Brake caliper

Abstract

To provide a brake caliper capable of improving rigidity of mounting as one example.SOLUTION: A brake caliper according to an embodiment includes: a piston; a caliper body for movably supporting the piston; and a mounting which includes an inner mounting arranged inward in a vehicle width direction relative to a disc rotor, an outer mounting arranged outward in the vehicle width direction relative to the disc rotor and having a length longer than that of the inner mounting in a circumferential direction around the center axis of rotation of the disc rotor and a mounting bridge for connecting the inner mounting and the outer mounting, and movably supports the caliper body.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] SUMMARY OF THE DISCLOSURE An embodiment of the present invention relates to a brake caliper. [Background technology]

[0002] Conventionally, a brake caliper has, for example, a mounting that is attached to the vehicle body straddling the disc rotor, two brake pads and a caliper body supported by the mounting, and a piston supported by the caliper body. The piston presses one of the two brake pads, and the claw of the caliper body presses the other of the two brake pads due to the reaction force of the piston (Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2009-074634 A Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the conventional configuration, the inner portion of the mounting in the vehicle width direction is attached to the vehicle body. That is, the inner portion of the mounting in the vehicle width direction is fixed to the vehicle body, and therefore has high rigidity. On the other hand, the outer portion of the mounting in the vehicle width direction is not fixed to the vehicle body, and therefore tends to have lower rigidity than the inner portion in the vehicle width direction.

[0005] Therefore, the present invention has been made in consideration of the above, and provides a brake caliper that can improve the rigidity of the mounting. [Means for solving the problem]

[0006] A brake caliper according to an embodiment of the present invention includes, as an example, a piston, a caliper body that movably supports the piston, an inner mounting configured to be disposed inward of a disc rotor in the vehicle width direction, an outer mounting configured to be disposed outward of the disc rotor in the vehicle width direction and longer than the inner mounting in the circumferential direction around the central axis of rotation of the disc rotor, and a mounting bridge that connects the inner mounting and the outer mounting, and a mounting that movably supports the caliper body. Therefore, as an example, the outer mounting is long in the circumferential direction, and therefore the rigidity can be improved. That is, the brake caliper according to this embodiment can improve the rigidity of the mounting. [Brief description of the drawings]

[0007] [Figure 1] FIG. 1 is a perspective view showing a disc brake device according to one embodiment. [Diagram 2] FIG. 2 is a front view showing the disc brake device of the embodiment. [Diagram 3] FIG. 3 is a cross-sectional view showing a part of the disk rotor of the embodiment. [Figure 4] FIG. 4 is a cross-sectional view showing a schematic view of a part of the disc brake device according to the embodiment, taken along line F4-F4 in FIG. [Diagram 5] FIG. 5 is a perspective view showing the mounting of the embodiment. [Figure 6] FIG. 6 is a cross-sectional view showing a part of the brake caliper of the above embodiment taken along line F6-F6 in FIG. [Figure 7] FIG. 7 is a perspective view showing the caliper body of the embodiment. [Figure 8] FIG. 8 is a cross-sectional view showing the caliper body of the above embodiment taken along line F7-F7 in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] An embodiment will be described below with reference to FIGS. 1 to 8. In this specification, components according to the embodiment and their descriptions may be described in a number of ways. The components and their descriptions are merely examples and are not limited by the expressions in this specification. The components may be identified by names different from those in this specification. The components may also be described by expressions different from those in this specification.

[0009] In the following description, "inhibit" is defined as, for example, preventing the occurrence of an event, action, or effect, or reducing the magnitude of an event, action, or effect.

[0010] Fig. 1 is a perspective view showing a disc brake device 10 according to this embodiment. The disc brake device 10 is mounted on a vehicle 1 such as a four-wheeled automobile. However, the disc brake device 10 is not limited to this example. As shown in Fig. 1, the disc brake device 10 has a disc rotor 11 and a brake caliper 12.

[0011] Fig. 2 is a front view showing the disc brake device 10 of this embodiment. The disc rotor 11 rotates integrally with the wheel of the vehicle 1 around a central axis Ax shown in Fig. 2. The central axis Ax is, for example, the central axis of an axle, and is also the central axis of the disc rotor 11 and the central axis of rotation of the disc rotor 11. Note that the central axis Ax is not limited to this example.

[0012] Hereinafter, for the sake of convenience, the axial direction, radial direction, and circumferential direction are defined. The axial direction is a direction along the central axis Ax. The radial direction is a direction perpendicular to the central axis Ax. The circumferential direction is a direction around the central axis Ax.

[0013] As shown in Fig. 1, the axial direction includes a first direction D1 and a second direction D2. The first direction D1 is a direction along the central axis Ax. The second direction D2 is the opposite direction to the first direction D1.

[0014] The first direction D1 substantially points to the outside in the vehicle width direction of the vehicle 1. The second direction D2 substantially points to the inside in the vehicle width direction of the vehicle 1. The vehicle width direction is the left-right direction of the vehicle 1. Note that the axial direction, the first direction, and the second direction are inclined with respect to the vehicle width direction according to the turning of the wheels.

[0015] Fig. 3 is a cross-sectional view showing a portion of the disc rotor 11 of this embodiment. As shown in Fig. 3, the disc rotor 11 is fixed to a hub 13 that supports a wheel. The hub 13 is rotatably supported by a knuckle 14 of a suspension that is supported on the body of the vehicle 1. The disc rotor 11 rotates integrally with the hub 13 and the wheel around a central axis Ax.

