Cable actuated disc brake system

Abstract

To provide high braking performance at a more affordable cost than hydraulic disc brakes by combining mechanical advantage and control cable technology.SOLUTION: The present invention relates to a cable actuated disc brake system (100) that is designed to address mismatching of the performance and cost between drum brakes and hydraulic disc brakes. Utilizing a floating caliper design, the system (100) allows engagement of one brake pad to trigger a caliper (101) to float and engage with the other pad. The system uses components such as a caliper (101), a caliper cap (102), a cam lever (103), an upper cam (104), a lower cam (105), a spherical rollers (106), an adjuster (107), a piston (108), a spring (109), multiple mounting bolts (110), and a dust cap (111), to combine mechanical advantage and control cable technology.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] (Introduction to the specification) The following specification particularly describes the invention and the manner in which it must be practiced.

[0002] The present invention relates to brakes designed for motorcycles. In particular, the present invention relates to a cable actuated disc brake system that utilizes a mechanical mechanism actuated by a control cable. The innovative system produces variable power output and provides highly efficient braking for motorcycles. [Background technology]

[0003] Braking systems are very important in ensuring safety and control of motorcycles. There are various types of braking systems, such as electromagnetic, friction, hydraulic, pneumatic, drum, and disc brakes. These systems work by absorbing energy from a moving system, typically through friction, to stop motion. Disc and drum brakes are the two main classifications based on the principle of operation. Disc brakes are directly connected to the front wheel, while drum brakes are mounted on the rear wheel. Traditional drum brakes are cost-effective but lack the desired performance and responsiveness. In contrast, hydraulic disc brakes offer superior performance but are often more costly and difficult to reach a broad market.

[0004] Among various braking systems, hydraulic disc brakes are widely used. A hydraulic disc brake system includes a brake rotor and brake pads that rotate with the wheel and are clamped by pressure from a piston. By utilizing a non-compressible fluid such as brake fluid, a hydraulic brake system effectively slows a vehicle by transmitting a force that engages the brake pads with the rotor.

[0005] However, hydraulic disc brake systems are associated with certain limitations. One of the drawbacks is the possible mess that comes with managing the hydraulic fluid. If a leak occurs, it can be difficult to address and may even pose a fire hazard. Furthermore, managing a hydraulic system can be costly due to the complexity and number of components involved.

[0006] To overcome the shortcomings of existing systems, several technologies have been developed over the decades to provide improved performance, easy to maintain and cost-effective braking systems.

[0007] Taiwan Patent No. I545052B, entitled "Brake System and Apparatus," discloses a braking system that includes a brake pad connected to a slider assembly that can move linearly within a guide. The slider assembly and the guide are coupled to a first brake. In addition, a second brake actuator is connected to the slider assembly, the guide, and the second brake. When the first brake is engaged, the slider assembly is pressed against the rotating braking surface. As a result, friction between the brake pad and the rotating braking surface causes the slider assembly to move within the guide and activate the second brake actuator. The second brake actuator then engages the second brake. Conversely, when the first brake is released, the slider assembly disengages from the rotating braking surface, releasing the second brake actuator, which then disengages the second brake.

[0008] Patent application US9126653B2, entitled "Straddle Type Vehicle Brake System and Straddle Type Vehicle," discloses a device for connecting a front disc and a rear drum to enhance braking performance and safety of a motorcycle. The device includes a shell, a brake connecting rod, a rear in-haul cable, a front in-haul cable, a steering rod, a balancer, and a connecting rod. The device effectively distributes braking force between the front disc brake and the rear drum brake to improve braking efficiency and reduce stopping distance. The device also helps to reduce skidding and drifting of the vehicle and maintains the center of gravity during braking. This enhances overall driving safety and reduces reliance on advanced driving skills.

