Brake caliper

Abstract

To provide a brake caliper capable of stabilizing elastic force of a spring as one example.SOLUTION: A brake caliper according to an embodiment includes: a brake pad; a support member which has a first surface facing a rotor and a second surface on the opposite side and supports the brake pad; a pad support which has an interposed portion interposed between the brake pad and the support member, and a support plate supported by the second surface; and a spring which has an attachment portion attached to the brake pad, an abutment portion, and an elastic portion provided between the attachment portion and the abutment portion, where the abutment portion is at a first position on the surface when the brake pad is separated from the rotor; the abutment portion is at a second position on the surface separated from the first position in a first direction when the brake pad comes into contact with the rotor; and the abutment portion is movably supported by the surface.SELECTED DRAWING: Figure 2

Description

[Technical Field]

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

[0002] A conventional brake caliper includes brake pads and a spring that separates the brake pads from the rotor when braking is released. The spring separates the brake pads from the rotor, thereby suppressing the generation of drag resistance (Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2015-028376 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in the conventional configuration, the spring is supported by, for example, a metal plate, and if the metal plate deforms, the elastic deformation of the spring caused by the movement of the brake pad becomes unstable, which may in turn cause the elastic force of the spring to become unstable.

[0005] Therefore, the present invention has been made in view of the above, and provides a brake caliper that can stabilize the elastic force of a spring. [Means for solving the problem]

[0006] As an example, a brake caliper according to an embodiment of the present invention includes a pad support having a brake pad, a support member having a first surface facing a rotor and a second surface located opposite to the first surface and supporting the brake pad movably in an axial direction along a central axis of rotation of the rotor, an intervening portion interposed between the brake pad and the support member, and a support plate supported by the second surface and connected to the intervening portion, a mounting portion attached to the brake pad, an abutting portion abutting against a surface of the support plate, and a contact portion provided between the mounting portion and the abutting portion. The brake pad includes a spring having an elastic portion formed on the surface of the support plate, the elastic portion pushing the brake pad away from the rotor by the elastic force of the elastic portion when the brake pad moves toward the rotor, the abutment portion being at a first position on the surface when the brake pad is away from the rotor, and the abutment portion being at a second position on the surface separated from the first position in a first direction along the surface when the brake pad is in contact with the rotor, the abutment portion being supported on the surface so as to be movable between the first and second positions. Therefore, as an example, the surface of the support plate allows movement of the abutment portion at least in the direction of movement of the abutment portion when the elastic portion elastically deforms. Furthermore, because the support plate is supported on the second surface of the support member, it is less likely to deform due to the load from the spring. In other words, the shape of the surface of the support plate is stable. Therefore, the abutment portion can naturally move on the surface of the support plate so as to stabilize the elastic deformation of the elastic portion. For example, the brake caliper can prevent the elastic force of the spring from becoming unstable. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 1 is a front view that schematically shows a disc brake device according to a first embodiment. [Figure 2] FIG. 2 is a front view showing the brake caliper of the first embodiment. [Figure 3] FIG. 3 is an exploded perspective view of the brake caliper of the first embodiment. [Figure 4]FIG. 4 is a top view showing the pad assembly of the first embodiment. [Figure 5] FIG. 5 is a partial cross-sectional view of the pad assembly, mounting, and pad support of the first embodiment. [Figure 6] FIG. 6 is a cross-sectional view schematically showing the disc rotor, pad assembly, mounting, and pad support of the first embodiment taken along line F6-F6 in FIG. [Figure 7] FIG. 7 is a perspective view showing the pad support of the first embodiment. [Figure 8] FIG. 8 is a perspective view showing the return spring of the first embodiment. [Figure 9] FIG. 9 is a cross-sectional view that schematically shows a disc rotor, a pad assembly, a mounting, and a pad support according to the second embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] (First embodiment) The first embodiment will be described below with reference to FIGS. 1 to 8. 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 a first 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 circumferential direction includes the forward rotation direction Dcn and the reverse rotation direction Dcr shown in FIG. 1. The forward rotation direction Dcn is one direction around the central axis Ax. The reverse rotation direction Dcr is the opposite direction around the central axis Ax. When the vehicle 1 moves forward, the disc rotor 11 rotates in the forward rotation direction Dcn. On the other hand, when the vehicle 1 moves backward, the disc rotor 11 rotates in the reverse rotation direction Dcr.

[0014] 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 axial direction. The hat portion 11b is formed in a substantially cylindrical shape and is coupled to, for example, an axle of the vehicle 1.

[0015] FIG. 2 is a front view showing the brake caliper 12 of the first embodiment. FIG. 3 is an exploded perspective view showing the brake caliper 12 of the first embodiment. As shown in FIG. 3, the brake caliper 12 of this embodiment is a floating caliper. However, the brake caliper may be another type of caliper, such as an opposed caliper. The brake caliper 12 is disposed so as to straddle the rotor body 11a.

[0016] The brake caliper 12 has a pair of brake pad assemblies (hereinafter referred to as pad assemblies) 21, a mounting 22, a movable caliper 23, and two pairs of pad supports 24. The mounting 22 is an example of a support member.

[0017] 4 is a top view showing the pad assembly 21 of the first embodiment. The pair of pad assemblies 21 are aligned in the axial direction and arranged in mirror symmetry. The rotor body 11a is arranged between the pair of pad assemblies 21.