[0016] The disk rotor 11 has two side surfaces 11a. The side surfaces 11a are formed to be substantially flat and face in the axial direction. In other words, the central axis Ax extends in a direction perpendicular to the side surfaces 11a. The two side surfaces 11a are located opposite each other.

[0017] Fig. 4 is a cross-sectional view showing a part of the disc brake device 10 of this embodiment, taken along line F4-F4 in Fig. 2. As shown in Fig. 4, the brake caliper 12 has a mounting 21, two brake pads 22, two pistons 23, and a caliper body 24. Furthermore, as shown in Fig. 1, the brake caliper 12 has two guide pins 25. The caliper body 24 may also be referred to as a cylinder.

[0018] The mounting 21 is attached to the knuckle 14. In other words, the mounting 21 is fixed to the body of the vehicle 1. The mounting 21 supports two brake pads 22 and a caliper body 24 so that they are axially movably.

[0019] 5 is a perspective view showing the mounting 21 of this embodiment. As shown in FIG. 5, the mounting 21 has an inner mounting 31, an outer mounting 32, and two mounting bridges 33.

[0020] In this embodiment, the inner mounting 31, the outer mounting 32, and the mounting bridge 33 are integrally formed. The mounting 21 may be disassembled.

[0021] The inner mounting 31 is formed, for example, in a substantially H-shape that is open radially inward and outward. The inner mounting 31 has two inner support portions 41 and an inner bridge 42. The inner support portion 41 may also be referred to as a torque receiving portion.

[0022] The two inner support parts 41 are spaced apart from each other in the circumferential direction. Each of the two inner support parts 41 extends substantially in the radial direction. In other words, the two inner support parts 41 extend substantially parallel to each other. Each of the two inner support parts 41 has an attachment part 45 and a pad support part 46.

[0023] A through hole 47 is provided in the attachment portion 45. The through hole 47 passes through the attachment portion 45 in a substantially axial direction. For example, the attachment portion 45 is attached to the knuckle 14 by a bolt passing through the through hole 47. Note that the inner mounting 31 may be attached to the body of the vehicle 1 by other methods.

[0024] The pad support portion 46 extends radially outward from the mounting portion 45. The pad support portion 46 has an inner side surface 46a and an outer side surface 46b. The inner side surface 46a and the outer side surface 46b each face in the circumferential direction. The inner side surface 46a of one pad support portion 46 and the inner side surface 46a of the other pad support portion 46 face each other. A recess 48 is provided in the pad support portion 46. The recess 48 is recessed in the circumferential direction from the inner side surface 46a. The recess 48 penetrates the pad support portion 46 in the axial direction.

[0025] The inner bridge 42 extends approximately in the circumferential direction between the two inner support portions 41 and connects the two inner support portions 41. The inner bridge 42 is connected to a portion of the inner support portion 41 between the attachment portion 45 and the pad support portion 46.

[0026] The outer mounting 32 is spaced apart from the inner mounting 31 in the first direction D1. The outer mounting 32 is formed, for example, in a substantially U-shape that is open radially outward. The outer mounting 32 has two outer support portions 51, an outer bridge 52, and two extension portions 53. The outer support portion 51 may also be referred to as a torque receiving portion.

[0027] The two outer support parts 51 are spaced apart from each other in the circumferential direction. Each of the two outer support parts 51 extends substantially in the radial direction. In other words, the two outer support parts 51 extend substantially parallel to each other.

[0028] Each of the two outer support parts 51 has an inner side surface 51a. The inner side surface 51a faces the circumferential direction. The inner side surface 51a of one outer support part 51 and the inner side surface 51a of the other outer support part 51 face each other. A recess 58 is provided in the outer support part 51. The recess 58 is recessed in the circumferential direction from the inner side surface 51a. The recess 58 penetrates the outer support part 51 in the axial direction.

[0029] Each of the two outer support parts 51 further has an outer surface 51b and a bottom surface 51c. The outer surface 51b faces the first direction D1 as a whole. A recess 59 is provided in the outer surface 51b. The recess 59 is recessed from the outer surface 51b in the second direction D2. The bottom surface 51c is provided at an end of the recess 59 in the second direction D2 and faces the first direction D1 as a whole. The recess 58 opens to the bottom surface 51c.

[0030] The outer bridge 52 extends approximately in the circumferential direction between the two outer support parts 51 and connects the two outer support parts 51. The outer bridge 52 is connected to the ends of the outer support parts 51 on the inside in the radial direction.

[0031] The two extending portions 53 extend in the circumferential direction from the two outer support portions 51. The two extending portions 53 extend so as to be spaced apart from each other from the two outer support portions 51. Therefore, each of the two outer support portions 51 is located between the outer bridge 52 and the corresponding extending portion 53.

[0032] The two mounting bridges 33 connect the inner mounting 31 and the outer mounting 32. More specifically, the two mounting bridges 33 connect the two inner support parts 41 and the two outer support parts 51.

[0033] The mounting bridge 33 is connected to an end of the inner support part 41 and an end of the outer support part 51 on the radial outside, and extends substantially in the axial direction. That is, the two mounting bridges 33 are spaced apart from each other in the circumferential direction and extend substantially parallel to each other.

[0034] Each of the two mounting bridges 33 has an outer surface 33a and an outer peripheral surface 33b. The outer surface 33a faces in the circumferential direction. The outer surface 33a of the mounting bridge 33 and the outer surface 46b of the pad support portion 46 are, for example, integrated and form approximately the same plane. The outer peripheral surface 33b extends approximately in the circumferential direction and faces radially outward. Although the outer peripheral surface 33b is illustrated as a flat surface in FIG. 1, it may be a curved surface along the circumferential direction. The outer peripheral surface 33b is the portion of the mounting bridge 33 that is farthest from the central axis Ax.

