caliper and the brake pads for interaction with the disc. In contrast to the floating caliper design, fixed caliper brakes include a housing that is stationary and accommodates opposing pistons. The brake caliper housing is concealed by a cover – also called a “design plate” or “symbol cover plate.” In a specific embodiment of the brake housing of the automotive brake caliper, such a cover includes a visible front surface as a visible cover or casing.The cover must be securely and stably attached to the housing – for example, locked in its mounting position – to prevent hazards or damage due to uncontrolled loss of the cover. At the same time, the cover should be as easy to install and remove as possible, for example, for brake maintenance purposes. A smooth appearance is preferred, but this can disadvantageously result in the cover's fasteners being concealed behind the cover's front surface, for example, on the back. The cover may be a multi-part assembly.

[0002] A symbol carrier plate or symbol carrier cover assembly can ensure efficient aerodynamics and self-cleaning function in conjunction with the vehicle brake caliper, as well as an elegant appearance, and allow for streamlined customer adaptations with the company's corporate design or logo. The construction and shape of these so-called design covers should meet defined customer requirements; a key customer requirement is the invisible and secure locking and unlocking of the brake caliper housing. It goes without saying that a good design has no visible locking mechanisms. The cover function should also prevent unwanted rattling noises when the vehicle travels on uneven road surfaces. A design cover can be manufactured as a combination of various components, technologies, and materials.One side of the cover can be individually assigned to each application and visibly display the customer's emblem / logo.

[0003] One object of the invention is to demonstrate a need for improved covers by means of alternative interface designs, and to contribute to the improvement of covers according to the prior art. The improved interfaces aim at enhanced safety with regard to the unintentional loss of a cover, the requirement to avoid rattling noises arises due to rough road conditions, and more convenience during the installation or removal of the cover is generally sought, because in known solutions "blind mounting situations" in conjunction with invisibly concealed fastening structures are problematic.

[0004] The following description, based on the drawing, details improved embodiments of the invention along with various modifications according to these embodiments. This relates to design variations as well as variations in the fastening process. The invention allows for precise and rapid, self-guided automatic pre-positioning, e.g., with self-locking. Accordingly, the fastening options are improved by means of the interface design according to the invention. The invention is based on a new, suitably improved interface design with modern automated assembly processes, including automatic pre-positioning, as well as during disassembly. This ensures that the matching and opposing components automatically align themselves and adjust their positions accordingly.The invention allows for a novel, improved, concealed, fixed screw connection between the components (cover component and brake caliper housing component). Although the cover plate is always described in the following description as being attached to a brake caliper housing, the cover plate can alternatively also be attached to a brake bracket (holder component).

[0005] The valuable assembly process improvement according to the invention enables a valuable automated holding function between the housing component and the cover component through the suitable arrangement and interaction between the interacting interfaces of the housing (or the holder) and the cover. In this way, the interaction during automatic pre-positioning can be achieved, for example, by utilizing natural weight and gravity, when the housing is oriented with its bridge section facing downwards so that it rests on the surface, and the cover is automatically held in a pre-positioned position by its natural weight as it rests on the housing. Alternatively, or in any combination of the individual options, the function can be achieved via an automatic positive-locking interaction between the interacting interfaces of the cover and the housing.Alternatively, or in any further combination of the individual options, the interaction between the housing and the cover during automatic pre-positioning can be based on adhesive interaction between the housing and the cover, in that, for example, an adhesive substance or an adhesive tape, such as a double-sided adhesive tape, can be used alternatively or additionally.

