Brake slide clip with active retraction element

Abstract

A brake assembly slide clip includes a base section. A clamping portion extends from the base section. A lower section extends from the base section. A tangential section extends from a second side of the lower section. An active retraction element extends from the tangential section and provides a surface against which the brake pad is disposed. The active retraction element is movable in a first axial direction responsive to a brake pad force against the retraction element surface, and resiliently returns following removal of the force so as to move the brake pad in a second axial direction opposite the first axial direction. The tangential section is formed from a metal strip having a longitudinal axis that is between 15 and 75 degrees from a lengthwise side of a blank from which the remaining sections of the clip are formed.

Description

BRAKE SLIDE CLIP WITH ACTIVE RETRACTION ELEMENTFIELD OF INVENTION

[0001] The disclosure herein relates to a brake slide clip for use in a disc brake assembly.BACKGROUND

[0002] Disc brake systems have been used extensively in the automotive industry. The friction between disc brake pads and brake rotors during braking generates large quantities of heat as brake systems convert kinetic energy into heat to slow or stop moving vehicles.

[0003] Typical disc brake systems are comprised of certain basic components. Among them is a caliper that surrounds at least a portion of a brake rotor. Mounted in the caliper are brake pads which are designed to press against the rotor causing the disc brake to slow the vehicle using the brake system.

[0004] Conventional disc brakes are often subject to undesirable drag of the disengaged pads on the rotors. The drag causes power losses, a shortening of the service life of the pad and possible overheating of the brake components and wheel bearings. Braking dragging increases CO2 emissions in vehicles having gasoline combustion engines as reduces vehicle range in electric vehicles. Drag is caused by brake pads being constantly or intermittently urged against the disc even after release of the application pressure.

[0005] What is needed is a way to avoid undesirable brake drag between the brake pads and the rotor.SUMMARY

[0006] According to one or more example embodiments, a brake slide clip is provided for use in a disc brake assembly and includes a base section having a first side and a second side opposite the first side. A clamping portion extends from the first side of the base section, theclamping portion including a base clamping section, an inner axial holding tab which extends from a first side of the base clamping section, and an outer axial holding tab which extends from a second side of the base clamping section that is opposite the first side thereof. The clamping portion is configured to clamp to a portion of an anchor bracket of the disc brake assembly. A lower section extends from the second side of the base section, the lower section having a first side which extends from the base section and a second side. A tangential abutment section extends from the second side of the lower section. An active retraction element extends from the tangential abutment section, including a flat link section providing a first surface on which a brake pad of a disc brake is disposed, a contact section providing a second surface against which the brake pad is disposed, a spring section coupled to the flat link section, the active retraction element disposed at least partly over the lower section, and a connection section connected between the spring section and the tangential abutment section. Wherein a distance between a lower portion of the connection section and the tangential abutment section is shorter than a distance between an upper portion of the connection section and the tangential abutment section. When the active retraction element is coupled to the brake pad, the active retraction element is movable from a retracted position relative to the base section and the lower section responsive to movement of the brake pad presenting a force against the second surface of the contact section, and resiliently returns to the retracted position upon a spring force acting on the flat link section by the spring section overcoming the force presented by the brake pad.

[0007] The lower section may be disposed perpendicular to the base section, and the tangential abutment section is disposed perpendicular to the lower section. The lower section extends from the base section via a first curved portion disposed between the lower section and the base section.

[0008] The flat link section may include a first lengthwise end portion connected to the contact section and a second lengthwise end portion connected to the spring section, and while the brake slide clip is disposed in the disc brake assembly and prior to engagement with the brake pad, the flat link section is positioned such that the first lengthwise end portion of the flat link section is closer to the clamping portion than the second lengthwise end portion is to theclamping portion, thereby allowing for the brake pad to be received on and engaged with the flat link section during insertion in the disk brake assembly.

[0009] The active retraction element applies a first lift force in a radial direction when the active retraction element is coupled to the brake pad in the disc brake assembly.

[0010] The brake slide clip may further include an extension section which extends from the tangential abutment section via a curved portion, the brake pad is disposed on a distal end portion of the extension section, and the extension section applies a second lift force in the radial direction on the brake pad when the brake slide clip is engaged therewith in the disc brake assembly.

[0011] An extension section which may extend from the tangential abutment section via a curved portion. The brake pad is disposed on a distal end portion of the extension section. The curved portion and the extension section includes a cutout defined therein. The cutout is centrally located in a lateral direction along the brake slide clip.

[0012] The brake slide clip is formed from a blank material having a main metal portion corresponding to the base section, the clamping portion, the lower section and the tangential abutment section, and a metal strip corresponding to the active retraction element. A longitudinal axis of the metal strip is disposed at an angle between 15 degrees and 75 degrees relative to a lengthwise side of the main metal portion. The angle between the longitudinal axis of the metal strip and a lengthwise side of the main metal portion may be between 15 degrees and 25 degrees.

[0013] The spring section of the active retraction element may include at least one cutout and the spring section undergoes elasto-plastic deformation when the active retraction element is moved in an axial direction from the retracted position during a braking operation.

[0014] The spring section may include a plurality of curved portions, wherein the curved portions align sections of the active retraction element relative to each other in an axial direction.

[0015] A majority of the connection section is in a plane that is disposed at a non-zero angle to a plane formed by radial and tangential axes of the brake slide clip.