[0035] The extension portion 53 of the outer mounting 32 extends in the circumferential direction from the outer support portion 51, beyond the outer surface 33a of the mounting bridge 33 and the outer surface 46b of the pad support portion 46. Therefore, the outer mounting 32 is longer in the circumferential direction than the inner mounting 31. Note that the outer surface 33a of the mounting bridge 33 may extend obliquely between the inner mounting 31, which is shorter in the circumferential direction, and the outer mounting 32, which is wider in the circumferential direction.

[0036] 4, the disc rotor 11 is located between an inner mounting 31 and an outer mounting 32. Therefore, the inner mounting 31 is disposed on the inner side of the disc rotor 11 in the vehicle width direction. Furthermore, the outer mounting 32 is disposed on the outer side of the disc rotor 11 in the vehicle width direction.

[0037] 1, the mounting bridge 33 extends substantially in the axial direction across the disc rotor 11 at a position spaced radially outward from the disc rotor 11. In other words, the mounting 21 is disposed so as to straddle the disc rotor 11.

[0038] As shown in Fig. 4, the two brake pads 22 are spaced apart from each other in the axial direction. The disc rotor 11 is located between the two brake pads 22. That is, the brake pad 22i, which is one of the two brake pads 22, is disposed on the inner side of the disc rotor 11 in the vehicle width direction. The brake pad 22o, which is the other of the two brake pads 22, is disposed on the outer side of the disc rotor 11 in the vehicle width direction.

[0039] The brake pad 22i is disposed between the two inner support parts 41. The pad support parts 46 of the two inner support parts 41 support the brake pad 22i movably in the axial direction. Furthermore, at least a portion of the brake pad 22i is spaced farther from the central axis Ax than the inner bridge 42.

[0040] The brake pad 22o is disposed between the two outer support parts 51. The two outer support parts 51 support the brake pad 22o movably in the axial direction. Furthermore, at least a portion of the brake pad 22o is spaced farther from the central axis Ax than the outer bridge 52.

[0041] The disc brake device 10 applies brakes to the disc rotor 11 and the wheel by pressing the brake pads 22 against a side surface 11a of the disc rotor 11. Each of the two brake pads 22 has a back plate 61, a friction material 62, and a shim 63.

[0042] The back plate 61 is disposed substantially perpendicular to the axial direction and is formed in a plate shape extending substantially in the circumferential direction. The back plate 61 has a mounting surface 61a and a back surface 61b. The mounting surface 61a faces the side surface 11a of the disc rotor 11. The back surface 61b is located on the opposite side to the mounting surface 61a.

[0043] Fig. 6 is a cross-sectional view showing a part of the brake caliper 12 of this embodiment taken along line F6-F6 in Fig. 4. As shown in Fig. 6, the back plate 61 has two end faces 61c and two protruding portions 61d.

[0044] The two end faces 61c are provided at both circumferential ends of the back plate 61. The end faces 61c face the inner side surface 46a of the pad support portion 46 of the inner support portion 41 or the inner side surface 51a of the outer support portion 51.

[0045] The two protrusions 61d protrude in the circumferential direction from the two end faces 61c. In other words, the two protrusions 61d are provided at both ends of the back plate 61 in the circumferential direction. The protrusion 61d of the brake pad 22i is fitted into the recess 48 of the pad support portion 46 of the inner support portion 41. The protrusion 61d of the brake pad 22o is fitted into the recess 58 of the outer support portion 51.

[0046] The brake caliper 12 further includes four pad supports 65 and two compression springs 66. The pad supports 65 and the compression springs 66 are an example of accessories. However, the accessories are not limited to the pad supports 65 and the compression springs 66.

[0047] The four pad supports 65 are fitted into the four recesses 48, 58 and attached to the mounting 21. Each pad support 65 is interposed between the protrusion 61d and the pad support portion 46 or between the protrusion 61d and the outer support portion 51.

[0048] A spring 65a is provided on the pad support 65. The spring 65a presses the protrusion 61d radially outward by elastic force. The spring 65a presses the protrusion 61d against the pad support 65, thereby holding the back plate 61 in the radial direction.

[0049] One of the two compression springs 66 is attached to the brake pad 22i. The other of the two compression springs 66 is attached to the brake pad 22o. The compression spring 66 is attached, for example, to the leading side convex portion 61d and contacts the pad support 65. The compression spring 66 presses the brake pad 22 in the circumferential direction by elastic force. The compression spring 66 presses the trailing side convex portion 61d against the pad support 65 to hold the back plate 61 in the circumferential direction.

[0050] 4, the friction material 62 is fixed to a mounting surface 61a of the back plate 61. The friction material 62 is located between the mounting surface 61a and the side surface 11a of the disc rotor 11. The shim 63 is attached to a back surface 61b of the back plate 61.

[0051] The pistons 23 are formed in a generally cylindrical shape extending in the axial direction. The two pistons 23 are spaced apart from each other in the circumferential direction. The shape and position of the pistons 23 are not limited to this example. The number of pistons 23 is not limited to two, and may be one, or three or more.

[0052] Fig. 7 is a perspective view showing the caliper body 24 of the present embodiment. As shown in Fig. 7, the caliper body 24 has a cylinder 71, a stopper 72, and a caliper bridge 73. The stopper 72 may also be referred to as a claw.

[0053] In this embodiment, the cylinder 71, the stopper 72, and the caliper bridge 73 are integrally formed. For example, the caliper body 24 is made of an aluminum alloy. The caliper body 24 may be disassembled.

