Brake caliper and stopper

Abstract

To obtain, as one example, a brake caliper which eliminates a need for removing a stopper before a component, such as a rotor, is disposed between two brake pads.SOLUTION: A brake caliper according to an embodiment has, as one example, a mounting, a first brake pad which is supported so as to be movable in a first direction and a second direction by the mounting, a second brake pad which separates from the first brake pad in the first direction, a cylinder body provided with a cylinder, a piston which is housed in the cylinder and presses the first brake pad in the first direction, and a stopper having a first contact part which contacts with the cylinder body and a second contact part which contacts with first brake pad, the stopper held between the cylinder body and the first brake pad so as to restrict movement of the first brake pad in the first direction.SELECTED DRAWING: Figure 4

Description

[Technical Field]

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

[0002] A conventional brake caliper includes a mounting attached to a vehicle body, two brake pads supported by the mounting, a cylinder body with a cylinder, and a piston housed in the cylinder. One of the brake pads is moved by being pushed by the piston (Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 6958169 Summary of the Invention [Problem to be solved by the invention]

[0004] A stopper is sometimes placed between two brake pads to prevent them from falling off the mountings during brake caliper manufacturing and shipping. However, because the stopper interferes with components such as rotors, it is removed before the components are assembled to the brake caliper.

[0005] SUMMARY OF THE INVENTION The present invention has been made in view of the above, and provides a brake caliper and stopper that does not require removal of the stopper before a component such as a rotor is placed between two brake pads. [Means for solving the problem]

[0006] As an example, a brake caliper according to an embodiment of the present invention includes a mounting, a back plate, and a friction material protruding from the back plate in a first direction, and includes: a first brake pad supported on the mounting so as to be movable in the first direction and a second direction opposite to the first direction; a second brake pad spaced from the first brake pad in the first direction and supported on the mounting; a cylinder body provided with a cylinder and supported on the mounting so as to be movable in the first direction and the second direction; a piston housed in the cylinder so as to be movable in the first direction and the second direction and configured to press the first brake pad in the first direction; and a stopper having a first abutment portion abutting the cylinder body and a second abutment portion abutting the first brake pad, and held between the cylinder body and the first brake pad so as to limit movement of the first brake pad in the first direction. Therefore, as an example, the stopper restricts the movement of the first brake pad in the first direction, thereby preventing the first brake pad from falling off. Because the stopper is held between the cylinder body and the first brake pad, it does not need to be interposed between the first brake pad and the second brake pad. Therefore, the brake caliper does not need to remove the stopper before a component such as a rotor is placed between the first brake pad and the second brake pad, and the first brake pad can be more reliably prevented from falling off. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a front view that schematically shows a disc brake device according to one embodiment. [Figure 2] FIG. 2 is a top view showing the brake caliper of the embodiment. [Figure 3] FIG. 3 is a cross-sectional view showing the brake caliper of the embodiment taken along line F3-F3 in FIG. [Figure 4] FIG. 4 is a cross-sectional view showing the brake caliper of the embodiment taken along line F4-F4 in FIG. [Figure 5] FIG. 5 is a side view showing the stopper of the embodiment. [Figure 6] FIG. 6 is a cross-sectional view showing the brake caliper in the embodiment in which the hook is released from its engagement. [Figure 7] FIG. 7 is a cross-sectional view showing the brake caliper from which the stopper of the embodiment is pulled out. DETAILED DESCRIPTION OF THE INVENTION

[0008] An embodiment will be described below with reference to FIGS. 1 to 7. In this specification, components according to the embodiment and descriptions of the components may be described using multiple expressions. The components and their descriptions are merely examples and are not limited by the expressions in this specification. The components may also be identified by names different from those in this specification. Furthermore, the components may also be described using expressions different from those in this specification.

[0009] In the following description, "suppress" is defined as, for example, preventing an event, action, or influence from occurring, or reducing the severity of an event, action, or influence. Also, in the following description, "restrict" is defined as, for example, preventing movement or rotation, or allowing movement or rotation within a predetermined range and preventing movement or rotation beyond the predetermined range.

[0010] FIG. 1 is a front view that schematically shows 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. The disc rotor 11 is an example of a rotor.

[0011] The disc rotor 11 rotates around a central axis Ax integrally with the wheel of the vehicle 1. The central axis Ax is, for example, the central axis of an axle, the central axis of the disc rotor 11, and also 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 convenience, the axial direction, radial direction, and circumferential direction are defined. The axial direction is the direction along the central axis Ax. The radial direction is the direction perpendicular to the central axis Ax. The circumferential direction is the direction around the central axis Ax.

[0013] The disc rotor 11 has a rotor body 11a and a hat portion 11b. The rotor body 11a is formed in a disk shape that is substantially perpendicular to the central axis Ax. The hat portion 11b is formed in a substantially cylindrical shape and is coupled to, for example, an axle of the vehicle 1.

[0014] Fig. 2 is a top view showing the brake caliper 12 of this embodiment. As shown in Fig. 2, the brake caliper 12 of this embodiment is, for example, a floating caliper. The brake caliper 12 is disposed so as to straddle the rotor body 11a.

[0015] The axial direction is a direction that is approximately along the width of the vehicle 1, and includes the outward direction Do and the inward direction Di shown in FIG. 2. The outward direction Do is a direction that is along the central axis Ax and is an example of a first direction. The inward direction Di is the opposite direction to the outward direction Do and is an example of a second direction. For example, the outward direction Do is a direction toward the outside of the vehicle 1, and the inward direction Di is a direction toward the inside of the vehicle 1.

[0016] Fig. 3 is a cross-sectional view of the brake caliper 12 of this embodiment taken along line F3-F3 in Fig. 2. Fig. 4 is a cross-sectional view of the brake caliper 12 of this embodiment taken along line F4-F4 in Fig. 3.