[0018] Each of the pair of pad assemblies 21 includes a brake pad 25 and a return spring 26. The return spring 26 is an example of a spring and may also be referred to as, for example, a pad mounting member or a pad wear indicator (PWI).

[0019] The pair of brake pads 25 of this embodiment are formed to have substantially the same shape. That is, each of the pair of brake pads 25 is formed to be mirror-symmetrical with respect to the caliper center Cc shown in FIG. 1. The caliper center Cc is an imaginary plane that extends radially through the center of the brake pad 25 in the circumferential direction. Note that the pair of brake pads 25 may have different shapes. As shown in FIG. 4, each of the pair of brake pads 25 has a back plate 31, a friction material 32, and a shim 33.

[0020] 5 is a cross-sectional view partially illustrating the pad assembly 21, mounting 22, and pad support 24 of the first embodiment. The back plate 31 is formed in a plate shape that is disposed approximately perpendicular to the axial direction and extends approximately in the circumferential direction. The back plate 31 has two end portions 31a in the circumferential direction. FIG. 5 shows the end portion 31a of the two end portions 31a in the reverse direction Dcr.

[0021] 4, the back plate 31 further has a mounting surface 31b and a back surface 31c that face substantially in the axial direction. The mounting surface 31b faces the rotor body 11a. The back surface 31c is located on the opposite side of the mounting surface 31b.

[0022] A pair of protrusions 35 is provided on the back plate 31. The protrusions 35 are provided on two end portions 31a of the back plate 31. The pair of protrusions 35 are formed integrally with the back plate 31.

[0023] As shown in Figure 5, each of the pair of protrusions 35 has an inner surface 35a, an outer surface 35b, and an end surface 35c. The inner surface 35a faces radially inward. The outer surface 35b is located opposite the inner surface 35a and faces radially outward. The end surface 35c is provided between the end of the inner surface 35a and the end of the outer surface 35b and faces in the circumferential direction as a whole. A recess 36 is provided in the end surface 35c.

[0024] 4, the friction material 32 is fixed to the mounting surface 31b of the back plate 31. The friction material 32 is located between the mounting surface 31b and the rotor body 11a. The shim 33 is attached to the back surface 31c of the back plate 31.

[0025] The return spring 26 is attached to one of the protrusions 35 of the brake pad 25. In this embodiment, the return spring 26 is attached to the protrusion 35 provided on the end 31a in the reverse rotation direction Dcr. Note that the return spring 26 may be attached to the protrusion 35 provided on the end 31a in the forward rotation direction Dcn, or two return springs 26 may be attached to two protrusions 35.

[0026] 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. As shown in FIG. 3 , the mounting 22 supports the pad assembly 21, the movable caliper 23, and the pad support 24.

[0027] The mounting 22 has two pairs of side frames 41. One pair of side frames 41 and the other pair of side frames 41 are aligned in the axial direction. Each pair of side frames 41 supports a pair of protrusions 35 of the corresponding brake pad 25 so that the brake pad 25 can move in the axial direction. The rotor body 11a is disposed between the pair of side frames 41 and the other pair of side frames 41. A corresponding pad support 24 is attached to each of the two pairs of side frames 41.

[0028] 6 is a cross-sectional view schematically showing the disc rotor 11, pad assembly 21, mounting 22, and pad support 24 of the first embodiment taken along line F6-F6 in FIG. 5. As shown in FIG. 6, each of the side frames 41 has two side surfaces 41a and 41b. The side surface 41a is an example of a first surface. The side surface 41b is an example of a second surface.

[0029] The side surfaces 41a and 41b are flat surfaces that are approximately perpendicular to the axial direction. The side surfaces 41a and 41b may be curved or inclined, or may have irregularities. The side surface 41a faces the rotor body 11a of the disc rotor 11. The side surface 41b is located on the opposite side of the side surface 41a.

[0030] The mounting 22 is made of, for example, cast iron and formed by casting. The side surface 41a of the mounting 22 is, for example, machined. On the other hand, the side surface 41b is a casting surface formed by casting. Therefore, the surface roughness of the side surface 41b is greater than the surface roughness of the side surface 41a. However, the side surfaces 41a and 41b are not limited to this example.

[0031] As shown in FIG. 5, each of the side frames 41 further has a recessed surface 41c. The recessed surface 41c extends in the axial direction between the two side surfaces 41a, 41b. The recessed surface 41c defines a recessed portion 45. That is, the recessed portion 45 is provided in each of the side frames 41. The recessed portion 45 extends in the axial direction and opens to the two side surfaces 41a, 41b. The axial lengths of the recessed surface 41c and the recessed portion 45 are longer than the axial length (thickness) of the back plate 31.

[0032] The concave surface 41c has an inner surface 45a, an outer surface 45b, and an end surface 45c. The end surface 45c may also be referred to as a torque transmission surface. The inner surface 45a faces radially outward. The outer surface 45b faces radially inward. The inner surface 45a and the outer surface 45b face each other. The end surface 45c is located between the end of the inner surface 45a and the end of the outer surface 45b and faces in the circumferential direction as a whole.