[0016] An example embodiment is directed to a method of forming a brake slide clip for a disc brake assembly. The method includes obtaining a material blank having a main metal portion and a metal strip extending at an angle between 15 degrees and 75 degrees from a lengthwise side of the main metal portion. The method further includes defining a base section, a lower section, a tangential abutment section and a lower clamping section from a first region of the main metal portion by bending the lower section relative to the base section, bending the tangential abutment section relative to the lower section, and bending the lower clamping section relative to the base section, the lower section extending from the base section via a first curved portion, and the tangential abutment section extending from the lower section via a second curved portion, and the lower clamping section extending from the base section via a third curved portion. A base clamping section is defined and includes an upper clamping section, an inner axial holding tab, and an outer axial holding tab from a second region of the main metal portion by bending opposed lateral end portions of the second region so as to form the inner and outer axial holding tabs, bending the base clamping section relative to the lower clamping section, and bending the upper clamping section relative to the base clamping section. An active retraction element is defined by bending the metal strip relative to the tangential abutment section in a plurality of bending operations so that portions of the active retraction element are aligned with each other in an axial direction.

[0017] Each bending operation of the plurality of bending operations of the metal strip bends the metal strip in a single direction.

[0018] The metal strip extends from the lengthwise side of the main metal portion at an angle between 15 degrees and 25 degrees.

[0019] The metal strip may include a material portion for a connection section of the active retraction element which extends directly from the tangential abutment section, and forming the active retraction element includes bending the material portion for the connection section of the active retraction element so that in the brake slide clip, a lower portion of the connection section is closer to the tangential abutment section than an upper portion of the connection section.

[0020] Forming the active retraction element may include bending the material portion for the connection section of the active retraction element so that a majority of the connection section is in a plane that is disposed at a non-zero angle to a plane that extends in a tangential direction formed by radial and tangential axes of the brake slide clip.

[0021] The metal strip may include at least one cutout and the spring section undergoes elasto-plastic deformation when the active retraction element is moved in an axial direction during a braking operation when the brake spring clip is engaged with a brake pad in a disc brake assembly.

[0022] In one aspect, prior to performing the bending operations, the metal strip is disposed along the lengthwise side of the main portion and has a first lengthwise end which extends from the lengthwise side of the main metal portion and a second lengthwise end which does not extend further than a lengthwise end of the main metal portion.

[0023] The active retraction element may include a flat link section configured to contact a brake bad, the flat link section includes a first lengthwise end portion and a second lengthwise end portion, and while the brake slide clip is disposed in the disc brake assembly and prior to engagement with the brake pad, the flat link section is positioned such that the first lengthwise end portion of the flat link section is closer to the clamping portion than the second lengthwise end portion is to the clamping portion, thereby allowing for the brake pad to be received on and engaged with the flat link section during insertion in the disk brake assembly.BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIG. 1 illustrates an exploded perspective view of a disc brake assembly according to an example embodiment.

[0025] FIG. 2 illustrates a perspective view of an assembled anchor element of the disc brake assembly of FIG. 1.

[0026] FIGS. 3-5 illustrate perspective views a brake slide clip of the disc brake assembly according to one or more example embodiments.

[0027] FIGS. 6A-6C illustrate front elevational views of a brake slide clip of the disc brake assembly according to multiple example embodiments.

[0028] FIG. 7 illustrates a partial perspective view of the brake slide clip, a brake pad and an anchor element of the disc brake assembly of FIG. 1.

[0029] FIGS. 8-10 illustrate a plan view of a material blank from which the brake slide clip of FIGS. 6A-6C are formed, respectively, according to multiple example embodiments.

[0030] FIG. 11 graphically depicts a brake slide clip retraction force over brake pad lifetime.

[0031] These and other embodiments, aspects, advantages, and features of the present invention will be set forth in part in the description which follows and will become apparent to those skilled in the art by reference to the following description of the invention and referenced drawings or by practice of the invention. The aspects, advantages, and features of the invention are realized and attained by the instrumentalities, procedures, and combinations particularly pointed out in the appended claims and their equivalents.DETAILED DESCRIPTION

[0032] The following detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the apparatus may be practiced. These embodiments, which are also referred to herein as "examples" or "options," are described in enough detail to enable those skilled in the art to practice the present embodiments. The embodiments may be combined, other embodiments may be utilized, or structural or logical changes may be made without departing from the scope of the invention. The following detailed description is, therefore, not to be taken in a limiting sense and the scope of the invention is defined by the appended claims and their legal equivalents.

[0033] In general terms, a brake slide clip for a disc brake assembly includes an active retraction element integrated therein in order to retract the brake pads in an opposite direction ofthe brake rotor to create clearance to the brake rotor. The active retraction element is designed to elasto-plastically deform with the wear of the brake pad and brake rotor and provides an almost constant retraction force with increasing wear.

[0034] FIG. 1 illustrates a disc brake assembly 100 according to an example embodiment. The general structure and operation of the disc brake assembly 100 is conventional in the art.

[0035] The disc brake assembly 100 includes a caliper 106, an anchor bracket 108, and outside and inside brake pads 110 and 112, respectively. The disc brake assembly 100 is illustrated for mounting on a stationary component of a motor vehicle.

[0036] The caliper 106 includes an inner section 114 and an outer section 116 connected by an intermediate section 118. The caliper 106 is supported on the anchor bracket 108 by first and second guide pins 120A and 120B that extend into the anchor bracket 108. The caliper 106 is configured to be secured to the first and second guide pins 120A and 120B by first and second guide pin bolts 122A and 122B, respectively. The anchor bracket 108 is configured to be secured to a stationary component of a motor vehicle.