[0009] China Utility Model No. 201124920, entitled "Hydraulic Related Braking System for Motorcycles," discloses a hydraulically coupled braking system specifically designed for motorcycles. The advanced system incorporates various major components, such as left and right side brake main pump assemblies, brake distribution delay valve assemblies, front and rear brake caliper assemblies, and a brake oil pump. By effectively controlling the initial braking time of both the front and rear wheels, the innovative system ensures a well-balanced distribution of braking force. The system achieves this by sensing the input pressure from the brake main pump through a valve. As a result, braking stability is greatly improved and safety is enhanced for the motorcycle as the system optimizes the coordination between the front and rear brake mechanisms.

[0010] None of the prior art provides a solution that bridges the gap between the limitations of traditional drum brakes and the high costs associated with hydraulic disc brakes. Thus, an innovative approach is needed to address the challenges faced by manufacturers and end users. The objective is to develop a practical, cost-effective braking system that provides optimal performance while ensuring accessibility to a wide range of users. Summary of the Invention

[0011] The present invention relates to a cable actuated disc brake system with several components that work together to provide efficient and reliable braking. The system includes a floating caliper that houses the internal mechanism and monitors the reaction force during braking. The caliper cap provides additional protection and safety for the internal components. The system incorporates a cam lever, an upper cam, and a lower cam to transmit the load and stroke, adjust the mechanical ratio, and convert the rotary motion into linear movement. Multiple spherical rollers in the upper and lower cams allow fine tuning of the braking system. An adjuster allows precise adjustment of the piston position to compensate for brake pad wear. The piston transmits the load that engages the brake pads with the disc rotor, and a spring assists in retracting the piston after the brake is released. Multiple mounting bolts ensure secure installation of the caliper and caliper cap, while a dust cap protects the system from water or dust ingress. These interconnected components together facilitate the operation of the cable actuated disc brake system to convert the applied force into an effective braking system.

[0012] When the brakes are applied, the front brake lever is depressed and the braking force is transmitted through a control cable to the cam lever. Rotation of the cam lever engages the upper cam, which pushes the lower cam axially. This movement is synchronized with a piston to bring one brake pad into contact with the disc rotor, generating the clamping force for effective braking. A spring allows the piston to retract upon brake release. A dust cover protects the system from dirt and debris. The process helps efficiently convert user-applied force into the required movement and clamping force for positive braking. [Brief description of the drawings]

[0013] [Figure 1] 1a-1k show cross-sectional views of various components of a system according to an embodiment of the present invention.

[0014] [Diagram 2] FIG. 2 shows a cross-sectional view of a system according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] To describe and illustrate the subject matter of the claimed invention, the following definitions are provided for certain terms that are used more clearly and concisely in the following description.

[0016] 1a-1k show cross-sectional views of various components of a system (100) for actuating a disc brake, according to various embodiments of the present invention. The system (100) includes a caliper (101) as shown in [FIG. 1a], which houses all the components in a mechanism and monitors the reaction force during braking.

[0017] Additionally, the system (100) includes an additional component known as the caliper cap (102), shown in FIG. 1b, that is specifically designed to enclose and protect the mechanism located within the caliper. By securely enclosing the mechanism, the caliper cap (102) ensures long life and optimal performance of the cable actuated disc brake.

[0018] Additionally, the system (100) is provided with another essential component, the cam lever (103) as shown in FIG. 1c. The cam lever (103) serves as a mechanism for transferring the load and stroke from the control cable to the brake system. Through its design, the cam lever (103) increases the load and stroke to a predetermined value, effectively increasing the force applied to the brake pads for efficient braking.

[0019] The system (100) further comprises an upper cam (104) as shown in FIG. 1d, which works in conjunction with the cam lever (103). The upper cam (104) converts the rotational motion generated by the cam lever (103) into a linear axial motion of the lower cam (105), which is shown in FIG. 1e. To achieve a variable mechanical advantage (MA), the upper cam (104) features a variable contact radius. This variability allows for precise adjustment and optimization of the braking force applied to the disc rotor. The lower cam (105) meshes with the upper cam (104) to facilitate the conversion of the rotational motion into linear motion through the use of three wedges. Similar to the upper cam (104), the lower cam (105) incorporates variable radius slots along the wedge faces to provide a variable mechanical advantage (MA) throughout its motion. This adjustability ensures that the brake system can adapt to varying braking requirements.