[0054] The cylinder 71 has a block 81 and two support protrusions 82. As shown in Fig. 4, the block 81 has an inner surface 81a and an outer surface 81b. The inner surface 81a faces generally in a first direction D1. The inner surface 81a faces the side surface 11a of the disc rotor 11 and the brake pad 22i. The outer surface 81b is located on the opposite side to the inner surface 81a and faces generally in a second direction D2.

[0055] Two holes 85 are provided in the block 81. The holes 85 may also be referred to as cylinder chambers. The holes 85 are recesses that open to the inner surface 81a. The two holes 85 are spaced apart from each other in the circumferential direction. The cross section of the holes 85 is formed to be approximately circular.

[0056] The two pistons 23 are disposed in the two holes 85 so as to be capable of reciprocating in the axial direction. As a result, the cylinder 71 of the caliper body 24 supports the pistons 23 so as to be capable of moving in the axial direction. A fluid chamber 86 is formed (defined, partitioned) by the pistons 23 and the block 81. The fluid chamber 86 is contained in the hole 85.

[0057] The brake caliper 12 further includes, for example, two piston seals 87. The piston seals 87 are formed, for example, in a substantially annular shape from synthetic rubber. The piston seals 87 are provided in the holes 85 and seal the gap between the piston 23 and the block 81 so that the piston 23 is movable in the axial direction. That is, the piston seals 87 seal the fluid chamber 86.

[0058] 1, the two support protrusions 82 protrude in the circumferential direction from both circumferential ends 81c of the block 81. The support protrusions 82 are spaced apart from the inner support portion 41 of the mounting 21 in the second direction D2.

[0059] Two guide pins 25 are attached to the two support protrusions 82. The guide pins 25 are attached to the support protrusions 82 so as to protrude from the support protrusions 82 in the first direction D1. The two guide pins 25 are inserted, for example, into two guide holes 89 provided in the mounting 21. In this way, the mounting 21 supports the caliper body 24 via the guide pins 25 so as to be axially movably.

[0060] The stopper 72 is spaced in the first direction D1 (axial direction) from the cylinder 71. The stopper 72 is disposed approximately perpendicular to the axial direction and is formed in a plate shape extending approximately in the circumferential direction.

[0061] As shown in Fig. 4, an inner surface 81a of the block 81 faces the stopper 72. Therefore, the hole 85 opens toward the stopper 72. The disc rotor 11 and the two brake pads 22 are positioned between the block 81 of the cylinder 71 and the stopper 72. The cylinder 71 is disposed on the inside of the disc rotor 11 in the vehicle width direction. The stopper 72 is disposed on the outside of the disc rotor 11 in the vehicle width direction.

[0062] The caliper bridge 73 connects the block 81 of the cylinder 71 and the stopper 72. The caliper bridge 73 is connected to an end of the block 81 and an end of the stopper 72 on the radially outer side. The caliper bridge 73 is spaced radially outward from the disc rotor 11. That is, the caliper body 24 is disposed so as to straddle the disc rotor 11.

[0063] As shown in Fig. 7, the length (width) of the caliper bridge 73 in the circumferential direction is approximately equal to the length (width) of the block 81 of the cylinder 71. On the other hand, the stopper 72 is longer than the caliper bridge 73 in the circumferential direction. Also, as shown in Fig. 1, the length of the stopper 72 and the length of the inner mounting 31 in the circumferential direction are approximately the same. The stopper 72 has a first portion 91 and two second portions 92. In this embodiment, the first portion 91 and the second portions are integrally formed.

[0064] The first portion 91 is connected to the caliper bridge 73. The first portion 91 extends radially inward from the caliper bridge 73. In other words, the first portion 91 extends from the caliper bridge 73 toward the central axis Ax.

[0065] In the circumferential direction, the length (width) of the first portion 91 is approximately equal to the width of the caliper bridge 73. The first portion 91 is a portion of the stopper 72 that extends straight radially inward from the caliper bridge 73. Therefore, the first portion 91 is located between both ends 73a of the caliper bridge 73 in the circumferential direction.

[0066] In the circumferential direction, the width of the first portion 91 may be at least partially smaller than the width of the caliper bridge 73. For example, the first portion 91 may extend from the caliper bridge 73 so as to taper toward the central axis Ax. Also, the first portion 91 may be provided with a recess recessed toward the center of the stopper 72 in the circumferential direction.

[0067] Fig. 8 is a cross-sectional view of the caliper body 24 of this embodiment taken along line F8-F8 in Fig. 4. Fig. 8 virtually illustrates the brake pad 22o, the piston 23, and the hole 85 with a two-dot chain line. As shown in Fig. 8, the first portion 91 at least partially covers the two holes 85 in the axial direction. In other words, the first portion 91 and the holes 85 overlap each other in a projection view seen in the axial direction.

[0068] The two second portions 92 extend in the circumferential direction from both ends 91a of the first portion 91 in the circumferential direction beyond both ends 73a of the caliper bridge 73 in the circumferential direction. That is, the stopper 72 extends in the circumferential direction beyond both ends 73a of the caliper bridge 73 in the circumferential direction.

[0069] 1, the two second portions 92, for example, are partially fitted into the recess 59 of the outer support portion 51. The two second portions 92 axially cover the bottom surface 51c, which is a part of the mounting 21, and the recess 58 that opens into the bottom surface 51c. Therefore, the two second portions 92 axially cover the protrusion 61d of the brake pad 22o that is fitted into the recess 58. Furthermore, the pad support 65 and the compression spring 66 are each at least partially covered in the axial direction by one of the two second portions 92.