[0033] The protrusion 35 is fitted (housed) in the recess 45. The inner surface 45a faces the inner surface 35a of the protrusion 35 via a gap. The outer surface 45b faces the outer surface 35b of the protrusion 35 via a gap. The end surface 45c faces the end surface 35c of the protrusion 35 via a gap.

[0034] 3, the movable caliper 23 has a pressing device 50. The pressing device 50 has, for example, a cylinder 51, a piston 52, and an actuator 53 that drives the piston. The pressing device 50 is disposed inward of the disc rotor 11 in the vehicle width direction.

[0035] The pressing device 50 is hydraulically or electrically operated, and presses the inner one of the pair of brake pads 25 in the axial direction using a piston 52. This causes the friction material 32 of the inner brake pad 25 to be pressed against the rotor body 11a.

[0036] When the inner brake pad 25 is pressed against the rotor body 11a, the movable caliper 23 moves in the opposite direction to the piston movement due to reaction, causing the movable caliper 23 to press one of the outer brake pads 25 against the rotor body 11a.

[0037] Specifically, the movable caliper 23 presses the back plate 31 via the shim 33. This causes the friction material 32 to come into contact with the rotor body 11a. Note that the shim 33 may be omitted, and the movable caliper 23 may press the back plate 31 directly.

[0038] FIG. 7 is a perspective view showing the pad support 24 of the first embodiment. As shown in FIG. 7, the pad support 24 is formed, for example, from a metal plate bent by press working, and has elasticity. The pad support 24 is made, for example, from stainless steel (SUS). That is, the pad support 24 has a higher hardness (for example, Vickers hardness) than the mounting 22. However, the material of the pad support 24 is not limited to this example.

[0039] Each of the pad supports 24 has an interposing portion 61, a spring portion 62, and two clip portions 63, 64. The clip portion 63 is an example of a holding plate. The interposing portion 61, the spring portion 62, and the clip portions 63, 64 are formed in a plate shape.

[0040] As shown in FIG. 5, the interposition portion 61 is formed in a substantially U-shape and is fitted into the corresponding recess 45. The interposition portion 61 is interposed between the protrusion 35 of the brake pad 25 and the recess surface 41c of the mounting 22, and holds the brake pad 25 axially movable. In other words, the mounting 22 supports the brake pad 25 via the pad support 24 so that the brake pad 25 is axially movable relative to the disc rotor 11. The interposition portion 61 has an inner plate portion 65, an outer plate portion 66, and a connecting plate portion 67. The connecting plate portion 67 may also be referred to as a torque transmission portion.

[0041] The inner plate portion 65 is located between the inner surface 35a of the protrusion 35 and the inner surface 45a of the mounting 22, and extends in a substantially circumferential direction. The outer plate portion 66 is located between the outer surface 35b of the protrusion 35 and the outer surface 45b of the mounting 22, and extends in a substantially circumferential direction.

[0042] The connecting plate portion 67 is provided between one circumferential end of the inner plate portion 65 and one circumferential end of the outer plate portion 66. The connecting plate portion 67 is located between the end face 35c of the protrusion 35 and the end face 45c of the mounting 22, and extends in a substantially radial direction. The connecting plate portion 67 contacts the end face 45c of the mounting 22.

[0043] The spring portion 62 is, for example, a leaf spring extending from an end of the inner plate portion 65 in the axial direction. A part of the spring portion 62 is located between the inner plate portion 65 and the protrusion 35, and contacts the inner surface 35a of the protrusion 35. The spring portion 62 presses the protrusion 35 against the outer plate portion 66, thereby holding the brake pad 25 in the radial direction.

[0044] The brake pad 25 can move within a predetermined range in the circumferential direction relative to the mounting 22 and the pad support 24. When the brake pad 25 moves to its maximum extent in one circumferential direction, the end face 35c of the protrusion 35 comes into contact with the connecting plate portion 67 of the pad support 24. When the brake pad 25 moves in the other circumferential direction, the end face 35c moves away from the connecting plate portion 67.

[0045] 6, the clip portion 63 extends from one axial end of the connecting plate portion 67. The clip portion 64 extends from the other axial end of the connecting plate portion 67. That is, the clip portions 63 and 64 are connected to the intermediate portion 61.

[0046] The clip portion 63 is located between the rotor body 11a of the disc rotor 11 and the side surface 41a of the side frame 41. The clip portion 63 abuts against the side surface 41a and is supported by the side surface 41a.

[0047] The clip portion 64 has a flat portion 71, a connecting end portion 72, and a curved end portion 73. The flat portion 71 is an example of a support plate. The flat portion 71 is formed in a flat plate shape and has two flat surfaces 71a and 71b. The flat surface 71b is an example of a surface of a support plate.

[0048] The flat surface 71a is disposed along the side surface 41b of the side frame 41 and is in surface contact with the side surface 41b. Therefore, the flat portion 71 abuts against the side surface 41b and is supported by the side surface 41b. Almost the entire area of ​​the flat surface 71a is in contact with the side surface 41b. Note that the flat surface 71a may be in partial contact with the side surface 41b. The flat surface 71b is located on the opposite side of the flat surface 71a. The flat surface 71b is disposed approximately parallel to the flat surface 71a and the side surface 41b.

