Hydraulic disc brake caliper used in a vehicle

Abstract

The present invention relates to a hydraulic disc brake caliper for automotive applications. It enables the manufacture of radially and axially mounted hydraulic disc brakes for passenger cars, commercial vehicles and armored vehicles, using a common casting and machining tooling design.

Description

Title of the invention: HYDRAULIC DISC BRAKE CALIPER USED IN A VEHICLE Technical field

[0001] The present invention relates to a hydraulic disc brake caliper for automotive applications. It enables the manufacture of radially and axially mounted hydraulic disc brakes for passenger cars, commercial vehicles, and armored vehicles, using a common casting and machining tooling. Prior art

[0002] Hydraulic disc brake calipers are essential components of modern vehicle braking systems, as they are crucial for generating and transmitting braking torque to the wheels. The hydraulic braking system operates by delivering pressurized hydraulic fluid to the calipers in response to the input force applied by the driver to the brake pedal. This force is often amplified by a pressurization system, such as a brake booster or a pneumatic brake booster. The resulting hydraulic pressure is transmitted to the pistons inside the caliper, which push the brake pads against the brake disc. The contact between the pads and the disc generates friction, creating braking torque and reducing the rotational speed of the wheels.

[0003] According to the current state of the art, mounting a radial hydraulic disc brake on an axle designed for axial mounting generally requires an additional mounting bracket and bolts. This solution involves separate investments in casting patterns and machining tools for the bracket and bolts, resulting in increased product cost, axle weight, and assembly and maintenance costs.

[0004] Furthermore, radial and axial mounting systems are often designed as separate products, requiring separate investments in casting patterns and machining tools for each type. This results in increased product complexity and reduced production efficiency. Currently, there is no hydraulic caliper design that uses a common casting pattern suitable for both radial and axial mounting configurations.

[0005] Consequently, in view of the aforementioned disadvantages and the inadequacy of existing solutions in this area, a development in the relevant technical field has become necessary. Purpose of the invention

[0006] The main object of the invention is to enable the production of radially and axially mounted hydraulic disc brakes using a common casting pattern and machining device.

[0007] Another object of the invention is to eliminate the need for a separate mounting bracket and the bolts required to attach the hydraulic brake to such a bracket.

[0008] Another object of the invention is to facilitate the production of axial calipers with different mounting bores, achieved through the innovative design of the caliper half, allowing direct attachment to the axle end. This design generates significant advantages in terms of cost and weight.

[0009] The structural and functional features of the invention, as well as its advantages, will be better understood from the accompanying figures and the detailed description. Therefore, the evaluation of the invention should be carried out taking into account these figures and

[0010] FIGURES TO FACILITATE UNDERSTANDING OF THE INVENTION

[0011] Fig. 1 is a perspective view of the hydraulic disc brake caliper according to the invention;

[0012] [Fig.2] is a perspective view of the hydraulic disc brake caliper at the end of the axle according to the invention;

[0013] [Fig.3] is a front perspective view of the molded part of the inner half of the stirrup according to the invention;

[0014] [Fig.4] is a rear perspective view of the molded part of the inner half of the stirrup according to the invention;

[0015] [Fig.5] is a front view of the molded part of the inner half of the stirrup according to the invention;

[0016] [Fig.6] is a rear view of the molded part of the inner half of the stirrup according to the invention;

[0017] [Fig.7] is a perspective view of the machined inner half of the stirrup suitable for axial fixing, according to the invention;

[0018] [Fig.8] is a cross-sectional view of the stirrup with axial fixing according to the invention;

[0019] [Fig.9] is a perspective view of the inner half of the stirrup which is machined for an alternative axial fixation according to the invention;

[0020] [Fig. 10] is a cross-sectional view of the stirrup with the alternative axial fixing according to the invention;

[0021] [Fig.1 1] is a perspective view of the inner half of the stirrup machined for radial attachment according to the invention;

[0022] [Fig. 12] is a view of the radially mounted brake according to the prior art;

[0023] [Fig. 13] is a view of the brake mounted axially according to the prior art. Explanation of part numbers

[0024] Hydraulic disc brake

[0025] 1.1 Inner half of stirrup

[0026] 1.1.1 Fixing boss

[0027] 1.1.2 Piston housing

[0028] 1.1.3 Fixing bolt boss

[0029] 1.1.4 Reinforcement

[0030] 1.1.5 Mounting hole

[0031] 1.1.6 Rear extension of the fixing boss

[0032] 1.2 Outer half of stirrup

[0033] 1.3 Piston

[0034] 1.4 Sealing gasket

[0035] 1.5 Brake pad

[0036] 1.6 Wafer pin

[0037] 1.7 Caliper fixing bolt

[0038] 1.8 Brake pad spring

[0039] 1.9 Purge valve

[0040] 1.10 Split pin

[0041] 2. Mounting plate

[0042] 3. Fixing bolt

[0043] 4. Brake disc DETAILED DESCRIPTION OF THE INVENTION

[0044] In this detailed description, the preferred configurations of the innovation relating to the hydraulic disc brake caliper used in vehicles, which is the subject of the invention, are explained in order to facilitate a better understanding of the concept.