[0070] 4, the stopper 72 further has an inner surface 72a and an outer surface 72b. The inner surface 72a faces generally in the second direction D2. The inner surface 72a faces the side surface 11a of the disc rotor 11 and the brake pad 22o. The outer surface 72b is located on the opposite side of the inner surface 72a and faces generally in the first direction D1.

[0071] Each of the first portion 91 and the two second portions 92 has a part of the inner surface 72a and a part of the outer surface 72b. In other words, the inner surface 72a and the outer surface 72b are provided across the first portion 91 and the two second portions 92.

[0072] As shown in Fig. 1, the outer surface 72b is a substantially uniform flat or curved surface extending in a substantially circumferential direction. Since the uniform outer surface 72b is formed relatively widely in the circumferential direction across the first portion 91 and the second portion 92, letters, figures, and patterns can be easily arranged on the outer surface 72b. The uniform outer surface 72b also contributes to a simple and geometrical design of the brake caliper 12. Note that the outer surface 72b is not limited to this example, and may have, for example, irregularities.

[0073] By fitting the stopper 72 into the recess 59 of the outer support part 51, the outer surface 72b of the stopper 72 and the outer surface 51b of the outer support part 51 can more integrally form the overall design of the brake caliper 12. Furthermore, the two extension parts 53 of the mounting 21 and the second part 92 of the caliper body 24 are formed into a triangular shape extending approximately in the circumferential direction. Therefore, the mounting 21 and the caliper body 24 can more integrally form the overall design of the brake caliper 12.

[0074] 2, the outer bridge 52 has three inner edges 52a, 52b, and 52c. The inner edges 52a, 52b, and 52c are radially inner edges of the outer bridge 52. The inner edges 52a, 52b, and 52c face radially inward.

[0075] The inner edges 52a, 52b extend linearly in a longitudinal direction Dl. The longitudinal direction Dl is an example of an extension direction. The longitudinal direction Dl is a direction perpendicular to a virtual line Lc that connects the center of the brake pad 22 in the circumferential direction to the central axis Ax, and is also perpendicular to the central axis Ax.

[0076] The inner edge 52a extends in the longitudinal direction Dl from an end portion on the radially inner side of one outer support part 51. The inner edge 52b extends in the longitudinal direction Dl from an end portion on the radially inner side of the other outer support part 51. The inner edge 52c is provided between the inner edges 52a and 52b. The inner edge 52c extends in a substantially circumferential direction.

[0077] In this embodiment, the portion where the inner edge 52a and the inner edge 52c are connected, or the portion where the inner edge 52b and the inner edge 52c are connected, is the radially innermost portion 52d of the outer bridge 52. Note that the radially innermost portion 52d of the outer bridge 52 may be located in another position.

[0078] The two extension portions 53 extend in the circumferential direction from the two outer support portions 51 beyond the intersection point Pc in Fig. 2 in an axial projection view such as Fig. 2. Note that the extension portions 53 may extend from the outer support portion 51 to the intersection point Pc.

[0079] The intersection point Pc is an intersection point between an imaginary extension line Lx extending in the longitudinal direction Dl from a radially innermost portion 52d of the outer bridge 52 and the outer edge 11b of the disc rotor 11 in an axial projection view. Note that the extension portion 53 may be located closer to the outer support portion 51 than the intersection point Pc.

[0080] In this embodiment, the two extension portions 53 extend radially inward from the two outer support portions 51 beyond the inner edges 52a, 52b of the outer bridge 52. In other words, parts of the extension portions 53 extend radially inward from the inner edges 52a, 52b.

[0081] 2, the extensions 53 are located inside an extension line La of the outer circumferential surface 33b extending in the substantially circumferential direction. In other words, the portion of the two extensions 53 that is farthest from the central axis Ax is closer to the central axis Ax than the portion of the outer circumferential surface 33b of the mounting bridge 33 that is farthest from the central axis Ax.

[0082] In this embodiment, the length of the outer mounting 32 in the longitudinal direction Dl is smaller than the diameter of the disc rotor 11. Therefore, the two extension portions 53 are located between both ends of the disc rotor 11 in the longitudinal direction Dl.

[0083] For example, when the driver of the vehicle 1 depresses the brake pedal to perform a braking operation, brake fluid is supplied to the fluid chamber 86, and the pressure in the fluid chamber 86 increases. The pressure causes the piston 23 to move in the first direction D1, and presses the brake pad 22i against one side surface 11a of the disc rotor 11.

[0084] When the piston 23 presses the brake pad 22i against the disc rotor 11, the caliper body 24 moves in the second direction D2 due to the reaction force. As a result, the stopper 72 presses the brake pad 22o against the other side surface 11a of the disc rotor 11. Specifically, the piston 23 and the stopper 72 come into contact with the shim 63 of the brake pad 22 and press the friction material 62 of the brake pad 22 against the side surface 11a of the disc rotor 11.

[0085] When the friction material 62 comes into contact with the rotating disc rotor 11, the brake pad 22 receives a circumferential force due to friction between the disc rotor 11 and the friction material 62. As a result, the back plate 61 presses the pad support portion 46 or the outer support portion 51 of the inner support portion 41 via the corresponding pad support 65.

[0086] The pad support portion 46 of the inner support portion 41 or the outer support portion 51 receives a braking force (braking torque) transmitted via the brake pad 22. The mounting 21 transmits the braking torque to the body of the vehicle 1. As a result, the disc brake device 10 brakes the disc rotor 11.