[0037] The anchor bracket 108 includes first and second spaced apart openings 124A and 124B and first and second spaced apart openings 126A and 126B. The first and second openings 124 A and 124B are each adapted to receive one of the associated first or second guide pins 120A or 120B. The first and second openings 126A and 126B are each adapted to receive a mounting bolt (not shown) which is received in threaded openings provided in the stationary vehicle component (not shown), thereby securing the anchor bracket 108 to the stationary vehicle component. In another implementation, the first and second openings 126 A and 126B are threaded openings and the corresponding mounting bolts extend through non-threaded openings provided in the stationary vehicle component for engagement with the first and second openings 126 A, 126B.

[0038] The anchor bracket 108 also includes an axially extending first arm 128 and second arm 130. The outer ends of arms 128, 130 are connected together by an outer tie bar 132 and the inner ends of arms 128, 130 are connected together by an inner tie bar 134.

[0039] The first and second arms 128 and 130 of anchor bracket 108 include notches or channels, indicated respectively generally at 136, formed along axial ends of the arms. The channels 136 are defined along an inner wall of first arm 128 and an inner wall of second arm 130. The channels 136 slidably support the outer brake pad 110 and the inner brake pad 112. Brake slide clips 102A and 102B are mounted to or within the channels 136 and on which outer brake pad 110 and inner brake pad 112 slidingly engage. The channels 136 are configured to receive the associated inner and outer brake slide clips 102A and 102B prior to assembly of the outer and inner brake pads 110 and 112 to the anchor bracket 108. Brake slide clip 102A is the mirror image of brake slide slip 102B. One pair of brake slide clips 102A and 102B supports outer brake pad 110, and a second pair of brake slide clips 102A and 102B supports inner brake pad 112.

[0040] Each outer brake pad 110 and inner brake pad 112 includes a backing plate 140, an insulator 143 secured to the backing plate 140, and a brake friction pad 142 is secured to the backing plate 140 along an opposite surface against which the insulator 143 is secured. Each backing plate 140 includes a pair of projecting protrusions or guide rails 144 disposed at opposite ends of the backing plate 140. The guide rails 144 are configured to support the brake friction pad 142 of a brake pad 110, 112 for sliding movement within the channels 136 of the anchor bracket 108 on brake slide clips 102 A and 102B.

[0041] In an example embodiment, inner brake pad 112 is supported and operatively coupled to a brake piston (not shown) of the disc brake assembly 100 for sliding movement within channels 136 along brake slide clips 102A and 102B responsive to movement of the brake piston. Alternatively, outer brake pad 110 may be supported and operatively coupled to the brake piston. Each guide rail 144 may have a generally rectangular cross sectional shape, though it is understood that other shapes are possible.

[0042] FIG. 2 is a perspective view of an assembled anchor bracket 108 with brake slide clips 102A, 102B and brake pads 110, 112 connected and engaged to the bracket.

[0043] Because brake slide clip 102A is a mirror image of brake slide clip 102B, the description herein of brake slide clip 102B also applies to brake slide clip 102A.

[0044] FIGS. 3-6 illustrate brake slide clip 102B according to one or more example embodiments. Brake slide clip 102B is formed from sheet metal and is configured to clamp or otherwise engage with a notch 136 of anchor bracket 108 (see FIGS. 1 and 7). As shown, brake slide clip 102B includes a base section 200 which is largely rectangular. Extending from an end portion of base section 200 is a clamping portion 202 which is configured for clamping or otherwise engaging with anchor bracket 108. Clamping portion 202 extends from a side 200A of base section 200 via a curved portion 204. Curved portion 204 is disposed between base section 200 and clamping portion 202 and includes a 90 degree curve.

[0045] Clamping portion 202 includes a base clamping section 206 which is generally rectangular. An inner axial holding tab 208 and an outer axial holding tab 210 extend from opposed axial sides of base clamping section 206. Each axial holding tab 208, 210 is bent from base clamping section 206 and extends in the same tangential direction for contacting opposed surfaces of anchor bracket 108. Clamping portion 202 further includes an upper clamping section 211 which extends from a top side of base clamping section 206 in the tangential direction for contacting a surface of anchor bracket 108 that is disposed between the surfaces of anchor bracket 108 which contact inner axial holding tab 208 and outer axial holding tab 210. Upper clamping section 211 includes a radial holding tab 212 having a curved portion which contacts the surface of the anchor bracket 108. Clamping portion 202 further includes a lower clamping section 213 which extends from base clamping section 206 and is disposed opposite upper clamping section 211. A curved portion 214, forming a generally 90 degree curve, is disposed between lower clamping section 213 and base clamping section 206. Inner axial holding tab 208 and outer axial holding tab 210 do not extend in an axial direction beyond axial sides of lower clamping section 213 and base section 200. In other words, base clamping section 206 is smaller in the axial direction than lower clamping section 213 and base section 200. In particular, the inner axial holding tab 208 does not extend in the axial direction farther than the sides of base section 200 in the axial direction. The inner axial holding tab 208, the outer axial holding tab 210, the upper clamping section 211 and the lower clamping section 213 engage with and clamp to the anchor bracket 108.

[0046] Extending from a side of base section 200 that is opposite the side from which clamping portion 202 extends is a lower section 216. A curved portion 218, which forms a 90 degree curve, is disposed between base section 200 and lower section 216. Extending from a side of lower section 216 that is opposite the base section 200 is a tangential abutment section 220. A curved portion 222, which forms a 90 degree curve, is disposed between tangential abutment section 220 and lower section 216.