[0049] The flat surfaces 71a and 71b are substantially perpendicular to the axial direction. Therefore, the flat surfaces 71a and 71b extend in the radial and circumferential directions. The flat surfaces 71a and 71b are formed in a substantially rectangular shape. However, the flat surfaces 71a and 71b are not limited to this example.

[0050] For example, a coating 75 is provided on the flat surface 71b. The coating 75 is made of a synthetic resin such as polytetrafluoroethylene (PTFE). The flat surface 71b is not limited to this example and may be made of stainless steel, which is the material of the pad support 24. The surface roughness of the flat surface 71b is smaller than the surface roughness of the side surface 41b of the side frame 41.

[0051] The connecting end 72 is provided between one end of the flat portion 71 in the circumferential direction and the connecting plate portion 67. That is, the flat portion 71 is connected to the interposed portion 61 via the connecting end 72. The curved end 73 is connected to the other end of the flat portion 71 in the circumferential direction. The connecting end 72 and the curved end 73 are bent so as to protrude from the plane 71b.

[0052] The clip portion 63 and the flat portion 71 of the clip portion 64 press the side frame 41 by elastic force. That is, the pad support 24 holds the side frame 41 of the mounting 22 between the clip portion 63 and the flat portion 71. In this way, the pad support 24 is attached to the side frame 41.

[0053] FIG. 8 is a perspective view showing the return spring 26 of the first embodiment. As shown in FIG. 8, the return spring 26 is formed, for example, from a bent metal plate and has elasticity. The return spring 26 is made, for example, from stainless steel. However, the material of the return spring 26 is not limited to this example. Each of the multiple return springs 26 has an attachment portion 81 and two spring portions 82 and 83. The attachment portion 81 and the spring portions 82 and 83 are formed in a plate shape.

[0054] The mounting portion 81 is formed in a substantially U-shape and has two clip portions 85, 86 and a connecting portion 87. As shown in FIG. 6 , the clip portion 85 abuts against the mounting surface 31b of the back plate 31. The clip portion 86 abuts against the back surface 31c of the back plate 31. The connecting portion 87 extends in a substantially axial direction between one end of the clip portion 85 in the circumferential direction and one end of the clip portion 86 in the circumferential direction. The connecting portion 87 connects the two clip portions 85, 86.

[0055] 5, the connection portion 87 is at least partially housed in the recess 36. As a result, the protrusion 35 of the back plate 31 restricts the connection portion 87 of the return spring 26 from moving in the radial direction.

[0056] 6, the mounting portion 81 holds the protrusion 35 of the back plate 31 between the two clip portions 85, 86 by elastic force. In this way, the mounting portion 81 is attached to the back plate 31 of the brake pad 25.

[0057] The two spring portions 82, 83 protrude away from the rotor body 11a from the other circumferential end of the clip portion 86. Each of the two spring portions 82, 83 is bent into a substantially U-shape or a substantially J-shape.

[0058] A part of the spring portion 82 is located between the protrusion 35 of the back plate 31 and the connecting plate portion 67 of the pad support 24, and is also located between the connection portion 87 of the mounting portion 81 and the connecting plate portion 67. The spring portion 82 is spaced apart from the connection portion 87.

[0059] The spring portion 82 abuts against the connecting plate portion 67. Note that the spring portion 82 may be temporarily separated from the connecting plate portion 67. The spring portion 82 presses the connecting plate portion 67 in the reverse direction Dcr by its elastic force. Furthermore, the spring portion 82 presses the brake pad 25 attached to the attachment portion 81 in the forward rotation direction Dcn by its elastic force (reaction force). As a result, the end face 35c of the protrusion 35 is pressed against the connecting plate portion 67 of the pad support 24 at the end portion 31a in the forward rotation direction Dcn. That is, the spring portion 82 holds the brake pad 25 in the circumferential direction by its elastic force.

[0060] The tip of the spring portion 82 protrudes toward the rotor body 11a beyond the mounting surface 31b of the back plate 31 and the clip portion 85. Therefore, when the friction material 32 of the brake pad 25 wears, the tip of the spring portion 82 may come into contact with the rotor body 11a.

[0061] When the tip of the spring portion 82 comes into contact with the rotating rotor body 11a, an alarm sound (chattering noise) is generated. The alarm sound enables the driver to notice that the friction material 32 has worn beyond a predetermined amount. The spring portion 82 can generate an alarm sound before the back plate 31 and the mounting portion 81 come into contact with the rotor body 11a. Note that the spring portion 82 is not limited to this example.

[0062] The spring portion 83 has an elastic portion 91 and a protrusion 92. The protrusion 92 is an example of a contact portion. The elastic portion 91 has a first straight portion 95, a first curved portion 96, a second straight portion 97, and a second curved portion 98.

[0063] The first straight portion 95 extends from the clip portion 86 away from the rotor body 11a. The first curved portion 96 extends from the end of the first straight portion 95 in a substantially arc-like shape around a curved portion center Cb. The curved portion center Cb is an imaginary straight line extending substantially parallel to the caliper center Cc. Note that the first curved portion 96 is not limited to an arc-like shape, as long as it is curved so as to extend around the curved portion center Cb.

[0064] The second straight portion 97 extends from the end of the first curved portion 96 toward the side surface 41b of the side frame 41 and the flat surface 71b of the flat portion 71. The second curved portion 98 extends in a substantially arc shape from the end of the second straight portion 97. The second curved portion 98 has a curved surface 98a. The curved surface 98a is, for example, a substantially cylindrical curved surface that curves so as to protrude toward the flat surface 71b.