[0087] The hole 85 in the caliper body 24 described above is formed, for example, as described below. As shown in Fig. 4, the cylinder 71 of the caliper body 24 has, for example, a base 101 and two covers 102. Two through holes 105 that become the hole 85 are provided in the base 101. The through holes 105 open to the inner surface 81a and the outer surface 81b of the block 81.

[0088] The through hole 105 is formed by, for example, a boring process. A boring bar cuts the block 81 from the outer surface 81b to form the through hole 105 in the base 101. The boring bar stops before reaching the stopper 72. Therefore, the stopper 72 at least partially covers the through hole 105 (hole 85) in the axial direction. The boring bar may cut a part of the stopper 72 to form a recess in the inner surface 72a of the stopper 72.

[0089] The lid 102 is fitted into the through hole 105 and is integrated with the base 101 by, for example, friction stir welding (FSW). As a result, a hole 85 opening to the inner surface 81a is provided in the block 81. The lid 102 forms a part of the outer surface 81b of the block 81.

[0090] The hole 85 is not limited to the above example, and may be formed by other methods. For example, an angle machining machine may form the hole 85. In this case, the stopper 72 does not interfere with the angle machining machine and at least partially covers the hole 85 in the axial direction.

[0091] In the brake caliper 12 according to the embodiment described above, the caliper body 24 has a cylinder 71 having a hole 85, a stopper 72 spaced from the cylinder 71 in an axial direction along the central axis Ax of rotation of the disc rotor 11, and a caliper bridge 73 connecting the cylinder 71 and the stopper 72. The hole 85 of the cylinder 71 opens toward the stopper 72 and is at least partially covered in the axial direction by the stopper 72. The two brake pads 22 are located between the cylinder 71 and the stopper 72 and are spaced from each other in the axial direction. The mounting 21 supports the caliper body 24 and each of the two brake pads 22 so as to be axially movable. The piston 23 is disposed in the hole 85 and configured to push one of the two brake pads 22 toward the disc rotor 11.

[0092] The stopper 72 has a size and shape that covers the hole 85 in the axial direction. On the other hand, the stopper (claw) in the conventional brake caliper is provided with a through hole or a notch for passing a tool (e.g., a boring bar) that forms a hole in the cylinder, and does not cover the hole. The brake caliper 12 of this embodiment can increase the contact area between the stopper 72 and the brake pad 22 compared to a case in which the stopper 72 has a size and shape that does not cover the hole 85. By increasing the contact area between the stopper 72 and the brake pad 22, the caliper body 24 can promote cooling of the brake pad 22. In addition, the brake caliper 12 of this embodiment can also increase the surface area and heat capacity of the stopper 72, and can promote cooling of the brake pad 22. As described above, the brake caliper 12 of this embodiment can promote cooling of the brake pad 22, and therefore can effectively suppress the occurrence of vapor lock, for example. Moreover, in the brake caliper 12 of this embodiment, it is easy to set the shape and area of ​​the contact surface between the stopper 72 and the brake pad 22 so as to adjust the natural frequency to a desired value, and squeal (noise) during braking can be suppressed. Furthermore, in the brake caliper 12 of this embodiment, the weight of the stopper 72 can be increased so as to adjust the natural frequency to a desired value, and squeal during braking can be suppressed, compared to a case in which the stopper 72 has a size and shape that does not cover the hole 85. Furthermore, in the brake caliper 12 of this embodiment, the decoratable outer surface 72b of the stopper 72 can be made larger, and the design can be improved, compared to a case in which the stopper 72 has a size and shape that does not cover the hole 85.

[0093] The stopper 72 has a first portion 91 and two second portions 92. The first portion 91 is connected to the caliper bridge 73 and is located between both ends 73a of the caliper bridge 73 in the circumferential direction about the central axis Ax. The two second portions 92 extend from both ends 91a of the first portion 91 in the circumferential direction beyond both ends 73a of the caliper bridge 73 in the circumferential direction.

[0094] The stopper 72 extends long in the circumferential direction by providing two second portions 92. On the other hand, the stopper (claw) in the conventional brake caliper has a circumferential length that is approximately equal to the caliper bridge. The brake caliper 12 of this embodiment can increase the contact area between the stopper 72 and the brake pad 22 compared to a case in which the length of the stopper 72 is equal to the caliper bridge 73. By increasing the contact area between the stopper 72 and the brake pad 22, the caliper body 24 can promote cooling of the brake pad 22. In addition, the brake caliper 12 of this embodiment can also increase the surface area and heat capacity of the stopper 72, and can promote cooling of the brake pad 22. In addition, the brake caliper 12 of this embodiment can easily set the shape and area of ​​the contact surface between the stopper 72 and the brake pad 22 so as to adjust the natural frequency to a desired value, and squeal during braking can be suppressed. Moreover, in the brake caliper 12 of this embodiment, the weight of the stopper 72 can be increased so as to adjust the natural frequency to a desired value, and squeal during braking can be suppressed, compared to when the length of the stopper 72 is equal to the caliper bridge 73. Furthermore, in the brake caliper 12 of this embodiment, the outer surface 72b of the stopper 72 can be made wider, and the design can be improved, compared to when the length of the stopper 72 is equal to the caliper bridge 73.

[0095] The two second parts 92 cover a part of the mounting 21 in the axial direction. By covering a part of the mounting 21, the second parts 92 can cover, for example, unevenness provided on the mounting 21 and parts attached to the mounting 21. For example, the second parts 92 can cover a recess 58 provided on the mounting 21 and into which a part of the brake pad 22 is fitted. If a foreign object enters the recess 58, the movement of the brake pad 22 may be hindered. The second parts 92 can protect the recess 58. That is, the second parts 92 can protect parts of the mounting 21 that have various functions, such as the recess 58. Furthermore, by covering the mounting 21, the second parts 92 can improve the design.