[0047] Extending from a side of the tangential abutment section 220 opposite lower section 216 is an extension section 224. A curved portion 226, which forms a 90 degree curve, is disposed between the extension section 224 and the lower tangential abutment section 220.Extension section 224 is generally flat and includes a distal portion 224A which extends from the generally flat region of extension section 224 and has a curved shape. A convex surface of distal portion 224A is configured to support a radial end portion of a brake friction pad 142, as shown in FIG. 7. FIG. 7 illustrates a brake slide clip 102B mounted to and engaged with the anchor bracket 108. As shown, base section 200, lower clamping section 213, base clamping section 206, lower section 216 and tangential abutment section 220 are disposed against and adjacent corresponding surfaces of the anchor element 108.

[0048] Brake slide clip 102B further includes cutout 250 defined along base section 200. Extending into the cutout from one side thereof is an axial retention tab 252. Axial retention tab 252 is bent so that it is not in the same plane as base section 200 and instead extends partly in the tangential direction. Axial retention tab 252 serves as a stop, in the axial direction, for brake pad 110 or 112 when the brake pad is disposed in its operable position along brake slide clip 102B and anchor bracket 108.

[0049] As shown in FIGS. 3-6, brake slide clip 102B includes an integrated active retraction element, generally shown at 230, which serves to retract a corresponding brake pad 110 or 112 from the corresponding rotor, thereby avoiding brake drag caused by brake pad 110, 112 contacting the brake rotor following completion of a braking operation. Active retraction element 230 has a pull-technology in that the element pulls the brake pad 110, 112. Active retraction element 230 is formed from a thin metal strip and includes simple curved or bent portions, such as curves each of which is in a single direction / dimension and are not twisted,torqued or otherwise bent in second or third directions / dimensions. Active retraction element 230 extends from tangential abutment section 220 and extends at least partly over lower section 216. A guide rail 144 of an inner brake pad 112 or outer brake pad 110 are disposed on the active retraction element 230 above lower section 216 (best seen in FIG. 7).

[0050] In an example embodiment, the active retraction element 230 includes a connection section 232 which is directly connected to and extends from the tangential abutment section 220. In the illustrated example embodiment, connection section 232 is bent such that the connection section 232 lies at least mostly in a plane that is at a non-zero angle 0 relative to a plane P formed by radial and tangential axes and extending in the tangential direction, as shown in FIGS. 6A-6C. Specifically and with reference to FIGS. 4 and 6A-6C, a distance between a lower portion 232LP of the connection section 232 and a location on the tangential abutment section 220, such as a center point CP of the tangential abutment section 220 that is centered along the tangential abutment section in the radial direction, is shorter than a distance between an upper portion 232UP of the connection section 232 and the center point CP of the tangential abutment section 220. This spacing difference of the upper and lower portions of the connection section 232 may be best seen in FIGS. 6A-6C. FIG. 5 shows the position of the connection section 232 relative to the connection section 232 being disposed in a tangential plane defined by radial and tangential axes of the brake slide clip 102B. The spacing difference between the distance from the upper portion 232UP (to the center point CP) and the distance from the lower portion 232LP (to the center point CP) in FIG. 6A is smaller than such spacing difference in FIG. 6B, and the spacing difference in FIG. 6B (between the distance from the upper portion 232UP to the center point CP and the distance from the lower portion 232LP to the center point CP) is smaller than such spacing difference in FIG. 6C. In addition, the angle 0 in FIG. 6A is smaller than the angle 0 in FIG. 6B which itself is smaller than the angle 0 in FIG. 6C. The relative spacing of the connection section 232 to the tangential abutment section 220 in each of FIGS. 6A-6C will be described in more detail below.

[0051] Active retraction element 230 further includes a spring section 236 which extends from curved portion 234, a flat link section 238 which extends from spring section 236 having a first surface on which a guide rail 144 is disposed, and a contact section 240 which extends fromlink section 238 and has a second surface against which the guide rail 144 is disposed. Spring section 236 is configured to return to its retracted position following a brake pad 110, 112 having moved link section 238 and contact section 240 in an axial direction towards the vehicle rotor during a braking operation. In returning to its retracted position, spring section 236 pulls the corresponding brake pad 110, 112 away from the rotor so as to ensure the brake pad no longer contacts the rotor.

[0052] In the illustrated example embodiments, spring section 236 includes a curved portion 234 which forms a 90 degree curve in the axial direction. The spring section 236 is formed by a thin metal strip being shaped in three curved portions 242, 244 and 246, each of which is a curve or bend in a single direction. In other words, curved portions 234, 242, 244 and 246 bend the thin metal strip in a plane formed by axial and radial axes, and do not bend the thin metal strip in a tangential direction. Curved portions 242, 244 and 246 position flat link section 238 above lower section 216 as shown in FIGS. 3-6. The sections of the active retraction element 230, i.e., spring section 236, link section 238 and contact section 240 are aligned with each other in the axial direction. Contact section 240 is disposed at the lengthwise end of link section 238. Contact section 240 is bent at least 90 degrees from flat link section 238. In one implementation, contact section 240 is bent from flat link section 238 by more than 90 degrees so that the distal end portion of contact section 240 contacts the friction pad 142 of a corresponding brake pad 110 or 112. As shown in FIG. 7, brake pad 110 or 112 is disposed against an upper portion or upper edge of the surface of contact section 240 which faces spring section 236.