[0065] As shown in FIG. 8 , a slit 99 is provided in the elastic portion 91. The slit 99 is provided across the first straight portion 95, the first curved portion 96, and the second straight portion 97. The slit 99 penetrates the elastic portion 91 and divides each of the first straight portion 95 and the first curved portion 96 into two portions. The spring portion 82 is located between the two portions divided by the slit 99 in the radial direction. Note that the position of the spring portion 82 is not limited to this example.

[0066] The two portions separated by the slit 99 join at the second straight portion 97. Therefore, the second straight portion 97 is formed in a substantially Y-shape or a substantially V-shape. In the radial direction, the length (width) of each of the first straight portion 95 and the first curved portion 96 is longer than the length (width) of the second curved portion 98.

[0067] 6, the second curved portion 98 is spaced apart in the circumferential direction from the back plate 31 and the mounting portion 81. Furthermore, the second curved portion 98 is spaced apart in the axial direction from the rotor body 11a more than the mounting portion 81.

[0068] The protrusion 92 protrudes from the curved surface 98a toward the flat surface 71b of the flat portion 71. That is, the elastic portion 91 is provided in the spring portion 83 between the attachment portion 81 and the protrusion 92. In this embodiment, the protrusion 92 is, for example, a substantially hemispherical protrusion.

[0069] The protrusion 92 abuts against the flat surface 71b of the flat portion 71. Because the protrusion 92 is a hemispherical protrusion, the area where the protrusion 92 and the flat surface 71b abut is small. The protrusion 92 makes point contact with the flat surface 71b, for example. Therefore, the length of the area where the protrusion 92 abuts against the flat surface 71b in the radial direction is shorter than the length (width) of the curved surface 98a of the second curved portion 98.

[0070] The protrusion 92 may be omitted, and the curved surface 98a of the second curved portion 98 may be an example of an abutting portion that abuts against the flat surface 71b of the flat portion 71. In this case, the curved surface 98a as the abutting portion makes line contact with the flat surface 71b.

[0071] The flat surface 71b of the flat portion 71 is wider than the portion where the protrusion 92 and the flat surface 71b abut. The protrusion 92 is supported on the flat surface 71b so as to be movable in the horizontal directions Dh1 and Dh2 and the vertical directions Dv1 and Dv2 shown in Figure 2. The horizontal direction Dh1 is an example of a first direction. The vertical directions Dv1 and Dv2 are an example of a second direction.

[0072] The lateral directions Dh1 and Dh2 are directions along the plane 71b and perpendicular to the caliper center Cc and the curved portion center Cb. The lateral direction Dh1 is a direction close to the reverse rotation direction Dcr. The lateral direction Dh2 is the opposite direction of the lateral direction Dh1 and is a direction close to the forward rotation direction Dcn.

[0073] The vertical directions Dv1 and Dv2 are directions along the plane 71b and perpendicular to the horizontal directions Dh1 and Dh2. In other words, the vertical directions Dv1 and Dv2 are directions along the caliper center Cc and the curved portion center Cb. The vertical direction Dv1 is a direction close to the inside in the radial direction. The vertical direction Dv2 is the opposite direction of the vertical direction Dv1 and is a direction close to the outside in the radial direction.

[0074] The directions in which the protrusion 92 can move are not limited to the horizontal directions Dh1, Dh2 and the vertical directions Dv1, Dv2. The protrusion 92 may be movable in a direction diagonal between the horizontal directions Dh1, Dh2 and the vertical directions Dv1, Dv2, as long as the direction is along the plane 71b. Furthermore, the second direction may not be perpendicular to the first direction, but may be a direction that diagonally intersects with the first direction.

[0075] 6, in the clip portion 64 of the pad support 24, the connection end portion 72 is connected to the end of the flat portion 71 in the lateral direction Dh2. The curved end portion 73 is connected to the end of the flat portion 71 in the lateral direction Dh1.

[0076] In the spring portion 83 of the return spring 26, the first straight portion 95 is connected to the end of the first bent portion 96 in the lateral direction Dh2. The second straight portion 97 is connected to the end of the first bent portion 96 in the lateral direction Dh1.

[0077] The elastic portion 91 and the protrusion 92 are spaced apart from the connecting end 72 and the curved end 73. Therefore, the protrusion 92 can move in either of the lateral directions Dh1 and Dh2. The connecting end 72 may temporarily come into contact with the protrusion 92.

[0078] When the disc brake device 10 brakes the disc rotor 11 and the wheel, the pressing device 50 moves the brake pad 25 in the axial direction toward the rotor body 11a. The brake pad 25 moves in the axial direction along the recess 45, and the friction material 32 comes into contact with the rotor body 11a.

[0079] As the brake pads 25 approach the rotor body 11a, the attachment portions 81 attached to the back plate 31 also move toward the rotor body 11a. On the other hand, the mountings 22 are attached to a non-rotating portion of the vehicle 1 and therefore do not move relative to the vehicle 1. The pad supports 24 are also attached to the mountings 22 and therefore remain in approximately the same position.