[0017] 3 and 4, the brake caliper 12 includes a pair of brake pads 21, a mounting 22, four pad supports 23, a cylinder body 24, and a piston 25. The pad supports 23 may also be referred to as pad support springs or elastic members.

[0018] As shown in FIG. 4 , one of the pair of brake pads 21 may be referred to as an inner pad 21A. The inner pad 21A is an example of a first brake pad. The other of the pair of brake pads 21 may be referred to as an outer pad 21B. The outer pad 21B is an example of a second brake pad. Below, explanations common to the inner pad 21A and the outer pad 21B will be described as explanations of the brake pad 21.

[0019] The pair of brake pads 21 are aligned in the axial direction. The outer pad 21B is spaced outwardly Do from the inner pad 21A. As shown imaginarily by the two-dot chain line in Figure 4, the rotor body 11a is disposed between the pair of brake pads 21. Each of the pair of brake pads 21 has a back plate 31, a friction material 32, and a shim 33.

[0020] 3, the back plate 31 is disposed substantially perpendicular to the central axis Ax and is formed in a plate shape extending substantially in the circumferential direction. The back plate 31 has a mounting surface 31a, a back surface 31b, an outer edge 31c, and an inner edge 31d shown in FIG. 4, and two end faces 31e in the circumferential direction shown in FIG.

[0021] As shown in FIG. 4, the mounting surface 31a faces the axial direction. The mounting surface 31a of the inner pad 21A and the mounting surface 31a of the outer pad 21B face each other. The mounting surface 31a faces the rotor body 11a. The back surface 31b is located on the opposite side of the mounting surface 31a. The outer edge 31c is provided at the end of the back plate 31 on the radially outer side and extends approximately in the circumferential direction. The inner edge 31d is located on the opposite side of the outer edge 31c.

[0022] 3, a pair of fitting protrusions 35 are provided on the back plate 31. The pair of fitting protrusions 35 are formed integrally with the back plate 31 and protrude from two end faces 31e of the back plate 31 in a substantially circumferential direction. The fitting protrusions 35 are formed in a substantially rectangular plate shape. However, the fitting protrusions 35 are not limited to this example.

[0023] As shown in FIG. 4, the friction material 32 is attached to the mounting surface 31a of the back plate 31. As a result, the friction material 32 of the inner pad 21A protrudes outward from the mounting surface 31a of the back plate 31 in a direction Do. The friction material 32 of the outer pad 21B protrudes inward from the back plate 31 in a direction Di. The friction material 32 is located between the rotor body 11a and the mounting surface 31a of the back plate 31. The friction material 32 has a friction surface 32a, an outer edge 32b, an inner edge 32c, and a bottom surface 32d. The friction surface 32a of the inner pad 21A is an example of an end of the friction material in the first direction. The bottom surface 32d is an example of a second support portion.

[0024] The friction surface 32a of the inner pad 21A is provided at the end of the friction material 32 in the outward direction Do and faces substantially in the outward direction Do. The friction surface 32a faces the rotor body 11a. The friction surface 32a may have a slope.

[0025] The outer edge 32b is provided at the radially outer end of the friction material 32. The inner edge 32c is located opposite the outer edge 32b. The outer edge 32b and the inner edge 32c each extend in a substantially circumferential direction.

[0026] A groove 36 is provided in the friction material 32. The groove 36 opens to the friction surface 32a, the outer edge 32b, and the inner edge 32c. The groove 36 passes through, for example, approximately the center of the friction material 32 in the circumferential direction and extends linearly in an approximately radial direction. For example, dust generated by wear of the friction material 32 can be discharged through the groove 36. However, the groove 36 is not limited to this example. A bottom surface 32d of the friction material 32 is provided at the bottom of the groove 36. That is, the bottom surface 32d of the inner pad 21A is provided at the end of the groove 36 in the inward direction Di and faces the outward direction Do.

[0027] The shim 33 is a thin plate made of, for example, metal and synthetic rubber. For example, the shim 33 may have a plate made of metal and a plate made of synthetic rubber, or may be a plate integrally formed of metal and synthetic rubber. The shim 33 is not limited to this example. The shim 33 has a cover 37, outer claws 38, and inner claws 39.

[0028] The cover 37 extends along the back surface 31b of the back plate 31 and covers the back surface 31b. The outer claws 38 protrude from the edge of the cover 37 and hook onto the outer edge 31c of the back plate 31. The inner claws 39 protrude from the edge of the cover 37 and hook onto the inner edge 31d of the back plate 31. As a result, the back plate 31 is held between the outer claws 38 and the inner claws 39, and the shim 33 is attached to the back plate 31.

[0029] The mounting 22 is made of, for example, metal. The mounting 22 is fixed to a non-rotating portion of the vehicle 1. For example, the mounting 22 is attached to the body of the vehicle 1. The mounting 22 supports the brake pads 21, the cylinder body 24, and the pad support 23. As shown in FIG. 2 , the mounting 22 has an inner mounting 41, an outer mounting 42, and two mounting bridges 43.

[0030] The inner mounting 41 and the outer mounting 42 are each formed in a plate shape that is disposed approximately perpendicular to the central axis Ax and extends approximately in the circumferential direction. However, the inner mounting 41 and the outer mounting 42 are not limited to this example.

[0031] The outer mounting 42 is spaced apart in the outward direction Do from the inner mounting 41. The rotor body 11a is disposed between the inner mounting 41 and the outer mounting 42. As shown in Fig. 3, each of the inner mounting 41 and the outer mounting 42 is provided with an accommodating recess 45 and a pair of fitting grooves 46.