[0053] As discussed, in each of FIGS. 6A-6C, the connection section 232 is bent relative to the tangential abutment section 220 such that the lower portion 232LP of the connection section 232 is at a shorter distance to the tangential abutment section 220, such as the center point CP centered in the radial direction along the section 220, than a distance of the connection section upper portion 232UP to the center point CP of the tangential abutment section. With the connection section lower portion 232LP being spaced closer to the tangential abutment section 220 than the spacing of the upper portion 232UP to the tangential abutment section 220, in contrast to the connection section lower portion 232LP and the connection section upper portion232UP having equal spacing to the center point CP of tangential abutment section, the connection section 232 is more resistive to movement and / or deformation in the axial direction during a braking operation when the corresponding brake pad 110, 112 moves link section 238 and contact section 240 in the axial direction towards the vehicle rotor. This increased resistance thereby better isolates the source of brake slide clip movement during and following a braking operation to that of spring function movement of the spring section 236, with less secondary effects. With less movement / deformation of the connection section 232, the active retraction is more assured to move solely in the axial direction during and following a braking operation.

[0054] It is noted that brake slide clips 102A and 102B are illustrated in the drawings as they are when engaged with the anchor bracket 108 and the brake pads 110 and 112, respectively. When the brake side clip is not engaged with and separated from the anchor bracket 108 and the brake pads 110, 112, such as prior to assembly of the brake assembly 100, the spring section 236 may orient the flat link section 238 and the contact section 240 at an oblique angle relative to the lower section 216 so that the lengthwise end portion of the flat link section 238 connected to the contact section 240 is positioned closer to the base clamping section 206 than the lengthwise end portion of flat link section 238 connected to spring section 236 is positioned relative to the base clamping section 206. FIG. 6A illustrates brake slide clip 102B in which the active retraction element 230 is depicted in solid lines in its unengaged or unloaded state prior to inclusion in the brake assembly 100 and prior to engagement with the guide rails 144 of a backing plate 140 of a brake pad 110, 112; and depicted in dashed lines in its engaged or loaded state after inclusion in the brake assembly 100 and engagement with the guide rail 144. When the active retraction element 230 is in its unengaged, natural state in which no forces are exerted on the active retraction element 230, the distal or unconnected end of the active retraction element 230 is positioned nearer to the base clamping section 206 than the end portion of the flat link section 238 which is connected to the spring section 236. In this unengaged state, the position of the flat link section 238 is well positioned for receiving a guide rail 144 of the backing plate 140 of a brake pad 110, 112 for engagement with the flat link section 238 during insertion of the brake pad 110, 112 within the anchor bracket 108. Engagement of the brake pad 110, 112 with the brake side clip 102B causes the active retraction element 230 to be in itsengaged, loaded state in which the flat link section 238 is disposed largely in parallel to 216 as shown in FIGS. 3-5 and 6B-6C.

[0055] The movement of the active retraction element 230 from its unengaged, unloaded state to its engaged, loaded state during engagement with a guide rail 144 of the backing plate 140 of a brake pad 110, 112 shows a lift force that is applied by the active retraction element 230 onto the backing plate 140. This lift force LF, illustrated in FIG. 6A and applied to the backing plate guide rail 144, has at least a component in the radial direction. The lift force LF in the radial direction advantageously allows for less retraction forces needed by the spring section 236 of the active retraction element 230 when the spring section 236 is returned to its retracted position with brake pad 110, 112 moved away in the axial direction from the vehicle rotor following completion of a braking operation. The lift force LF from the active retraction element 230 is combined with the spring and / or lift force LF2 applied by extension section 224 to the guide rail 44, itself having a component in the radial direction, to provide a combined lift force acting on the backing plate 140 of the brake pad 110, 112 in the radial direction. It is understood that lift force LF1 from the active retraction element 230 and LF2 from the extension section 224 exist in the brake slide clip embodiments of FIGS. 6B and 6C.

[0056] The thin metal strip forming the spring section 236 includes at least one cutout 248 defined through the metal strip. The number, size and position of cutout 248 serve to create sites for localized yielding of the spring as the brake pads wear. Cutout 248 facilitates the elasto- plastic deformation of the spring section 236 during the life of the friction pad 142. In particular, the cutout 248 facilitates the active retraction element 230 to provide a constant or near constant retraction force over the life of the friction pad 142 as the thickness of the friction pad decreases over time. This constant or near constant retraction force results in the retracted position of the active retraction element 230 changing over the life of the friction pad 142. FIG. 11 illustrates simulation test results of the retraction force of the brake slide clips 102A and 102B over the lifetime of the corresponding brake pad 110, 112. As the brake pad thickness lessens over time, the distance of travel of the active retraction element 230 in the axial direction increases. The graph of FIG. 11 shows that the retraction force of the brake slide clip 102A, 102B is largelyconstant and mostly independent of the distance traveled by the active retraction element 230 over the lifetime of the brake pad 110, 112.

[0057] Brake slide clips 102A and 102B each includes a cutout 280 disposed in the extension section 224 and the curved portion 226. Best seen in FIGS. 4 and 5, the cutout 280 is centrally disposed in the axial direction relative to the tangential abutment section 220, and has a longitudinal axis that largely extends laterally along the extension section 224. In an example embodiment, the cutout 280 does not extend into the tangential abutment section 220. The cutout 280 serves to reduce the stiffness of the extension section 224 by lowering its spring rate. This lowering of the spring rate results in less radial spring force variation in the installation range. Cutout 280 allows for the extension section 224 to be shorter while achieving the same spring rate, thereby allowing for the length of the material blank, from which the brake slide clip 102A, 102B is created, to be shorter which saves material cost. The details of the material blank is discussed in greater detail below. Further, cutout 280 serves to limit bowing or bulging of the tangential abutment section 220 relative to the anchor bracket 108, which results in a reduction in the positioning of the spring section 236 and its corresponding spring function during and following the completion of a braking operation.