[0080] The protrusion 92 of the spring portion 83 abuts against the flat surface 71b of the flat portion 71 of the pad support 24. Therefore, the protrusion 92 also remains in approximately the same position in the axial direction. That is, the distance between the mounting portion 81 and the protrusion 92 in the axial direction increases.

[0081] When the distance between the mounting portion 81 and the protrusion 92 increases, for example, the first curved portion 96 of the elastic portion 91 elastically deforms. As a result, the spring portion 83 pushes the flat surface 71b of the flat portion 71 toward the rotor body 11a due to the elastic force of the elastic portion 91. Furthermore, the spring portion 83 pushes the brake pad 25 attached to the mounting portion 81 away from the rotor body 11a due to the reaction force (the elastic force of the elastic portion 91).

[0082] The force with which the spring portion 83 presses the brake pad 25 is smaller than the force with which the pressing device 50 presses the brake pad 25. Therefore, the pressing device 50 moves the brake pad 25 toward the rotor body 11a against the force with which the spring portion 83 presses the brake pad 25.

[0083] When the friction material 32 comes into contact with the disc rotor 11 rotating in the forward rotation direction Dcn, the brake pad 25 receives a force in the forward rotation direction Dcn due to friction between the rotor body 11a and the friction material 32. As a result, at the end 31a in the forward rotation direction Dcn, the end face 35c of the protrusion 35 presses against the end face 45c of the mounting 22 via the corresponding connecting plate portion 67 of the pad support 24.

[0084] The mounting 22 receives the braking force (braking torque) transmitted via the brake pads 25 and transmits it to the body of the vehicle 1. In this way, the disc brake device 10 brakes the disc rotor 11.

[0085] When the braking is released and the pressure is released, the spring portion 83 separates the brake pad 25 from the rotor body 11a by the elastic force of the elastic portion 91, against the friction (sliding resistance) between the protrusion 35 and the pad support 24, for example. As a result, the friction material 32 is quickly separated from the rotor body 11a, and it is possible to suppress the generation of drag resistance (drag torque) between the friction material 32 and the rotor body 11a.

[0086] As described above, the flat portion 71 is pushed by the spring portion 83. However, the flat surface 71a of the flat portion 71 is in surface contact with the side surface 41b of the side frame 41, and the flat portion 71 is supported by the side surface 41b. Therefore, the flat portion 71 can be prevented from being deformed by the elastic force of the spring portion 83, and for example, tilting or distortion of the flat surface 71b can be prevented.

[0087] 6, when no braking operation is being performed, the brake pad 25 is spaced apart from the disc rotor 11. When no braking is being performed, the protrusion 92 is located at a first position P1 on the plane 71b of the flat portion 71.

[0088] 6, during braking when the brake pad 25 contacts the rotor body 11a of the disc rotor 11, the protrusion 92 is located at a second position P2 on the plane 71b of the flat portion 71. The second position P2 is spaced apart from the first position P1 in the lateral direction Dh1.

[0089] During braking, the first curved portion 96 elastically expands so that the distance between the first straight portion 95 and the second straight portion 97 increases. Therefore, the protrusion 92 slides on the flat surface 71b of the flat portion 71 from the first position P1 to the second position P2. On the other hand, during decompression, the protrusion 92 slides on the flat surface 71b of the flat portion 71 from the second position P2 to the first position P1. In other words, the protrusion 92 is supported on the flat surface 71b of the flat portion 71 so as to be movable between the first position P1 and the second position P2.

[0090] The surface roughness of the flat surface 71b of the flat portion 71 is small. For example, the flat surface 71b of the flat portion 71 has fewer irregularities than the side surface 41b of the side frame 41, which is a cast surface. This allows the protrusion 92 to slide smoothly between the first position P1 and the second position P2.

[0091] When the protrusion 92 is located at either the first position P1 or the second position P2, the protrusion 92 is spaced apart from the connecting end 72 and the curved end 73. That is, when the protrusion 92 is not braking or is not braking, the protrusion 92 can move in the lateral directions Dh1 and Dh2 on the plane 71b of the flat portion 71.

[0092] When the friction material 32 of the brake pad 25 wears, the position of the back plate 31 during braking approaches the rotor body 11a. As a result, the axial distance between the mounting portion 81 and the protrusion 92 further increases, and the deformation of the elastic portion 91 also becomes greater. Therefore, the second position P2 when the friction material 32 is worn is spaced apart in the lateral direction Dh1 from the second position P2 before the friction material 32 was worn. Note that the first position P1 when the friction material 32 is worn may also be spaced apart in the lateral direction Dh1 from the first position P1 before the friction material 32 was worn.

[0093] Even if the friction material 32 is worn, as long as at least the spring portion 82, which is the PWI, is separated from the rotor body 11a, the protrusion 92 at the second position P2 is separated from the curved end 73. In other words, the pad support 24 can prevent the curved end 73 from restricting the movement of the protrusion 92 until the friction material 32 is worn to the point where an alarm is generated. Note that the protrusion 92 may temporarily come into contact with the curved end 73 due to wear or vibration of the friction material 32, for example.

[0094] For example, vibration may cause the brake pad 25 to move in the radial direction. In this case, the attachment portion 81 attached to the back plate 31 also moves in the vertical directions Dv1 and Dv2. On the other hand, the mounting 22 and the pad support 24 do not move relative to the vehicle 1.