[0020] Yet another important component of the system (100), assembled between the wedges of the upper and lower cams, are a number of spherical rollers (106) as shown in FIG. 1f. The spherical rollers (106) change the contact radius by moving within slots in both the upper cam (104) and the lower cam (105). By adjusting the contact radius, the spherical rollers (106) provide fine tuning of the braking system, allowing precise control and modulation of the braking force.

[0021] The system (100) further includes an adjuster (107), as shown in FIG. 1g, and a piston (108), as shown in FIG. 1h. The adjuster (107) is specially designed to adjust the position of the piston (108) in relation to brake pad wear. As the brake pads wear over time, the adjuster (107) allows for precise adjustment to compensate for changes in brake pad thickness. By ensuring optimal positioning of the piston (108), the adjuster (107) helps maintain consistent braking performance and extends the overall life of the brake system.

[0022] The piston (108) plays a vital role in the cable actuated disc brake system (100) by transferring the load from the cam to the brake pads. When engaged, the piston (108) applies the necessary force to bring the brake pads into contact with the disc rotor to provide effective braking.

[0023] The system (100) incorporates a spring (109) as shown in [FIG. 1i] that aids in the return of the piston (108) after the brake is released. When the brake is no longer applied, the spring (109) aids in the return of the piston (108) to its initial position. By exerting a force in the opposite direction, the spring (109) ensures that the brake pads disengage from the disc rotor, allowing smooth rotation and preventing unwanted rubbing. The role of the spring (109) in retraction contributes to the overall efficiency and functionality of the cable actuated disc brake.

[0024] The system (100) further comprises a number of mounting bolts (110) as shown in FIG. 1j to ensure structural integrity and secure mounting of the components. The mounting bolts (110) are specially designed to join the caliper (101) and caliper cap (102) together. By securely connecting these components, the mounting bolts (110) provide stability and strength to the brake assembly. The presence of these bolts ensures that the caliper (101) and caliper cap (102) remain securely fastened, allowing for consistent and reliable operation of the cable actuated disc brake system (100).

[0025] The system (100) further comprises a protective component known as the dust cap (111) as shown in FIG. 1k. The dust cap (111) plays a vital role in protecting the brake mechanism from damage that may be caused by the ingress of water and dust. By preventing the ingress of external elements, the dust cap (111) helps maintain the integrity of the internal components. The dust cap contributes to the long-term reliability and performance of the system (100) by reducing the risk of contamination and potential wear and tear. Furthermore, the dust cap (111) ensures that the system (100) remains well protected and operates optimally under various environmental conditions.

[0026] Referring now to FIG. 2, a cross-sectional view of a cable actuated disc brake system (100) is depicted, which comprises interconnected components that work seamlessly to facilitate the operation of the cable actuated disc brake. A floating caliper (101) houses the mechanism and monitors the reaction forces, while a caliper cap (102) encloses and protects the internal components. A cam lever (103) transmits load and stroke, which is further translated by an upper cam (104) into a linear axial movement of a lower cam (105), thereby adjusting the mechanical advantage through a variable contact radius and slot. Spherical rollers (106) within the upper cam (104) and lower cam (105) vary the contact radius, while an adjuster (107) adjusts the position of a precise piston (108) to compensate for brake pad wear. The piston (108) efficiently transfers load to engage the brake pads and disc rotor, and a spring (109) assists in retracting the piston after the brake is released. A number of mounting bolts (110) ensure a secure fit between the caliper (101) and caliper cap (102), and a dust cap (111) provides protection against water and dirt to maintain the integrity of the brake mechanism. Together, these interconnected components synergistically enable reliable and efficient operation of the cable actuated disc brake system (100).