[0032] The accommodating recess 45 is a cutout that opens radially outward. The pair of fitting grooves 46 communicate with both circumferential ends of the accommodating recess 45. The accommodating recess 45 and the pair of fitting grooves 46 open outward Do and inward Di.

[0033] The pad support 23 is, for example, a metal plate bent into a substantially U-shape along the fitting groove 46. However, the pad support 23 is not limited to this example. The pad support 23 fits into the corresponding fitting groove 46.

[0034] The corresponding brake pad 21 is accommodated in the accommodation recess 45. As a result, the fitting protrusion 35 of the brake pad 21 fits into the fitting groove 46. The inner mounting 41 supports the inner pad 21A via the pad support 23 so that the inner pad 21A can move axially (outward direction Do and inward direction Di). The outer mounting 42 supports the outer pad 21B via the pad support 23 so that the outer pad 21B can move axially.

[0035] For example, a coating C is provided on the surface of the pad support 23. The coating C is, for example, a fluororesin, and reduces the coefficient of friction between the pad support 23 and the brake pad 21. The fitting protrusion 35 of the brake pad 21 comes into contact with the coating C provided on the pad support 23. Note that the fitting protrusion 35 may also come into direct contact with the pad support 23.

[0036] The cylinder body 24 is made of, for example, metal. As shown in FIG. 4, the cylinder body 24 has an inner body 51, an outer body 52, and a bridge 53. The inner body 51 is an example of a first portion. The outer body 52 is an example of a second portion. The bridge 53 is an example of a third portion.

[0037] The inner body 51 is spaced inwardly Di from the inner mounting 41. The inner body 51 may be partially fitted into the accommodating recess 45 of the inner mounting 41. The outer body 52 is spaced outwardly Do from the inner body 51 and fitted into the accommodating recess 45 of the outer mounting 42.

[0038] The rotor body 11a and the pair of brake pads 21 are disposed between the inner body 51 and the outer body 52. ​​The outer body 52 supports the outer pad 21B so as to restrict movement of the outer pad 21B in the outward direction Do. The outer pad 21B is positioned between the rotor body 11a and the outer body 52.

[0039] The bridge 53 extends substantially in the axial direction between a radially outer end of the inner body 51 and a radially outer end of the outer body 52. ​​The bridge 53 is located radially outward of the disc rotor 11 and the pair of brake pads 21.

[0040] 2 and 3, for example, an axially extending pin 54 is attached to the inner body 51. The pin 54 is inserted into a hole provided in the mounting 22. This allows the cylinder body 24 to be supported by the mounting 22 so as to be movable in the axial direction (outward direction Do and inward direction Di).

[0041] 4, a cylinder 55 is provided in the inner body 51. A plurality of cylinders 55 may be provided in the inner body 51. The cylinder 55 is a generally cylindrical recess that opens in the outward direction Do. The cylinder 55 opens toward the shim 33 of the inner pad 21A.

[0042] The inner body 51 has an inner circumferential surface 51a, a bottom surface 51b, and an outer surface 51c. The inner circumferential surface 51a and the bottom surface 51b define a cylinder 55. The inner circumferential surface 51a is a substantially cylindrical curved surface extending in the axial direction. The bottom surface 51b is provided at an end of the cylinder 55 in the inward direction Di and is connected to the end of the inner circumferential surface 51a in the inward direction Di. The bottom surface 51b is provided with holes, for example, through which brake fluid is supplied and discharged. The outer surface 51c is located on the opposite side of the inner circumferential surface 51a. The outer surface 51c is spaced radially outward from the inner circumferential surface 51a and faces radially outward as a whole.

[0043] The piston 25 is formed in a generally cylindrical shape extending in the axial direction. The piston 25 is housed in a cylinder 55 so as to be movable in the axial direction (outward direction Do and inward direction Di). The piston 25 comes into contact with, for example, the shim 33 of the inner pad 21A. Note that another member may be interposed between the piston 25 and the shim 33.

[0044] As shown in FIG. 2, a through hole 56 is provided in the bridge 53. The through hole 56 penetrates radially through approximately the center of the bridge 53 in the circumferential direction. The through hole 56 exposes the groove 36 of the friction material 32 of the inner pad 21A. For example, the through hole 56 makes it possible to visually check the thickness of the friction material 32 that is reduced due to wear. However, the through hole 56 is not limited to this example.

[0045] The bridge 53 has an edge 57 that defines the through hole 56. The edge 57 has a support portion 57a. The support portion 57a ​​is an example of a first support portion. The support portion 57a ​​is provided at the end of the through hole 56 in the outward direction Do and faces substantially in the inward direction Di. As shown in FIG. 4, the support portion 57a ​​tapers, for example, toward the inward direction Di.

[0046] An engaging portion 57b is provided on the support portion 57a. The engaging portion 57b is an example of a first engaging portion. The engaging portion 57b is, for example, a protrusion that protrudes from an end of the support portion 57a ​​in the inward direction Di. For example, the engaging portion 57b is a parting line provided on the cast cylinder body 24. However, the engaging portion 57b is not limited to this example.

[0047] For example, when brake fluid is supplied to the cylinder 55, the pressure in the cylinder 55 increases. The pressure in the cylinder 55 moves the piston 25 in the outward direction Do. The piston 25 pushes the inner pad 21A in the outward direction Do, and presses the friction material 32 of the inner pad 21A against the rotor body 11a.

[0048] When the inner pad 21A is pressed against the rotor body 11a, the cylinder body 24 moves inward in reaction Di. As a result, the outer body 52 of the cylinder body 24 presses the outer pad 21B inward Di, pressing the friction material 32 of the outer pad 21B against the rotor body 11a.

[0049] The brake pads 21 receive a circumferential force from the disc rotor 11 due to friction between the rotor body 11a and the friction material 32. The mounting 22 receives the braking force (braking torque) transmitted via the pair of brake pads 21 and transmits it to the body of the vehicle 1. In this way, the disc brake device 10 brakes the disc rotor 11.