[0006] The following is a detailed explanation of alternative solutions or embodiments, each in detail but nevertheless fundamentally reduced or simplified form as follows: Fig. 1a, Fig. Figure 1b is a perspective exploded view of a disc brake caliper as a subassembly, comprising the following components: a brake caliper housing 10, a design cover 20, and a mounting screw 30, which is implemented radially from below (aligned in the radial direction 01, the tangential direction 02, and the axial direction 03, the latter being parallel to the brake actuation = brake rotor / wheel rotation axis); it is understood that all axis relationships are based on the Cartesian coordinate system; Fig. 2 a,b a brake caliper housing component before cover assembly; in Fig. 2a The brake caliper housing is located in the position according to the invention for mounting the cover, i.e., in a sense upside down (bridge section at the bottom), wherein g symbolizes natural gravity in the working space and wherein the radial axis 01 for the automatic pre-positioning function runs parallel to g when a cover is supplied and positioned for mounting; wherein furthermore the radial interface 11 on the brake caliper housing is shown as a recessed cavity that is tubular and has a convertible-style configuration (without a roof - open at the top), and furthermore a tangential 13 and axial 12 interface are shown; in addition, Fig. 2b represents a radial mounting hole 14 for a screw; Fig. Figure 3 is a perspective rear view of a cast cover plate (made of plastic or light metal) showing details of a very specific lightweight design alternative that features varying plate thickness achieved through reinforcing ribs. These ribs can be arranged or combined with special rear profile structures, which may be configured as honeycomb-shaped ribs or other intelligent support structures for improved rigidity. Ultimately, the examples shown may preferably feature an innovative rib pattern structure. For weight reduction and increased rigidity, the cover body may be at least partially hollow. This results in improved vibration and noise reduction of the cover body due to its special structure.This novel structure can be applied to the entire cover or only partially. A newly structured grid pattern can be implemented as a 3D back profile (preferably by molding, modeling, or casting) as an embodiment with a clear preference for newly developed design cover components – such a body structure can, for example, be manufactured from metal or plastic material using modeling technology. The shaping can be achieved using deformable metal material such as steel or, alternatively, by die casting, for example, from aluminum. Fig. Figure 3 further details possible covers with several other interface features that can cooperate with the interfaces of the associated counterpart of a brake caliper housing, and which may, in principle, have a rear surface with a grid-patterned surface profile in a bottom section, followed by a section comprising a flat axial (contact) surface 22 and an orthogonally vertically oriented projection comprising a radial contact surface 21, a tangential guide surface 23, a cover guide hole 24, and, in the head section, an axially stepped projection 25. All of this is coordinated and ready to interact with interfaces of a brake housing edge region of the brake housing periphery, which has special interface features and fastening means; Fig. 4 a, b, c represents the preferred free design cover according to Fig. 3 in three alternative embodiment variants with different axially stepped projections 22 for the precise definition of contact with an axial contact surface of the housing 12; Fig. 5 a,b is a cross-sectional view of the subassembly with gap 26 and the subassembly without gap 27; Fig. 6 a,b is a perspective view of the subassembly of the housing 10, the design cover 20 and the screw 30; Fig. 7 a,b sectioned in exploded view another embodiment of the improved brake subassembly comprising the housing 10, the design cover 20, the screw 30 and fastening element 40 as a screw bolt, wherein this embodiment allows a through hole without threading means in the housing and the drilling process either starts radially outwards and aims radially inwards or vice versa, wherein the cover interface may integrate a threaded counterpart for the screw or alternatively another part, which may be, for example, a nut, a threaded insert or other counterpart, to serve as a suitable fastening counterpart for the screw; Fig. 8 a,b is an alternative covered brake caliper design, which is essentially based on the fastening strategies and embodiments as in Fig. 1 and Fig. 5; furthermore, the preferred cover comprises a multi-part sheet metal structure instead of a metal or plastic casting as shown in the cross-sectional exploded view based on housing 100, sheet metal design cover 200, screw 300 and projection 400.