[0058] Brake slide clips 102A and 102B are formed from sheet metal. Brake slide clip 102A or 102B is formed from a material blank of sheet metal. In an example embodiment, a material blank from which brake slide clip 102 A or 102B is formed is configured to be relatively small so as to advantageously increase the number of blanks which can be made from the metal sheet. This is at least partly accomplished by having the thin metal strip from which the active retraction element 230 is formed to be disposed along a lengthwise side of a main portion of the blank and that a distal end of the thin metal strip does not extend beyond a lengthwise end of such blank main portion.

[0059] FIGS. 8-10 illustrate a material blank 60 according to example embodiments. Material blank 60 includes a main portion 62 of the material blank 60 having a length L. The main portion 62 of the material blank 60 includes the material portion 200’ from which the base section 200 is formed; a material 216’ portion from which the lower section 216 is formed; a material portion 220’ from which the tangential abutment section 220 is formed; a materialportion 224’ from which the extension section 224 is formed; a material portion 206’ from which the base clamping section 206 is formed; a material portion 208’ from which the inner axial holding tab 208 is formed; a material portion 210’ from which the outer axial holding tab 210 is formed; a material portion 213’ from which the lower clamping section 213 is formed; and a material portion 211’ from which the upper clamping section 211 is formed. Material portions 200’, 216’, 220’, 224’ and 213’ may be seen as a first region of main portion 62 from which base section 200, lower section 216, tangential abutment section 220, lower extension section 224 and lower clamping section 213 are formed, respectively. Material portions 206’, 208’, 210’ and 211 ’ may be seen as a second region of main portion 62 from which the base clamping section 206, inner axial holding tab 208, outer axial holding tab 210 and upper clamping section 211 are formed, respectively.

[0060] The thin metal strip 64, from which active retraction element 230 is formed, extends along main portion 62 of material blank 60. The metal strip 64 includes a first lengthwise end which is connected to and extends from the main portion 62 of material blank 60, and a second (distal) lengthwise end. Because the length of the metal strip 64 exceeds half the length of main portion 62 of material blank 60 and extends a majority of the length L of the main portion 62, positioning the second lengthwise end of the thin metal strip 64 so that it is does not extend beyond the corresponding lengthwise end of main portion 62 of material blank 60 results in the first lengthwise end of thin metal strip 64 being connected to the material portion 220’ of the main portion 62 from which the tangential abutment section 220 is formed. The positioning of the thin metal strip 64 relative to the main portion 62 of material blank 60 in this way reduces the overall size and / or footprint of material blank 60 thereby resulting in more blanks 60 being available on a metal sheet and / or less unused space on the metal sheet.

[0061] As shown in FIGS. 8-10, the metal strip 64 forms an oblique angle with the main portion 62. In an example embodiment, the metal strip 64 forms an angle a that is between 15 degrees and 75 degrees, such as between 15 and 45 degrees or between 15 and 25 degrees. In an example embodiment, the oblique angle a is 15 degrees as depicted in FIG. 8. FIG. 9 illustrates the angle a at 45 degrees, and FIG. 10 illustrates the angle a at 75 degrees. It is understood that the angle a formed between the metal strip 64 and the main portion 62 of the material blank 60may be any angle between and including 15 degrees and 75 degrees. An advantage of the metal strip 64 disposed at an oblique angle relative to the main portion 62 of the material blank 60 is that the material portion 208’ from which the outer axial holding tab 210 is formed may extend further in the lateral direction as needed in order to provide an improved clamping function of the clamping section 211 to the anchor bracket 108.

[0062] In addition, the metal strip 64, which is used to form the active retraction element 230, is disposed along a lengthwise side of main portion 62 of material blank 60 by having the material portion 232’ of metal strip 64 (from which connection section 232 of the active retraction element 230 is formed) with only a single curved portion, which in this case is the above-discussed oblique angle between 15 and 75 degrees. This single curved portion also results in sections of the active retraction element 230 (i.e., spring section 236, flat link section 238 and contact section 240) being disposed or aligned in the axial direction with each other following formation of brake slide clip 102.

[0063] As shown in FIG. 8, the metal strip 64, and thus the active retraction element 230 formed thereby, decreases in width near material portion 232’ which results in a majority portion of the spring section 236 having a width that is less than a width of the connection section 232.

[0064] A method of forming brake slide clip 102 from material blank 60 may include a series of bending and / or folding operations on the main portion 62 of the material blank 60 to form and / or create the relative positioning of the base section 200, the base clamping section 206, the inner axial holding tab 208, the outer axial holding tab 210, the radial holding tab 212, the lower section 216, the tangential abutment 220 and the extension section 224. The bending operations typically form 90 degree curved portions, though it is understood that bending operations which result in curves other than 90 degree curves are possible.

[0065] Forming the active retraction element 230 from material blank 60 also includes a series of bending and / or folding operations on the thin metal strip 64. The bending operations may include bending the material portion 232’ of the metal strip 64 along a bend axis that is at the oblique angle a relative to the main portion 62, which results in the connection section 232 being at least partly in a plane that is disposed at a non-zero angle relative to a tangential plane formed by radial and tangential axes and extending in the tangential direction. The bendingoperations to form the spring section 236 may include bending a first portion of the spring section 236 to have a 90 degree curve (curved portion 234) in the axial direction, bending a second portion of the spring section 236 to have a 90 degree curve (curved portion 242) in the radial direction, bending a third portion of the spring section 236 in the axial and radial directions to form curved portion 244, and bending a fourth portion of the spring section 236 in the axial direction to form curved portion 246. Bending the distal end of the thin metal strip 64 to have a 90 degree curve in the radial direction forms contact section 240 from the flat link section 238. With the exception of the bending to form the connection section 232, the bending operations for forming the active retraction element 230 from the thin metal strip 64 do not bend the thin metal strip 64 in the tangential direction. In the disclosed example embodiments, the material blank 60 having the thin metal strip 64 at a 15 degree angle as shown in FIG. 8 results in the brake slide clip 102A, 102B as shown in FIGS. 3-5 and 6A. The blank 60 having the thin metal strip 64 at a 45 degree angle as shown in FIG. 9 results in the brake slide clip 102A, 102B as shown in FIG. 6B, and the blank 60 having the thin metal strip 64 at a 75 degree angle as shown in FIG. 10 results in the brake slide clip 102A, 102B as shown in FIG. 6C.