[0096] The pad support 65 and the compression spring 66 are attached to one of the two brake pads 22 or the mounting 21, and are at least partially covered in the axial direction by one of the two second parts 92. The second part 92 can protect the pad support 65 and the compression spring 66. Furthermore, by covering the pad support 65 and the compression spring 66, the second part 92 can improve the design.

[0097] The caliper body 24 movably supports the piston 23. The mounting 21 has an inner mounting 31, an outer mounting 32, and a mounting bridge 33. The inner mounting 31 is configured to be located inward of the disc rotor 11 in the vehicle width direction. The outer mounting 32 is configured to be located outward of the disc rotor 11 in the vehicle width direction, and is longer than the inner mounting 31 in the circumferential direction. The mounting bridge 33 connects the inner mounting 31 and the outer mounting 32. The mounting 21 movably supports the caliper body 24.

[0098] Generally, the inner mounting 31 located on the inside in the vehicle width direction has high rigidity by being attached to the vehicle body. On the other hand, in the brake caliper 12 of this embodiment, the outer mounting 32 is long in the circumferential direction, so that the rigidity can be improved. That is, the brake caliper 12 of this embodiment can improve the rigidity of the mounting 21. Therefore, the brake caliper 12 of this embodiment can suppress the mounting 21 from being twisted when the inner mounting 31 and the outer mounting 32 receive a braking torque from the brake pad 22 during braking. Furthermore, the brake caliper 12 of this embodiment can increase the weight of the mounting 21 so as to adjust the natural frequency to a desired value, compared to a case in which the circumferential lengths of the inner mounting 31 and the outer mounting 32 are the same, and can suppress squeal (noise) during braking.

[0099] The outer mounting 32 has two outer support parts 51, an outer bridge 52, and two extension parts 53. The two outer support parts 51 are spaced apart from each other in the circumferential direction and movably support the brake pad 22. The outer bridge 52 connects the two outer support parts 51. The two extension parts 53 extend in the circumferential direction from the two outer support parts 51. In the axial projection, an extension line Lx extends from a part 52d of the outer bridge 52 located at the innermost radial position in the radial direction in a longitudinal direction Dl that is perpendicular to a virtual line Lc connecting the center of the brake pad 22 in the circumferential direction and the central axis Ax, and perpendicular to the central axis Ax. In the projection, the two extension parts 53 extend from the two outer support parts 51 to an intersection Pc of the extension line Lx and the outer edge 11b of the disc rotor 11, or beyond the intersection Pc.

[0100] When the extension portion 53 extends to the intersection point Pc, the extension portion 53 can improve the rigidity of the outer mounting 32 and more reliably suppress interference with surrounding components. When the extension portion 53 extends beyond the intersection point Pc, the extension portion 53 can further improve the rigidity of the outer mounting 32.

[0101] The two extension portions 53 are located between both ends of the disc rotor 11 in the longitudinal direction Dl. This makes it possible to reliably prevent the extension portions 53 from interfering with parts around the disc rotor 11, such as wheels.

[0102] Of the two extending portions 53, the portion furthest from the central axis Ax is closer to the central axis Ax than the outer peripheral surface 33b of the mounting bridge 33, which is the portion furthest from the central axis Ax. The mounting bridge 33 extends across the disc rotor 11 and is therefore surrounded by the wheel. The two extending portions 53 are closer to the central axis Ax than the mounting bridge 33. In other words, the two extending portions 53 are farther from the wheel than the mounting bridge 33. For this reason, it is possible to reliably suppress the extending portions 53 from interfering with parts around the disc rotor 11, such as wheels.

[0103] The brake caliper according to at least one embodiment described above includes, as an example, a piston, a caliper body that movably supports the piston, an inner mounting configured to be disposed on the inner side of a disc rotor in the vehicle width direction, an outer mounting configured to be disposed on the outer side of the disc rotor in the vehicle width direction and longer than the inner mounting in the circumferential direction around the central axis of rotation of the disc rotor, and a mounting bridge that connects the inner mounting and the outer mounting, and a mounting that movably supports the caliper body. Thus, as an example, generally, an inner mounting that is located on the inner side in the vehicle width direction has high rigidity by being attached to a vehicle body. On the other hand, in the brake caliper of this embodiment, the outer mounting is long in the circumferential direction, and therefore the rigidity can be improved. That is, the brake caliper of this embodiment can improve the rigidity of the mounting. Therefore, the brake caliper of this embodiment can suppress the mountings from being twisted when the inner mounting and the outer mounting receive braking torque from the brake pads during braking. Also, compared to a case in which the circumferential lengths of the inner mounting and the outer mounting are the same, the brake caliper of this embodiment can increase the weight of the mountings to adjust the natural frequency to a desired value, thereby suppressing squeal (noise) during braking.

[0104] The brake caliper further includes, as an example, a brake pad, and the outer mounting includes two outer support parts that are spaced apart from each other in the circumferential direction and movably support the brake pad, an outer bridge that connects the two outer support parts, and two extension parts that extend in the circumferential direction from the two outer support parts, and the two extension parts extend from the two outer support parts from a radially innermost part of the outer bridge perpendicular to the central axis in an axial projection along the central axis to an intersection of an extension line that extends in an extension direction perpendicular to a virtual line connecting the center of the brake pad in the circumferential direction and the central axis, and an outer edge of the disc rotor, or beyond the intersection. Therefore, as an example, when the extension parts extend to the intersection, the rigidity of the outer mounting can be improved and interference with surrounding parts can be more reliably suppressed. When the extension portion extends beyond the intersection point, the extension portion can further improve the rigidity of the outer mounting.