[0050] When braking is released and pressure is released, the brake pad 21 is separated from the rotor body 11a, for example, by a spring. Because the coating C reduces the friction force between the brake pad 21 and the pad support 23, the friction material 32 is quickly separated from the rotor body 11a. This allows the disc brake device 10 to suppress the generation of drag resistance (drag torque) between the friction material 32 and the rotor body 11a.

[0051] For example, during manufacturing of the disc brake device 10 or during transportation of the brake caliper 12, the brake caliper 12 has a stopper 60. The stopper 60 is attached to the inner pad 21A and the cylinder body .

[0052] The stopper 60 is made of a synthetic resin such as polypropylene (PP). The stopper 60 has lower rigidity than the brake pad 21, the mounting 22, and the cylinder body 24. The color of the stopper 60 is, for example, a fluorescent color, which is easily distinguishable from the silver color of the cylinder body 24. However, the stopper 60 is not limited to this example.

[0053] Fig. 5 is a side view showing a stopper 60 of this embodiment. As shown in Fig. 5, the stopper 60 is formed in a plate shape. The stopper 60 has an intermediate portion 61 and a tab 62. The intermediate portion 61 has an outer portion 65 and an inner portion 66.

[0054] The outer portion 65 is a portion of the interposed portion 61 that is located radially outward of the brake pad 21. The outer portion 65 is formed in a substantially rectangular shape extending in the axial direction, and is housed in the through-hole 56. Note that the outer portion 65 is not limited to this example. The outer portion 65 has multiple edges 65a, 65b, 65c, 65d, and 65e. The edge 65a is an example of a first abutment portion.

[0055] The edge 65a is provided at the end of the outer portion 65 in the outward direction Do. The edge 65a tapers toward the outward direction Do. The edge 65b is located opposite the edge 65a. That is, the edge 65b is provided at the end of the outer portion 65 in the inward direction Di.

[0056] Edge 65c extends in the inward direction Di from the end of edge 65a on the inside in the radial direction. Edge 65d extends in the outward direction Do from the end of edge 65b on the inside in the radial direction. Edge 65d extends approximately parallel to edge 65c and is located more inward than edge 65c in the radial direction. Edge 65e is located on the opposite side of edge 65c. Edge 65e extends in the inward direction Di from the end of edge 65a on the outside in the radial direction.

[0057] 4, the edge 65a abuts against the support portion 57a ​​of the edge 57 of the cylinder body 24. The support portion 57a ​​supports the edge 65a so as to restrict the movement of the stopper 60 in the outward direction Do. The edge 65b is spaced apart from the edge 57 of the cylinder body 24 and faces the edge 57.

[0058] As shown in Fig. 5, an engagement portion 65f is provided on the edge 65a. The engagement portion 65f is an example of a second engagement portion. The engagement portion 65f is, for example, a recess recessed from the end of the edge 65a in the outward direction Do. The engagement portion 65f in this embodiment is a groove opening in the outward direction Do and in the circumferential direction. However, the engagement portion 65f is not limited to this example.

[0059] 4, the engaging portion 65f fits into the engaging portion 57b of the cylinder body 24. That is, the engaging portion 57b, which is a convex portion, fits into the engaging portion 65f, which is a concave portion. As a result, the engaging portion 65f restricts the radial movement of the stopper 60.

[0060] For example, when the cylinder body 24 is cast, the surface roughness of the edge 57 increases. This increases the friction between the edge 57 of the cylinder body 24 and the edge 65a of the stopper 60. The friction between the edge 57 and the edge 65a prevents the engaging portion 65f from coming off the engaging portion 57b.

[0061] The edge 65c faces the rotor body 11a, and the edge 65d faces the inner pad 21A. The distance between the edge 65c and the rotor body 11a is longer than the distance between the edge 65d and the inner pad 21A.

[0062] As shown in FIG. 5, the inner portion 66 protrudes radially inward from edges 65c, 65d of the outer portion 65. The inner portion 66 is a portion of the interposed portion 61 that is located radially inward of the outer portion 65. As shown in FIG. 4, the inner portion 66 penetrates the groove 36 in the radial direction. That is, a portion of the inner portion 66 is received in the groove 36. The inner portion 66 has two edges 66a, 66b and a hook 66c. The edge 66a is an example of an end of the inner portion in the first direction. The edge 66b is an example of a second abutment portion.

[0063] The edge 66a is provided at the end of the inner portion 66 in the outward direction Do. The edge 66a extends approximately radially inward from the edge 65c of the outer portion 65. The edge 66b is located opposite the edge 66a. The edge 66b extends radially inward from the edge 65d of the outer portion 65.

[0064] The edge 66b abuts against the bottom surface 32d of the inner pad 21A. The bottom surface 32d supports the edge 66b so as to restrict the movement of the stopper 60 in the inward direction Di. In other words, the edge 66b supports the bottom surface 32d so as to restrict the movement of the inner pad 21A and the piston 25 in the outward direction Do.

[0065] The distance (width) between the two edges 66a, 66b decreases radially inward. In the axial direction, the maximum distance (width) between the two edges 66a, 66b is shorter than the length (depth) of the groove 36. Therefore, the edge 66a is spaced inward in the direction Di from the friction surface 32a of the inner pad 21A. In other words, the stopper 60 is completely housed in the groove 36 between the outer edge 32b and the inner edge 32c of the friction material 32. The inner portion 66 is spaced inward in the direction Di from the disc rotor 11.