[0095] When the return spring 26 moves in the vertical directions Dv1 and Dv2, the protrusion 92 slides in the vertical directions Dv1 and Dv2 on the plane 71b of the flat portion 71. That is, the distance between the attachment portion 81 and the protrusion 92 is kept substantially constant. This allows the pad support 24 to suppress twisting of the elastic portion 91 caused by an increase in the distance between the attachment portion 81 and the protrusion 92.

[0096] In the brake caliper 12 according to the first embodiment described above, the protrusion 92 is supported on the flat surface 71b so as to be movable between the first position P1 and the second position P2. That is, the flat surface 71b of the flat portion 71 allows movement of the protrusion 92 at least in the movement direction (the lateral directions Dh1 and Dh2) of the protrusion 92 when the elastic portion 91 elastically deforms. Furthermore, because the flat portion 71 is supported on the side surface 41b of the mounting 22, it is less likely to deform due to the load received from the return spring 26. That is, the shape of the flat surface 71b of the flat portion 71 is stable. Therefore, for example, when the brake pad 25 moves due to a braking operation or when the position of the brake pad 25 changes due to wear of the friction material 32, the protrusion 92 can move naturally on the flat surface 71b of the flat portion 71 so as to stabilize the elastic deformation of the elastic portion 91. For example, the brake caliper 12 can prevent the elastic force of the return spring 26 from becoming unstable due to unexpected interference between the protrusion 92 and the flat portion 71 or an unstable shape of the flat surface 71b of the flat portion 71. As described above, the brake caliper 12 can stably separate the brake pad 25 from the disc rotor 11 using the return spring 26, thereby preventing the generation of drag torque.

[0097] Because the flat portion 71 is less likely to deform, the brake caliper 12 can prevent the rigidity of the pad support 24 and the precision of the press working of the pad support 24 from affecting the design (dimensions and shape) of the return spring 26. Furthermore, the brake caliper 12 can simplify the shape of the pad support 24, which in turn can reduce costs.

[0098] The pad support 24 is smaller than the mounting 22 and can be easily formed by, for example, press working. Therefore, the pad support 24 has smaller individual dimensional variations than the mounting 22. Therefore, the brake caliper 12 can reduce individual variations in the elastic force of the return spring 26.

[0099] The protrusion 92 is supported on the flat surface 71b of the flat portion 71 so as to be movable along the flat surface 71b and in vertical directions Dv1, Dv2 that intersect with the horizontal direction Dh1. For example, when the return spring 26 moves in the vertical directions Dv1, Dv2 due to vibration of the brake pad 25, the protrusion 92 also moves in the vertical directions Dv1, Dv2. This allows the brake caliper 12 to suppress twisting of the elastic portion 91 caused by the mounting portion 81 and the protrusion 92 moving away from each other in the vertical directions Dv1, Dv2. Therefore, the brake caliper 12 can suppress the elastic force of the return spring 26 from becoming unstable.

[0100] The protrusion 92 protrudes from the elastic portion 91. The contact area of ​​the return spring 26 with the flat surface 71b can be made smaller than when the curved surface 98a of the second curved portion 98 of the elastic portion 91 abuts against the flat surface 71b of the flat portion 71. This allows the brake caliper 12 to reduce friction between the protrusion 92 and the flat surface 71b, and ultimately prevents the elastic force of the return spring 26 from becoming unstable.

[0101] The pad support 24 has a clip portion 63. The clip portion 63 is supported by the side surface 41a and connected to the interposition portion 61. The pad support 24 holds the mounting 22 between the flat portion 71 and the clip portion 63. In other words, the flat portion 71 serves multiple functions. Therefore, the pad support 24 can be made smaller.

[0102] (Second embodiment) The second embodiment will be described below with reference to Fig. 9. In the following description of the embodiment, components having the same functions as components already described are given the same reference numerals as the components already described, and further description may be omitted. Furthermore, multiple components given the same reference numerals do not necessarily have all the same functions and properties, and may have different functions and properties according to each embodiment.

[0103] 9 is a cross-sectional view schematically showing the disc rotor 11, pad assembly 21, mounting 22, and pad support 24 according to the second embodiment. As shown in FIG. 9, in the second embodiment, the side frame 41 has a side surface 41d instead of the side surface 41b. The side surface 41d is substantially the same as the side surface 41b, except as described below.

[0104] The side surface 41d is, for example, a flat surface that is inclined with respect to the side surface 41a so as to move away from the rotor body 11a as it approaches the caliper center Cc. Note that the side surface 41d may also be a curved surface.

[0105] The pad support 24 of the second embodiment has a flat portion 201 instead of the flat portion 71. The flat portion 201 has flat surfaces 201a and 201b instead of the flat surfaces 71a and 71b. Except as described below, the flat portion 201 and the flat surfaces 201a and 201b are substantially equal to the flat portion 71 and the flat surfaces 71a and 71b. The flat surface 201b is an example of a surface of a support plate.

[0106] The flat surface 201a is in surface contact with the side surface 41d of the side frame 41. Therefore, the flat surfaces 201a and 201b are inclined with respect to the side surface 41a so as to move away from the rotor body 11a as they approach the caliper center Cc. Because the flat surface 201b is inclined, the first position P1 is farther away from the side surface 41a of the side frame 41 and the rotor body 11a of the disc rotor 11 in the axial direction than the second position P2.