[0105] In the brake caliper, as one example, the two extension portions are located between both ends of the disc rotor in the extension direction, and therefore, as one example, the extension portions can reliably suppress interference with parts around the disc rotor, such as a wheel.

[0106] In the above brake caliper, as an example, the portion of the two extensions that is farthest from the central axis is closer to the central axis than the portion of the mounting bridge that is farthest from the central axis. Thus, as an example, the mounting bridge extends across the disc rotor and is surrounded by the wheel. The two extensions are closer to the central axis than the mounting bridge. In other words, the two extensions are farther from the wheel than the mounting bridge. Therefore, it is possible to reliably suppress the extensions from interfering with parts around the disc rotor, such as the wheel.

[0107] In the above brake caliper, as an example, the caliper body includes a cylinder configured to be disposed inside the disc rotor in the vehicle width direction and movably supporting the piston, a stopper configured to be disposed outside the disc rotor in the vehicle width direction, and a caliper bridge connecting the cylinder and the stopper, the stopper includes a first portion connected to the caliper bridge and positioned between both ends of the caliper bridge in the circumferential direction, and two second portions extending from both ends of the first portion in the circumferential direction beyond both ends of the caliper bridge in the circumferential direction, and the two second portions cover the two outer support parts in the axial direction along the central axis. Thus, as an example, the stopper extends long in the circumferential direction by providing two second portions. On the other hand, the stopper in the conventional brake caliper has a length in the circumferential direction that is approximately equal to the caliper bridge. The brake caliper of this embodiment can increase the contact area between the stopper and the brake pad compared to a case in which the length of the stopper is equal to the caliper bridge. By increasing the contact area between the stopper and the brake pad, the caliper body can promote the cooling of the brake pad. Moreover, the brake caliper of this embodiment can also increase the surface area and heat capacity of the stopper, and can promote the cooling of the brake pad. Moreover, the brake caliper of this embodiment can easily set the shape and area of ​​the contact surface between the stopper and the brake pad so as to adjust the natural frequency to a desired value, and can suppress squeal during braking. Moreover, the brake caliper of this embodiment can increase the weight of the stopper so as to adjust the natural frequency to a desired value, and can suppress squeal during braking, compared to a case in which the length of the stopper is equal to the caliper bridge. Moreover, the brake caliper of this embodiment can widen the outer surface of the stopper that can be decorated, and can improve the design, compared to a case in which the length of the stopper is equal to the caliper bridge. Furthermore, the stopper can be made longer in the circumferential direction, and thus the mounting, the brake pad, and various parts can be protected.

[0108] Although the embodiments of the present invention have been illustrated above, the above-mentioned embodiments and modifications are merely examples and are not intended to limit the scope of the invention. The above-mentioned embodiments and modifications can be implemented in various other forms, and various omissions, substitutions, combinations, and modifications can be made without departing from the gist of the invention. In addition, the configurations and shapes of each embodiment and each modification can be partially replaced and implemented. [Explanation of symbols]

[0109] 11...disc rotor, 11b...outer edge, 12...brake caliper, 21...mounting, 22o...brake pad, 23...piston, 24...caliper body, 31...inner mounting, 32...outer mounting, 33...mounting bridge, 33b...outer surface (part), 51...outer support part, 52...outer bridge, 52d...part, 53...extension part, 71...cylinder, 72...stopper, 73...caliper bridge, 73a...end, 91...first part, 91a...end, 92...second part, Ax...central axis, Pc...intersection, Dl...longitudinal direction (extension direction), Lc...virtual line, Lx...extension line.

Claims

1. The piston and a caliper body that movably supports the piston; a mounting including: an inner mounting configured to be disposed on the inner side of a disc rotor in a vehicle width direction; an outer mounting configured to be disposed on the outer side of the disc rotor in the vehicle width direction and longer than the inner mounting in a circumferential direction around a central axis of rotation of the disc rotor; and a mounting bridge connecting the inner mounting and the outer mounting; and a mounting that movably supports the caliper body; A brake caliper comprising:

2. Brake pads, Further comprising: the outer mounting includes two outer support parts that are spaced apart from each other in the circumferential direction and movably support the brake pads, an outer bridge that connects the two outer support parts, and two extension parts that extend in the circumferential direction from the two outer support parts, the two extension portions extend from the two outer support portions to an intersection of an extension line, the extension line being perpendicular to an imaginary line connecting a center of the brake pad in the circumferential direction and the central axis, and an outer edge of the disc rotor, in an axial projection view along the central axis, from a portion of the outer bridge located radially innermost therein and perpendicular to the central axis, or beyond the intersection point; 2. The brake caliper of claim 1.

3. The two extension portions are located between both ends of the disk rotor in the extension direction. The brake caliper of claim 2.

4. The portion of the two extensions that is farthest from the central axis is closer to the central axis than the portion of the mounting bridge that is farthest from the central axis.

4. The brake caliper of claim 3.

5. the caliper body includes: a cylinder configured to be disposed inward of the disc rotor in the vehicle width direction and movably supporting the piston; a stopper configured to be disposed outward of the disc rotor in the vehicle width direction; and a caliper bridge connecting the cylinder and the stopper; the stopper has a first portion connected to the caliper bridge and located between both ends of the caliper bridge in the circumferential direction, and two second portions extending from both ends of the first portion in the circumferential direction beyond both ends of the caliper bridge in the circumferential direction, The two second portions cover the two outer support parts in an axial direction along the central axis.

2. The brake caliper of claim 1.

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