[0066] The hook 66c protrudes inward in the Di direction from an end of the edge 66b on the radially inner side. The hook 66c may protrude from another position on the inner portion 66. The hook 66c abuts against the inner edge 31d of the back plate 31 of the inner pad 21A. The hook 66c is not limited to this example and may abut against another portion, such as the inner claw 39 or the inner edge 32c of the friction material 32. By abutting against the inner pad 21A, the hook 66c restricts the stopper 60 from moving outward in the radial direction.

[0067] In the axial direction, the maximum distance between the edge 66a of the inner portion 66 and the tip of the hook 66c in the inward direction Di is shorter than the length (depth) of the groove 36 of the inner pad 21A. Therefore, when the tip of the hook 66c in the inward direction Di abuts against the bottom surface 32d, the inner portion 66 does not protrude in the outward direction Do beyond the friction surface 32a of the inner pad 21A. Note that the inner portion 66 is not limited to this example.

[0068] An edge 65a of the outer portion 65 is supported by the support portion 57a ​​of the cylinder body 24, and an edge 66b of the inner portion 66 is supported by the bottom surface 32d of the inner pad 21A. As a result, the stopper 60 is held between the cylinder body 24 and the inner pad 21A so as to restrict movement of the inner pad 21A in the outward direction Do.

[0069] Distance L1 shown in Fig. 4 is shorter than distance L2 shown in Fig. 5. Distance L1 is the axial distance between bottom surface 32d and support portion 57a ​​when piston 25 has moved the furthest inward direction Di. Distance L2 is the axial distance between edge 65a and edge 66b when stopper 60 is disengaged from cylinder body 24 and inner pad 21A. Note that even if distances L1 and L2 are not axial distances but are the shortest distances, distance L1 is shorter than distance L2.

[0070] When the piston 25 moves to the maximum in the inward direction Di, the piston 25 is supported by, for example, a stopper provided in the cylinder 55, and is restricted from moving further in the inward direction Di. At this time, the piston 25 is separated from the bottom surface 51b. Note that the piston 25 may be in contact with the bottom surface 51b.

[0071] Because the distance L1 is smaller than the distance L2, the interposed portion 61 is elastically deformed or compressed between the bottom surface 32d and the support portion 57a. That is, the interposed portion 61 of the stopper 60 has an axial interference. Therefore, the interposed portion 61 pushes the inner pad 21A and the piston 25 in the inward direction Di by its elastic force.

[0072] The tab 62 extends from an edge 65e of the outer portion 65 along the outer surface 51c of the inner body 51. In other words, the tab 62 protrudes from the outer portion 65. The tab 62 is disposed with a gap between it and the outer surface 51c of the inner body 51. The outer portion 65 and the tab 62 are exposed radially outward from the cylinder body 24.

[0073] 2, the inner body 51 of the cylinder body 24 has, for example, a cylindrical portion 51d that defines the cylinder 55, a bracket 51e to which the pin 54 is attached, and a pipe 51f that, for example, exhausts air from the cylinder 55, and is not flat. For this reason, for example, during the manufacture of the disc brake device 10 or during the transportation of the brake caliper 12, if the brake caliper 12 is placed so that the inner body 51 is positioned below the outer body 52, the brake caliper 12 is difficult to stabilize.

[0074] The outer body 52 is formed to be flatter than the inner body 51. Therefore, the brake caliper 12 is stable when the outer body 52 is placed below the inner body 51. In this case, the inner pad 21A is located above the outer pad 21B, the outward direction Do is a substantially downward direction, and the inward direction Di is a substantially upward direction.

[0075] Before the rotor body 11a is disposed between the pair of brake pads 21, the brake caliper 12 has a stopper 60. The stopper 60 restricts the inner pad 21A from moving downward (outward Do) due to, for example, gravity. Therefore, the stopper 60 can prevent the inner pad 21A from falling off the mounting 22 even if, for example, the coating C reduces friction between the inner pad 21A and the pad support 23.

[0076] The stopper 60 is spaced apart from the rotor body 11a. That is, when the stopper 60 is attached to the inner pad 21A and the cylinder body 24, the rotor body 11a can be disposed between the pair of brake pads 21 without interfering with the stopper 60.

[0077] For example, once the rotor body 11a is disposed between the pair of brake pads 21, the stopper 60 is removed from the brake caliper 12 as described below. Note that the method for removing the stopper 60 from the brake caliper 12 is not limited to the following example.

[0078] Figure 6 is a cross-sectional view showing the brake caliper 12 in this embodiment when the hook 66c is released. The stopper 60 is rotated in the release direction Dr shown in Figure 6. By rotating the stopper 60 in the release direction Dr, the hook 66c moves away from the inner edge 31d, the inner edge 32c, and the inner claw 39 of the inner pad 21A in the outward direction Do. In other words, the hook 66c disengages from the inner pad 21A.

[0079] When the stopper 60 rotates in the release direction Dr, the edge 65a of the outer portion 65 moves radially outward. This causes the stopper 60 to elastically deform, disengaging the engaging portion 57b, which is a convex portion, from the engaging portion 65f, which is a concave portion. The edge 65a of the outer portion 65 may be in contact with the support portion 57a ​​of the edge 57. Furthermore, the tab 62 abuts against the outer surface 51c of the inner body 51. This causes the outer surface 51c of the inner body 51 to restrict further rotation of the stopper 60 in the release direction Dr.

[0080] When the hook 66c is separated from the inner pad 21A, the edge 65a is in contact with the support portion 57a, and the tab 62 abuts against the outer surface 51c, a part of the inner portion 66 may protrude in the outward direction Do beyond the friction surface 32a of the inner pad 21A. However, the inner portion 66 is separated from the rotor body 11a. That is, when the edge 65a of the outer portion 65 rotates in the release direction Dr while contacting the support portion 57a ​​of the edge 57, the tab 62 abuts against the outer surface 51c of the inner body 51, thereby restricting the stopper 60 from rotating until the inner portion 66 abuts against the rotor body 11a.