[0027] In one embodiment, when a user applies the brakes using the cable actuated disc brake system (100), the front brake lever is depressed to initiate the transmission of braking force and stroke through the control cable. This motion initiates the rotation of the cam lever (103). As the cam lever (103) rotates, it engages the upper cam (104) which in turn pushes the lower cam (105) axially. This axial movement of the lower cam (105) is synchronized with the movement of the piston (108). Thus, one of the brake pads comes into contact with the disc rotor. When force is then transmitted to the brake pads, a clamping force required for effective braking is generated, allowing the brake pads to grip the disc rotor tightly. When the brake is released, the spring (109) urges the piston (108) back to its initial position. Additionally, a dust cap (111) secured to the cam lever (103) protects the system (100) from dirt and debris to ensure optimal performance. Through this process, the cable actuated disc brake system (100) efficiently converts user applied force into the necessary movement and clamping forces for positive braking.

[0028] The present invention discloses a system (100) that efficiently converts the force applied by the user into the precise travel and clamping forces required for reliable braking. This efficient conversion ensures that the braking mechanism operates efficiently and provides the desired level of performance and safety. Additionally, the system (100) is designed with the goal of maintaining optimal performance and extending the life of the braking system by effectively preventing the ingress of dirt and debris. [Explanation of symbols]

[0029] (Components...Reference numbers) System…100 Caliper…101 Caliper cap...102 Cam lever…103 Upper cam...104 Lower cam...105 Spherical roller...106 Adjuster...107 Piston…108 Spring...109 Mounting bolts: 110 Dust cap...111

Claims

1. 1. A cable actuated disc brake system comprising:

1. A system (100) comprising a cam lever (103) rigidly connected to an upper cam (104) connected to a lower cam (105) featuring a plurality of variable radius grooves along a wedge surface by a plurality of spherical rollers (106) positioned within said grooves to form an interconnection mechanism for translating rotational motion of said cam lever (103) into linear axial movement of said lower cam (105).

2. 2. The system (100) of claim 1, wherein the cam lever (103) is coupled to the user-actuated brake lever via a control cable that facilitates the transmission of a braking force from the user-actuated brake lever to the cam lever (103) whenever the user-actuated brake lever is depressed.

3. 2. The system (100) of claim 1, wherein the internal components of the system (100) are housed within a floating caliper (101), the floating caliper being further protected by a caliper cap (102) for protection from external corrosive and erosive agents.

4. 2. The system (100) of claim 1, wherein the varying contact radius of the plurality of spherical rollers (106) seated in the variable radius grooves of the lower cam (105) facilitates tuning and optimization of the braking force applied to a disk rotor, thereby enabling the system (100) to achieve a variable mechanical advantage (M.A.) throughout operation.

5. 2. The system (100) of claim 1, wherein the lower cam (105) moves axially with a piston (108) disposed between the lower cam (105) and the brake pads to transfer load from the cam lever (103) to the brake pads and facilitate effective engagement of the brake pads with a disc rotor to ensure efficient braking.

6. 2. The system (100) of claim 1, wherein the plurality of variable radius grooves between the lower cam (105) and the upper cam (104) are designed to accommodate movement of the plurality of spherical rollers (106) to allow fine tuning of the system (100) and facilitate control of braking force.

7. 2. The system (100) of claim 1, wherein the position of the piston (108) in response to brake pad wear is adjusted by an adjuster (107) assembled to the lower cam (105) using a fixing mechanism that maintains a contact gap between the disc rotor and the brake pad, thereby enabling the system (100) to achieve optimal braking force.

8. 2. The system (100) of claim 1, wherein retraction of the piston (108) after release of the brake pads is assisted by a spring (109) assembled between the piston (108) and the caliper (101) to facilitate disengagement of the brake pads from the disc rotor for smooth rotation and to aid in the return of the piston (108) to its initial position.

9. 2. The system (100) of claim 1, wherein the structural integrity of the system (100) is ensured by securely attaching the floating caliper (101) and the caliper cap (102) with a plurality of mounting bolts (110).

10. 10. The system (100) of claim 1, wherein the system (100) incorporates a dust cap (111) as a protective measure to protect the brake mechanism from external corrosive and erosive agents.

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