[0066] With brake slide clips 102A and 102B operably disposed in the brake assembly 100 as described above, a brake pad 110 or 112 coupled to and disposed on a corresponding pair of the brake slide clips 102 are caused to move in a first axial direction during a braking operation, toward the corresponding brake rotor so as to make contact therewith. Due to contact between the brake pad 110 or 112 with the contact section 240 of each corresponding brake slide clip 102A, 102B, this brake pad movement causes the active retraction element 230 to similarly move in the same axial direction. Upon completion of the braking operation, the force which caused the movement of the brake pad 110 or 112 is removed, which results in the active retraction element 230 returning to its retracted position by moving in a second axial direction that is opposite to the first axial direction. Contact section 240 likewise pulls the now disengaged brake pad 110 or 112 to move in this second axial direction so that the brake pad is retracted from and no longer contacts the brake rotor, thereby avoiding brake drag.

[0067] The use of the brake slide clips 102 as discussed above assists in avoiding undesirable brake drag caused by brake pad-to-rotor contact. The active retraction elementprovides brake pad retraction away from rotor post brake application. The active retraction element is configured to provide a nearly constant retraction force over the pad wear and rotor wear. The constant retraction force is achieved by the geometry and cut-outs of the spring section 236 of the active retraction element 230. In addition, the blank shape of the clip is enhanced in order to reduce scrap sheet metal when stamping the material blanks 60 from a metal sheet, and increases the yield of the metal sheet.

[0068] The above description is intended to be illustrative, and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. Embodiments discussed in different portions of the description or referred to in different drawings can be combined to form additional embodiments of the present application. The scope should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

CLAIMS1. A brake slide clip (102B, 102A, 102) for use in a disc brake assembly (100) comprising: a base section (200) having a first side and a second side opposite the first side; a clamping portion (202) extending from the first side of the base section (200), the clamping portion (202) comprising a base clamping section (206), an inner axial holding tab (208) which extends from a first side of the base clamping section (206), and an outer axial holding tab (210) which extends from a second side of the base clamping section (206) that is opposite the first side thereof, the clamping portion (202) configured to clamp to a portion of an anchor bracket (108) of the disc brake assembly (100); a lower section (216) which extends from the second side of the base section (200), the lower section (216) having a first side which extends from the base section (200) and a second side; a tangential abutment section (220) extending from the second side of the lower section (216); and an active retraction element (230) which extends from the tangential abutment section (220), the active retraction element (230) including a flat link section (238) providing a first surface on which a brake pad (112, 110) of a disc brake is disposed, a contact section (240) providing a second surface against which the brake pad (112, 110) is disposed, a spring section (236) coupled to the flat link section (238), the active retraction element (230) disposed at least partly over the lower section (216), and a connection section (232) connected between the spring section (236) and the tangential abutment section (220), wherein a distance between a lower portion (232LP) of the connection section (232) and the tangential abutment section (220) is shorter than a distance between an upper portion (232UP) of the connection section (232) and the tangential abutment section (220); wherein when the active retraction element (230) is coupled to the brake pad (112, 110), the active retraction element (230) is movable from a retracted position relative to the base section (200) and the lower section (216) responsive to movement of the brake pad (112, 110) presenting a force against the second surface of the contact section (240), and resiliently returnsto the retracted position upon a spring force acting on the flat link section (238) by the spring section (236) overcoming the force presented by the brake pad (112, 110).

2. The brake slide clip (102B, 102A, 102) of claim 1, wherein the lower section (216) is disposed perpendicular to the base section (200), and the tangential abutment section (220) is disposed perpendicular to the lower section (216), the lower section (216) extends from the base section (200) via a first curved portion (218) disposed between the lower section (216) and the base section (200).

3. The brake slide clip (102B, 102A, 102) of claim 1, wherein the flat link section (238) includes a first lengthwise end portion connected to the contact section (240) and a second lengthwise end portion connected to the spring section (236), and while the brake slide clip (102B, 102A, 102) is disposed in the disc brake assembly (100) and prior to engagement with the brake pad (112) (110), the flat link section (238) is positioned such that the first lengthwise end portion of the flat link section (238) is closer to the clamping portion (202) than the second lengthwise end portion is to the clamping portion (202), thereby allowing for the brake pad (112, 110) to be received on and engaged with the flat link section (238) during insertion in the disk brake assembly.

4. The brake slide clip (102B, 102A, 102) of claim 1, wherein the active retraction element (230) applies a first lift force in a radial direction when the active retraction element (230) is coupled to the brake pad (112, 110) in the disc brake assembly (100).

5. The brake slide clip (102B, 102A, 102) of claim 4, further comprising an extension section (224) which extends from the tangential abutment section (220) via a curved portion (226), wherein the brake pad (112, 110) is disposed on a distal end portion of the extension section (224), and wherein the extension section (224) applies a second lift force in the radialdirection on the brake pad (112, 110) when the brake slide clip (102B, 102 A, 102) is engaged therewith in the disc brake assembly (100).