[0081] 7 is a cross-sectional view showing the brake caliper 12 in which the stopper 60 of this embodiment is being pulled out. As shown in FIG. 7, after the hook 66c is disengaged from the inner pad 21A, the inner portion 66 passes through the through-hole 56 and is pulled out radially outward from the groove 36. The tip of the hook 66c in the inward direction Di moves along the bottom surface 32d, so that the inner portion 66 does not protrude beyond the friction surface 32a in the outward direction Do. Therefore, the stopper 60 can be removed from the brake caliper 12 while remaining separated from the rotor body 11a.

[0082] Even if the stopper 60 is removed, the rotor body 11a remains positioned between the pair of brake pads 21. Therefore, the rotor body 11a restricts the movement of the inner pad 21A in the outward direction Do, and prevents the inner pad 21A from falling off the mounting 22.

[0083] On the other hand, when the stopper 60 is attached to the brake caliper 12, the inner portion 66 passes through the through hole 56 and is inserted radially inward into the groove 36. The groove 36 guides the inner portion 66. The inner portion 66 can be inserted into the groove 36 without coming into contact with the friction surface 32a of the friction material 32. Therefore, the stopper 60 can prevent the friction surface 32a from being soiled.

[0084] When the inner portion 66 passes through the groove 36, the stopper 60 is rotated in the mounting direction Dl shown in Fig. 6. By rotating the stopper 60 in the mounting direction Dl, the edge 66b of the inner portion 66 abuts against the bottom surface 32d of the inner pad 21A, and the hook 66c abuts against the inner edge 31d of the back plate 31 of the inner pad 21A.

[0085] When the stopper 60 rotates in the mounting direction Dl, the edge 65a of the outer portion 65 moves radially inward. As a result, the stopper 60 is elastically deformed, and the engaging portion 57b, which is a convex portion, fits into the engaging portion 65f, which is a concave portion. Furthermore, the edge 65a of the outer portion 65 comes into contact with the supporting portion 57a ​​of the edge 57. As a result, the stopper 60 is held between the cylinder body 24 and the inner pad 21A.

[0086] The stopper 60 can be attached to the inner pad 21A and the cylinder body 24 without requiring the brake caliper 12 to have a special shape. The stopper 60 can also be reused. Therefore, the stopper 60 can prevent an increase in the cost of the brake caliper 12.

[0087] In the brake caliper 12 according to the embodiment described above, the stopper 60 is held between the cylinder body 24 and the inner pad 21A so as to restrict movement of the inner pad 21A in the outward direction Do. The portion of the cylinder body 24 near the cylinder 55 has a shape that makes it difficult to stably place the brake caliper 12 due to the cylindrical portion 51d and the tube 51f. Therefore, the brake caliper 12 is stabilized during manufacturing and transportation by positioning the cylinder 55 above the inner pad 21A and the outer pad 21B. In this case, the inner pad 21A is pulled downward (outward direction Do) by gravity. However, the stopper 60 restricts downward movement of the inner pad 21A, thereby preventing the inner pad 21A from falling off. Because the stopper 60 is held between the cylinder body 24 and the inner pad 21A, it is not necessary for the stopper 60 to be interposed between the inner pad 21A and the outer pad 21B. Therefore, the brake caliper 12 does not require the stopper 60 to be removed before parts such as the rotor body 11a are placed between the inner pad 21A and the outer pad 21B, which more reliably prevents the inner pad 21A from falling off and makes manufacturing easier.

[0088] The distance L1 between the support portion 57a ​​and the bottom surface 32d when the piston 25 has moved the farthest in the inward direction Di is shorter than the distance L2 between the edge 65a and the edge 66b when the stopper 60 is disengaged from the cylinder body 24 and the inner pad 21A. The stopper 60 is held between the support portion 57a ​​and the bottom surface 32d while being elastically deformed or compressed. Therefore, the stopper 60 uses its elastic force to push the cylinder body 24 in the outward direction Do and the inner pad 21A in the inward direction Di. Therefore, the stopper 60 can be prevented from disengaging from the cylinder body 24 due to friction between the stopper 60 and the cylinder body 24. Furthermore, the stopper 60 can more reliably prevent the inner pad 21A from moving.

[0089] A portion of the stopper 60 is housed in the groove 36. By being housed in the groove 36, the stopper 60 can have a shape that allows it to abut against the inner pad 21A while being spaced apart from components such as the rotor body 11a. Furthermore, the stopper 60 can abut against the inner pad 21A at a position closer to the center of the inner pad 21A in the circumferential direction, compared to when the stopper 60 is spaced apart from the friction material 32 in the circumferential direction. Therefore, the stopper 60 can support the inner pad 21A in a well-balanced manner, and can prevent the inner pad 21A from tilting.

[0090] The outer portion 65 of the stopper 60 is located radially outward from the inner pad 21A. The inner portion 66 protrudes from the outer portion 65 and is located radially inward from the outer portion 65. The edge 66a of the inner portion 66 is spaced inward from the friction surface 32a of the friction material 32 in the inward direction Di. In other words, the inner portion 66 does not protrude beyond the friction material 32 toward the rotor body 11a. This prevents the stopper 60 from interfering with the rotor body 11a. Therefore, the brake caliper 12 can easily position the rotor body 11a between the inner pad 21A and the outer pad 21B.