[0007] Fig. Figure 1 a,b presents an overview of a completely new interface design between a plate and a brake caliper, comprising a novel design of interacting component interfaces. It provides clear, rattle-free interface contacts for smooth assembly between the designed cover component subassembly 20 and the respective brake caliper housing 10. The proposed design cover 20 includes a projection in the form of an upright post or rod that extends into the cavity or at least towards a mounting surface of the brake caliper housing 10, e.g., with the interface cavity serving as a receptacle for the projection / rod. This interface design can serve as a guide for simplified handling during component pairing. For this reason, the interface cavity of the housing 10 can be designed, in particular, as a partially open tube (e.g.,The projection on the cover is preferably arranged in a "convertible" shape as an open-top guide channel or at least partially configured in a similar manner. The projection on the cover is preferably in the form of a post / rod for attachment, substantially orthogonal, preferably at right angles, to a plate front and can comprise a radial contact surface 21, an axial contact surface 22, and a tangential guide surface 23 for the simplified positioning process of the radial contact surface 11, the axial contact surface 12, and the tangential guide surface 13 of the housing 10. The post / rod can include a through-hole in the radial direction so that the selected locking means is invisible / concealed when viewed from the front.The locking means is preferably designed as a screw or bolt with a head and a shank, which may be a metric socket head cap screw 30. This screw is positioned through the cover guide hole 24 and is secured in a radial mounting hole 14 of the caliper housing. The locking function can be ensured by a fixed connection between the radial contact surfaces and by a defined tightening torque of the screw 30. The nut thread, as the threaded counterpart for the screw, can either be integrated as a thread in a receiving hole of the caliper housing, as a thread in a receiving hole of the cover projection, or it can be an additional component of the nut. Variations with alternative and / or additional locking means are possible if deemed advantageous.Alternative or additional locking means may include snap-lock devices. Alternative or additional safety features may include positive locking devices, frictional locking devices, other devices, and various combinations thereof. Preferred additional locking devices may include a chemical substance, for example, a dry, self-activating, two-component thread-locking adhesive. Such a chemical adhesive may preferably be applied as a thin-film structure to bolt threads, hole threads, nut threads, or alternatively, any combination thereof. During the fastening process, the design cover subassembly 20 is preferably pressed axially toward the brake caliper housing component 10.The axial movement with a specific tension then ensures good contact between the interfaces without a gap between the axial housing contact surface 12 and the axial contact surface 22 of the design cover 20. A further radial and / or axial preload force can prevent unwanted rattling noises for the driver on an uneven road surface. Fig. Figure 4 represents various axially stepped projections 22 that ensure a precise contact interface with axial contact of the housing 12. The subassembly consisting of the design cover 20 and the housing 10 can be manufactured in two basic variants: as a subassembly with a gap 26 and as a subassembly without a gap 27. The subassembly with a gap is ensured by a precise axially stepped projection 25 of the design cover.

[0008] Fig. 6 represents a subassembly consisting of the design cover 20 and the housing 10 in a variant intended for use with brake calipers with multiple (more than one) brake piston solutions.

[0009] The assembly principle, installation, and details regarding brake caliper mounting are consistent with the explanation of Fig. 1 a,b.

[0010] Fig. Figure 7 represents a subassembly consisting of the housing 10, the design cover 20, the screw 30, and the fastener 40. The screw is installed from the side and top, and an additional threaded fastener 40 ensures a quick connection. The screw with the threaded locking mechanism can be used to ensure the proper connection of the design cover to the brake caliper housing.

[0011] Fig. Figure 8 represents a subassembly consisting of the housing 100, the design cover 200, the screw 300, and the holder 400. The holder 400 is attached together with the design cover 200. The principle of installation and fastening is identical to that described in Figure 8. Fig. 1 explained. This variant can be manufactured as a combination of different components, technologies, and materials. List of reference symbols 01 radial direction 02 tangential direction 03 axial direction g natural gravity 10 brake caliper housings 11, 21 radial contact surface 12, 22 axial contact surface 13, 23 tangential guide surface 14 holes 20 Cover / Plate 24 guide holes 25 graduated lead 26 with gap 27 without gap 30 Screw fasteners, in particular screws 40 Fastening element 100 cases 200 sheet metal covers 300 screw fasteners, in particular screws 400 Interface of the cover projection