[0045] As illustrated in [Fig. 2], the invention comprises a hydraulic disc brake (1), a mounting plate (2), mounting bolts (3), and a brake disc (4). The hydraulic disc brake (1) is attached to the end of the vehicle axle by the axle end mounting plate (2) and the mounting bolts (3). The hydraulic disc brake (1) comprises an inner caliper half (1.1), an outer caliper half (1.2), pistons (1.3), seals (1.4), brake pads (1.5), pad pins (1.6), caliper mounting bolts (1.7), pad springs (1.8), bleed valves (1.9), and cotter pins (1.10).

[0046] According to the prior art illustrated in [Fig. 12] and [Fig. 13], the hydraulic disc brake (1) can be attached to the axle end radially or axially along the bolt fixing axis. The invention relates to the molding design of an inner half of the caliper (1.1) common to both types of mounting. Thanks By machining the inner caliper half (1.1) molded for radial and axial mounting, hydraulic disc brakes (1) with radial and axial mounting are obtained. To be machined from the same molded part, the inner caliper halves (1.1) compatible with radial and axial mounting, elliptical mounting bosses (1.1.1) and rear extensions of mounting bosses (1.1.6) are located on the front and rear faces of the inner caliper half.

[0047] The mounting bosses (1.1.1) and rear extensions of the mounting bosses (1.1.6) are integrated into the inner half of the caliper (1.1) by molded surfaces supporting piston housings (1.1.2) and mounting bolt bosses (1.1.3). Between the mounting bosses (1.1.1) and the mounting bolt bosses (1.1.3), a prismatic stiffener (1.1.4) is positioned, which widens towards the mounting bosses (1.1.1). This stiffener (1.1.4) reduces stresses in the mounting area under braking loads. Furthermore, conical or misaligned wear of the brake pads (1.5) is prevented by increasing the rigidity of the caliper. Thanks to the elliptical shape of the mounting bosses (1.1.1), the mounting holes (1.1.5) located on the caliper's axle end plate can be moved up and down by machining. This gives the product great flexibility for use on different vehicles.

[0048] As illustrated in [Fig. 8], this is an axially mounted axle end configuration with threaded holes on the axle end mounting plate (2). The axle end mounting plate (2) is located closer to the median plane of the brake. In axially mounted axle end configurations where the axle end mounting plate (2) does not have threaded holes, the threads for screws must be located on the inner caliper housing, as illustrated in [Fig. 10]. To this end, the rear extensions of the mounting bosses (1.1.6), located beyond the mounting bosses (1.1.1) in the molded model of the inner caliper half (1.1), extend inward, where the brake pads (1.5) are located.

[0049] Since the casting pattern for the inner caliper half (1.1) is common, no additional investment in manufacturing casting patterns and specific machining tools for radially and axially mounted inner caliper halves is required. Furthermore, the brackets and mounting components for connecting the brakes to the axle end plates with axial mounting interface are unnecessary. This results in advantages in terms of product cost, weight per axle, assembly operations, and maintenance. Thanks to this invention, the weight saving reaches 1.9 kg per axle end (15%) compared to the prior art solution with the mounting bracket illustrated in [Fig. 12]. Moreover, a weight reduction of up to 6.7 kg per axle end (38%) is achieved compared to the axial mounting of the prior art illustrated in [Fig. 13].

Claims

Demands

1. Hydraulic disc brake caliper (1) designed to allow the production of radially and axially mounted hydraulic disc brakes for passenger vehicles, commercial vehicles and armored vehicles using a common casting pattern and machining device, comprising: - an inner caliper half (1.1), configured to allow radial and axial mountings by machining hydraulic disc brakes (1) with radial mounting; - mounting bosses (1.1.1), of elliptical shape, allowing the inner caliper half (1.1) to be machined for radial and axial mountings from the same casting; - rear extensions of the mounting bosses (1.1.6), extending from the mounting bosses (1.1.1) and structurally connecting the inner half of the caliper (1.1) to the piston housings (1.1.2) and the mounting bolt bosses (1.1.3) via the molding surfaces.

2. Hydraulic disc brake caliper (1) according to claim 1, characterized in that: - the fixing bosses (1.1.1) and the rear extensions of the fixing bosses (1.1.6) include stiffeners (1.1.4), configured to reduce stresses in the fixing area under braking loads.

3. Hydraulic disc brake caliper (1) according to claim 1, characterized in that: • the fixing bosses (1.1.1) and the rear extensions of the fixing bosses (1.1.6) include fixing holes (1.1.5), the vertical position of which can be adjusted by machining, thanks to the elliptical shape of the fixing bosses (1.1.1) and the rear extensions of the fixing bosses (1.1.6), thus offering flexibility for various vehicle applications.

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