[0091] An edge 57 of the cylinder body 24 defines a through-hole 56 that penetrates the bridge 53. An edge 65a of the stopper 60 abuts against the edge 57. Therefore, the stopper 60 can be held between the cylinder body 24 and the inner pad 21A by being inserted into the through-hole 56 from the outside of the cylinder body 24. Furthermore, the stopper 60 can be removed from the outside of the cylinder body 24. Therefore, the brake caliper 12 can easily install and remove the stopper 60 between the inner pad 21A and the outer pad 21B compared to when the installation and removal work of the stopper is performed from the inside in the radial direction. Furthermore, the brake caliper 12 allows the stopper 60 to be removed after a component such as the rotor body 11a has been installed. Furthermore, the brake caliper 12 makes the stopper 60 visible through the through-hole 56, thereby preventing the stopper 60 from being left behind.

[0092] An engagement portion 57b, which is a convex portion, is provided on the cylinder body 24. An engagement portion 65f, which is a concave portion, is provided on the edge 65a. The engagement portion 65f fits into the engagement portion 57b, thereby restricting radial movement of the stopper 60. As a result, the engagement portion 57b and the engagement portion 65f can prevent the stopper 60 from easily coming off the cylinder body 24 and the inner pad 21A due to an external force such as vibration. Furthermore, the engagement portion 57b and the engagement portion 65f can be easily fitted together by snap fitting.

[0093] In this embodiment, the engaging portion 57b is a convex portion and the engaging portion 65f is a concave portion. However, the engaging portion 57b may be provided as a concave portion on the support portion 57a, and the engaging portion 65f may be provided as a convex portion on the edge 65a.

[0094] The hook 66c of the stopper 60 abuts against the inner pad 21A, thereby restricting radial outward movement of the stopper 60. This prevents the stopper 60 from easily coming off the cylinder body 24 and the inner pad 21A due to an external force such as vibration.

[0095] As an example, the brake caliper according to at least one embodiment described above includes: a mounting, a back plate, and a friction material protruding from the back plate in a first direction, a first brake pad supported on the mounting so as to be movable in the first direction and a second direction opposite to the first direction; a second brake pad spaced from the first brake pad in the first direction and supported on the mounting; a cylinder body provided with a cylinder and supported on the mounting so as to be movable in the first direction and the second direction; a piston housed in the cylinder so as to be movable in the first direction and the second direction and configured to press the first brake pad in the first direction; and a stopper having a first abutment portion abutting the cylinder body and a second abutment portion abutting the first brake pad, and held between the cylinder body and the first brake pad so as to limit movement of the first brake pad in the first direction. For example, the portion of the cylinder body near the cylinder may be formed in a generally cylindrical shape corresponding to the cylinder, or a pipe for supplying brake fluid to the cylinder may be connected, making it difficult to place stably. Therefore, during manufacturing and transportation, the brake caliper is stabilized by positioning the cylinder above the first and second brake pads. In this case, gravity pulls the first brake pad downward (in the first direction). However, the stopper restricts the downward movement of the first brake pad, thereby preventing the first brake pad from falling off. Because the stopper is held between the cylinder body and the first brake pad, there is no need for a stopper to be interposed between the first and second brake pads. Therefore, the brake caliper does not require the stopper to be removed before placing a component such as a rotor between the first and second brake pads. This more reliably prevents the first brake pad from falling off, facilitating manufacturing.

[0096] In the above-described brake caliper, as an example, the cylinder body has a first support portion supporting the first contact portion, and the first brake pad has a second support portion supporting the second contact portion. The distance between the first support portion and the second support portion when the piston moves the most in the second direction is shorter than the distance between the first contact portion and the second contact portion when the stopper is disengaged from the cylinder body and the first brake pad. Therefore, as an example, the stopper is elastically deformed or compressed and held between the first support portion and the second support portion. Therefore, the stopper uses its elastic force to push the cylinder body in the first direction and the first brake pad in the second direction. Therefore, the stopper can be prevented from coming off the cylinder body due to friction between the stopper and the cylinder body. Furthermore, the stopper can more reliably prevent the first brake pad from moving.

[0097] In the above-described brake caliper, for example, a groove is provided in the friction material, and a portion of the stopper is housed in the groove. Therefore, for example, the stopper can have a shape that allows it to abut against the first brake pad while being spaced apart from a component such as a rotor by being housed in the groove. Furthermore, the stopper can abut against the first brake pad at a position closer to the center of the first brake pad in the circumferential direction than when the stopper is spaced apart from the friction material in the circumferential direction. Therefore, the stopper can support the first brake pad in a balanced manner, and can prevent the first brake pad from tilting.

[0098] In the above-described brake caliper, for example, the friction material is configured to be pressed against the rotor when the piston presses the first brake pad in the first direction, the first direction and the second direction being along the central axis of rotation of the rotor, and the stopper has an outer portion located outside the first brake pad in a radial direction perpendicular to the central axis, and an inner portion protruding from the outer portion and located inside the outer portion in the radial direction, the end of the inner portion in the first direction being spaced apart in the second direction from the end of the friction material in the first direction. Thus, for example, the inner portion does not protrude toward the rotor beyond the friction material. This prevents the stopper from interfering with the rotor. Therefore, the brake caliper can easily position the rotor between the first brake pad and the second brake pad.

[0099] In the above-described brake caliper, as one example, the cylinder body has a first portion in which the cylinder is provided, a second portion spaced from the first portion in the first direction and restricting movement of the second brake pad in the first direction, a third portion extending between the first portion and the second portion, and a rim defining a through hole penetrating the third portion, and the first abutment portion abuts against the rim. Thus, as one example, the stopper can be inserted into the through hole from outside the cylinder body to be held between the cylinder body and the first brake pad. Furthermore, the stopper can be removed from outside the cylinder body. Therefore, the brake caliper facilitates installation and removal of the stopper, and the stopper can be removed after a component such as a rotor is installed.