Claims

[1] Fastening process for a cover (20, 200) of a motor vehicle disc brake caliper assembly, which in particular comprises a floating caliper housing (10, 100) with an actuating section, a bridge section and a floating section, wherein the bridge section is positioned at the bottom in a working space, the floating section comprises an abutment for supporting the cover (20, 200), wherein the brake caliper housing (10, 100) comprises an axial actuating axis 03 which extends parallel to an axis of wheel rotation, wherein the assembly comprises a releasable fastening means which interacts with the abutment for the cover, wherein the fastening means has at least one screw fastening means (30, 300) which comprises an axis which extends substantially radially, wherein the cover (20, 200) comprises a visible front with an invisible back behind the front, wherein the back serves for the locking contact with the brake caliper housing (10, 100),together with the screw fastening means (30, 300) as a releasable fastening means, (30, 300) is invisibly concealed behind the front of the cover (20, 200), wherein the fist section comprises an interface opening for receiving an interface projection that extends from the rear of the cover and interacts with the interface opening of the fist in such a way that the assembly process includes a pre-assembly step with placement of the cover (20, 200) on the housing (10, 100) such that the cover (20, 200) automatically remains in a pre-assembly position, i.e., is held correctly positioned in relation to the housing (10, 100) before a final fastening step with the screw fastening means (30, 300), through interaction, in particular through interaction between the interacting interfaces of the housing (10, 100) and the cover (20, 200). [2] Fastening process for a cover (20,200) of an automotive disc brake caliper assembly according to claim 1, wherein the interaction in the automatic pre-positioning between the housing (10,100) and the cover (20,200) comprises positive locking means, preferably snap-lock means, which interact as an additional feature of the interacting interfaces of the cover (20,200) and the housing (10,100). [3] Fastening process for a cover (20,200) of an automotive disc brake caliper assembly according to claim 1, wherein the interaction in the automatic pre-positioning between the housing (10,100) and the cover (20,200) is based on the natural force of gravity g, such that the cover (20,200) is automatically held in the pre-position by its natural weight resting on the housing (10,100). [4] Fastening process for a cover (20,200) of an automotive disc brake caliper assembly according to one or more of the preceding claims 1-3, wherein the interaction in the automatic pre-positioning between the housing (10,100) and the cover (20,200) is based on an automatic positive-locking interaction between the interacting interfaces of the cover (20,200) and the housing (10,100). [5] Fastening process for a cover (20,200) of an automotive disc brake caliper assembly according to one or more of the preceding claims 1-4, wherein the interaction in the automatic pre-positioning between the housing (10,100) and the cover (20,200) is based on an adhesive interaction between the housing (10,100) and the cover (20,200). [6] Fastening process for a cover (20,200) of an automotive disc brake caliper assembly according to the preceding claim 5, wherein an adhesive substance which can be applied in the form of an adhesive tape can be applied to at least one or to both components (10,100; 20;200) or component interfaces. [7] Fastening process for a cover (20,200) of an automotive disc brake caliper assembly according to at least one of the preceding claims, wherein after final fastening and locking together preload force clamps are placed between the cover (20,200) and the housing (10,100). [8] Cover (20, 200) with an automotive disc brake caliper assembly comprising a floating caliper housing with an actuating section, a bridge section and a floating section, wherein the floating section comprises an abutment for supporting the cover (20, 200), wherein the brake caliper housing (10, 100) comprises an axial actuating axis 03 parallel to an axis of wheel rotation, wherein the assembly comprises a releasable fastening means cooperating with the abutment for the cover (20, 200), wherein the fastening means is at least one screw fastening means comprising an axis that is substantially radial, wherein the cover (20, 200) comprises a visible front with an invisible back behind the front, the back serving as the locking contact with the brake caliper housing (10, 100), together with the screw fastening means (30, 300) as a releasable fastening means behind the front of the cover (20,200) is concealed, wherein the fist section includes an interface opening for receiving an interface projection extending from the rear of the cover and interacting with the interface opening of the fist. [9] Cover (20,200) with an automotive disc brake caliper assembly according to at least one of the preceding claims, wherein the interacting interfaces comprise positive locking means for their interaction and wherein the positive locking means are preferably designed as snap-lock means. [10] Cover (20,200) with an automotive disc brake caliper assembly according to claim 8, wherein the screw fastening means is designed in the form of a screw such as a setscrew or, in particular, preferably in the form of a countersunk screw. [11] Cover (20,200) with an automotive disc brake caliper assembly according to at least one of the preceding claims, wherein the counter-thread means of the screw fastening means are integrated either preferably in a through hole of the fist section or alternatively in a blind hole of the fist section of the housing (10,100). [12] Cover (20, 200) with an automotive disc brake caliper assembly according to at least one of the preceding claims, wherein the screw fastening means comprise a radially oriented through-hole which is preferably without threads in the housing (10, 100), wherein the through-hole is preferably located between a window opening of the housing bridge section ( Fig. 7 a,b) is hidden. [13] Cover (20,200) with an automotive disc brake caliper assembly according to at least one of the preceding claims, wherein the mating thread means of the screw fastening means is integrated into the cover (20,200), is manufactured in connection with it and / or is mounted in connection with it. [14] Cover (20,200) with an automotive disc brake caliper assembly according to at least one of the preceding claims, wherein the counter-thread means of the screw fastening means is integrated into an additional component, which is preferably designed in the form of a special insert or as a nut. [15] Cover (20, 200) with an automotive disc brake caliper assembly according to at least one of the preceding claims, wherein the axial contact interface of the housing (front of housing) (12, 22) for the cover (20, 200) is substantially flat ( Fig. 5b, Fig. 8b) is or alternatively as a stepped surface for integrating the cover (20,200; Fig. 5a, Fig. 7b) is designed.

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