6. The brake slide clip (102B, 102A, 102) of claim 1, further comprising an extension section (224) which extends from the tangential abutment section (220) via a curved portion (226), wherein the brake pad (112, 110) is disposed on a distal end portion of the extension section (224), and wherein the curved portion (226) and the extension section (224) includes a cutout (280) defined therein, the cutout (280) is centrally located in a lateral direction along the brake slide clip (102B, 102A, 102).

7. The brake slide clip (102B, 102A, 102) of claim 1, wherein the brake slide clip (102B, 102A, 102) is formed from a blank material (60) having a main metal portion corresponding to the base section (200), the clamping portion (202), the lower section (216) and the tangential abutment section (220), and a metal strip corresponding to the active retraction element (230), and wherein a longitudinal axis of the metal strip is disposed at an angle between 15 degrees and 75 degrees relative to a lengthwise side of the main metal portion.

8. The brake slide clip (102B, 102A, 102) of claim 7, wherein the angle between the longitudinal axis of the metal strip and a lengthwise side of the main metal portion is between 15 degrees and 25 degrees.

9. The brake slide clip (102B, 102A, 102) of claim 1, wherein the spring section (236) of the active retraction element (230) includes at least one cutout (248) and the spring section (236) undergoes elasto-plastic deformation when the active retraction element (230) is moved in an axial direction from the retracted position during a braking operation.

10. The brake slide clip (102B, 102A, 102) of claim 1, wherein the spring section (236) includes a plurality of curved portions, the curved portions align sections of the active retraction element (230) relative to each other in an axial direction.

11. The brake slide clip (102B, 102A, 102) of claim 1, wherein a majority of the connection section (232) is in a plane that is disposed at a non-zero angle to a plane formed by radial and tangential axes of the brake slide clip (102B, 102A, 102).

12. A method of forming a brake slide clip (102B, 102A, 102) for a disc brake assembly (100), comprising: obtaining a material blank (60) having a main metal portion (62) and a metal strip (64) extending at an angle between 15 degrees and 75 degrees from a lengthwise side of the main metal portion (62); defining a base section (200), a lower section (216), a tangential abutment section (220) and a lower clamping section (213) from a first region of the main metal portion (62) by bending the lower section (216) relative to the base section (200), bending the tangential abutment section (220) relative to the lower section (216), and bending the lower clamping section (213) relative to the base section (200), the lower section (216) extending from the base section (200) via a first curved portion (218), and the tangential abutment section (220) extending from the lower section (216) via a second curved portion (222), and the lower clamping section (213) extending from the base section (200) via a third curved portion (204); defining a base clamping section (206), an upper clamping section (211), an inner axial holding tab (208), and an outer axial holding tab (210) from a second region of the main metal portion by bending opposed lateral end portions of the second region so as to form the inner and outer axial holding tabs, bending the base clamping section (206) relative to the lower clamping section (213), and bending the upper clamping section (211) relative to the base clamping section (206); anddefining an active retraction element (230) by bending the metal strip relative to the tangential abutment section (220) in a plurality of bending operations so that portions of the active retraction element (230) are aligned with each other in an axial direction.

13. The method of claim 12, wherein each bending operation of the plurality of bending operations of the metal strip bends the metal strip in a single direction.

14. The method of claim 12, wherein the metal strip extends from the lengthwise side of the main metal portion at an angle between 15 degrees and 25 degrees.

15. The method of claim 12, wherein the metal strip includes a material portion for a connection section (232) of the active retraction element (230) which extends directly from the tangential abutment section (220), and forming the active retraction element (230) comprises bending the material portion for the connection section (232) of the active retraction element (230) so that in the brake slide clip (102B, 102A, 102), a lower portion (232LP) of the connection section (232) is closer to the tangential abutment section (220) than an upper portion (232UP) of the connection section (232).

16. The method of claim 12, wherein the metal strip includes a material portion for a connection section (232) of the active retraction element (230) which extends directly from the tangential abutment section (220), and forming the active retraction element (230) comprises bending the material portion for the connection section (232) of the active retraction element (230) so that a majority of the connection section (232) is in a plane that is disposed at a nonzero angle to a plane that extends in a tangential direction formed by radial and tangential axes of the brake slide clip (102B, 102A, 102).

17. The method of claim 12, wherein the metal strip comprises at least one cutout (248) and the spring section (236) undergoes elasto-plastic deformation when the active retraction element (230) is moved in an axial direction during a braking operation when the brake spring clip is engaged with a brake pad (112, 110) in a disc brake assembly (100).

18. The method of claim 12, wherein prior to performing the bending operations, the metal strip is disposed along the lengthwise side of the main portion and has a first lengthwise end which extends from the lengthwise side of the main metal portion and a second lengthwise end which does not extend further than a lengthwise end of the main metal portion.

19. The method of claim 12, wherein the active retraction element (230) includes a flat link section (238) configured to contact a brake bad, the flat link section (238) includes a first lengthwise end portion and a second lengthwise end portion, and while the brake slide clip (102B, 102A, 102) is disposed in the disc brake assembly (100) and prior to engagement with the brake pad (112, 110), the flat link section (238) is positioned such that the first lengthwise end portion of the flat link section (238) is closer to the clamping portion (202) than the second lengthwise end portion is to the clamping portion (202), thereby allowing for the brake pad (112, 110) to be received on and engaged with the flat link section (238) during insertion in the disk brake assembly.

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