[0100] In the above-described brake caliper, for example, the friction material is configured to be pressed against the rotor when the piston presses the first brake pad in the first direction, the first direction and the second direction being along the central axis of rotation of the rotor, the cylinder body being provided with a first engagement portion, which is one of a protrusion and a recess, and the first abutment portion being provided with a second engagement portion, which is the other of the protrusion and the recess and engages with the first engagement portion to limit movement of the stopper in a radial direction perpendicular to the central axis. Thus, for example, the first engagement portion and the second engagement portion can prevent the stopper from easily coming off the cylinder body and the first brake pad due to, for example, an external force. Furthermore, the first engagement portion and the second engagement portion can be easily engaged with each other by snap-fitting.

[0101] In the brake caliper, as one example, the friction material is configured to be pressed against the rotor when the piston presses the first brake pad in the first direction, the first direction and the second direction are along a central axis of rotation of the rotor, and the stopper has a hook that abuts against the first brake pad to limit the stopper from moving outward in a radial direction perpendicular to the central axis. Thus, as one example, the hook can prevent the stopper from easily coming off the cylinder body and the first brake pad due to, for example, an external force.

[0102] At least one of the stoppers according to the embodiments described above includes, for example, a first contact portion configured to contact a cylinder body of a brake caliper and a second contact portion configured to contact a brake pad of the brake caliper, and an interposition portion configured to be held between the cylinder body and the brake pad to restrict movement of the brake pad. Therefore, for example, the interposition portion restricts movement of the brake pad, thereby preventing the brake pad from falling off. Because the interposition portion is held between the cylinder body and the brake pad, it does not need to be interposed between the two brake pads. Therefore, the stopper does not need to be removed before a component such as a rotor is placed between the two brake pads, which more reliably prevents the brake pad from falling off and facilitates manufacturing of the brake caliper.

[0103] While the embodiments of the present invention have been described above, the above-described embodiments and modifications are merely examples and are not intended to limit the scope of the invention. The above-described embodiments and modifications can be implemented in various other forms, and various omissions, substitutions, combinations, and modifications can be made without departing from the spirit of the invention. Furthermore, the configurations and shapes of each embodiment and each modification can be partially interchanged. [Explanation of symbols]

[0104] 11...Disc rotor (rotor), 12...Brake caliper, 21A...Inner pad (first brake pad, brake pad), 21B...Outer pad (second brake pad), 22...Mounting, 24...Cylinder body, 25...Piston, 31...Back plate, 32...Friction material, 32a...Friction surface (edge), 32d...Bottom surface (second support part), 36...Groove, 51...Inner body (first part), 52...Outer body (second Part 2), 53...bridge (third part), 55...cylinder, 56...through hole, 57...edge, 57a...support part (first support part), 57b...engagement part (first engagement part), 60...stopper, 61...intervening part, 65...external part, 65a...edge (first abutment part), 65f...engagement part (second engagement part), 66...inner part, 66b...edge (second abutment part), 66c...hook, Ax...central axis, Do...outer direction (first direction), Di...inner direction (second direction).

Claims

1. Mounting and a first brake pad having a back plate and a friction material protruding from the back plate in a first direction, the first brake pad being supported by the mounting so as to be movable in the first direction and a second direction opposite to the first direction; a second brake pad spaced from the first brake pad in the first direction and supported by the mounting; a cylinder body provided with a cylinder and supported by the mounting so as to be movable in the first direction and the second direction; a piston housed in the cylinder so as to be movable in the first direction and the second direction, and configured to push the first brake pad in the first direction; a stopper having a first contact portion that contacts the cylinder body and a second contact portion that contacts the first brake pad, the stopper being held between the cylinder body and the first brake pad so as to restrict movement of the first brake pad in the first direction; A brake caliper comprising:

2. the cylinder body has a first support portion that supports the first abutment portion, the first brake pad has a second support portion that supports the second abutment portion, a distance between the first support portion and the second support portion when the piston has moved the furthest in the second direction is shorter than a distance between the first abutment portion and the second abutment portion when the stopper is disengaged from the cylinder body and the first brake pad; The brake caliper of claim 1.

3. The friction material has grooves, A portion of the stopper is received in the groove. The brake caliper of claim 1.

4. the friction material is configured to be pressed against the rotor when the piston presses the first brake pad in the first direction; the first direction and the second direction are along a central axis of rotation of the rotor; the stopper has an outer portion located outward from the first brake pad in a radial direction perpendicular to the central axis, and an inner portion protruding from the outer portion and located inward from the outer portion in the radial direction, an end of the inner portion in the first direction is spaced apart in the second direction from an end of the friction material in the first direction; The brake caliper of claim 1.

5. the cylinder body has a first portion in which the cylinder is provided, a second portion spaced from the first portion in the first direction and restricting movement of the second brake pad in the first direction, a third portion extending between the first portion and the second portion, and a rim defining a through hole passing through the third portion; the first abutment portion abuts against the edge; The brake caliper of claim 1.

6. the friction material is configured to be pressed against the rotor when the piston presses the first brake pad in the first direction; the first direction and the second direction are along a central axis of rotation of the rotor; a first engaging portion, which is one of a protrusion and a recess, provided on the cylinder body; a second engaging portion, which is the other of the convex portion and the concave portion and which is fitted with the first engaging portion to limit movement of the stopper in a radial direction perpendicular to the central axis, is provided on the first abutment portion; The brake caliper of claim 1.

7. the friction material is configured to be pressed against the rotor when the piston presses the first brake pad in the first direction; the first direction and the second direction are along a central axis of rotation of the rotor; the stopper has a hook that abuts against the first brake pad to limit the stopper from moving outward in a radial direction perpendicular to the central axis. The brake caliper of claim 1.

8. an interposition portion having a first abutment portion configured to abut against a cylinder body of a brake caliper and a second abutment portion configured to abut against a brake pad of the brake caliper, the interposition portion being configured to be held between the cylinder body and the brake pad to restrict movement of the brake pad; A stopper comprising:

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