[0107] The second position P2 when the friction material 32 is worn is spaced in the lateral direction Dh1 from the second position P2 before the friction material 32 was worn. However, the second position P2 when the friction material 32 is worn is closer to the side surface 41a and the rotor body 11a than the second position P2 before the friction material 32 was worn. Therefore, compared to when the flat surface 201b is parallel to the side surface 41a, the difference between the elastic force of the elastic portion 91 when the friction material 32 is worn and the elastic force of the elastic portion 91 before the friction material 32 was worn is smaller.

[0108] In the brake caliper 12 of the second embodiment described above, the plane 201b of the flat portion 201 is inclined with respect to the side surface 41a so that the first position P1 is farther from the side surface 41a in the axial direction than the second position P2. Therefore, the protrusion 92 moves in the lateral direction Dh1, thereby approaching the side surface 41a and the disc rotor 11 in the axial direction. When the friction material 32 wears and the position of the brake pad 25 approaches the disc rotor 11, the first position P1 and the second position P2 also move in the lateral direction Dh1 and approach the disc rotor 11 in the axial direction. Therefore, even if the position of the brake pad 25 changes due to wear of the friction material 32, the brake caliper 12 can reduce an increase in the distance between the brake pad 25 and the protrusion 92 in the axial direction, and thereby suppress the elastic force of the return spring 26 from becoming unstable.

[0109] The brake caliper according to at least one embodiment described above may, for example, include a pad support including a brake pad, a support member having a first surface facing a rotor and a second surface located opposite to the first surface, and supporting the brake pad movably in an axial direction along the central axis of rotation of the rotor, an intervening portion interposed between the brake pad and the support member, and a support plate supported by the second surface and connected to the intervening portion, a mounting portion attached to the brake pad, a contact portion that contacts the surface of the support plate, and a contact portion between the mounting portion and the contact portion. and an elastic portion disposed between the support plate and the rotor, the elastic force of the elastic portion pushing the brake pad away from the rotor when the brake pad moves toward the rotor, the abutment portion being at a first position on the surface when the brake pad is away from the rotor, and at a second position on the surface separated from the first position in a first direction along the surface when the brake pad is in contact with the rotor, the abutment portion being supported on the surface so as to be movable between the first and second positions. Thus, for example, the surface of the support plate allows movement of the abutment portion at least in the direction of movement of the abutment portion when the elastic portion elastically deforms. Furthermore, because the support plate is supported on the second surface of the support member, it is less likely to deform under the load from the spring. In other words, the shape of the surface of the support plate is stable. Therefore, for example, when the brake pad moves during braking or when the position of the brake pad changes due to wear of the friction material, the abutment portion can naturally move on the surface of the support plate so as to stabilize the elastic deformation of the elastic portion. For example, the brake caliper can prevent the spring's elastic force from becoming unstable due to unexpected interference between the contact portion and the support plate or an unstable surface shape of the support plate. As a result, the brake caliper can stably separate the brake pad from the rotor using the spring, thereby preventing the generation of drag torque.

[0110] In the above-described brake caliper, as one example, the abutment portion is supported on the surface of the support plate so as to be movable along the surface and in a second direction intersecting the first direction. Therefore, as one example, when the spring moves in the second direction due to vibration of the brake pad, the abutment portion also moves in the second direction. This allows the brake caliper to suppress twisting of the elastic portion caused by the mounting portion and the abutment portion moving away from each other in the second direction. Therefore, the brake caliper can suppress instability in the elastic force of the spring.

[0111] In the brake caliper, for example, the abutment portion protrudes from the elastic portion. Therefore, for example, the contact area between the abutment portion and the surface of the support plate can be reduced compared to when the abutment portion is the elastic portion itself. This reduces friction between the abutment portion and the surface of the support plate, and ultimately prevents the elastic force of the spring from becoming unstable.

[0112] In the above-described brake caliper, as one example, the surface of the support plate is inclined with respect to the first surface so that the first position is farther from the first surface in the axial direction than the second position. Therefore, as one example, the abutment portion moves in the first direction, thereby approaching the first surface and the rotor in the axial direction. When the friction material wears and the position of the brake pad approaches the rotor, the first and second positions also move in the first direction and approach the rotor in the axial direction. Therefore, even if the position of the brake pad changes due to wear of the friction material, the brake caliper can reduce an increase in the distance between the brake pad and the abutment portion in the axial direction, thereby preventing the elastic force of the spring from becoming unstable.

[0113] In the above-described brake caliper, as one example, the pad support has a retaining plate supported by the first surface and connected to the interposition portion, and the support member is held between the retaining plate and the pad support. Therefore, as one example, the support plate, together with the retaining plate, attaches the pad support to the support member and supports the contact portion of the spring. In other words, the support plate serves multiple functions. Therefore, the pad support can be made smaller.

[0114] 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]

[0115] 11...disc rotor (rotor), 12...brake caliper, 22...mounting (support member), 24...pad support, 25...brake pad, 26...return spring (spring), 41a...side surface (first surface), 41b, 41d...side surface (second surface), 61...interposition portion, 63...clip portion (retaining plate), 71, 201...flat portion (support plate), 71b, 201b...flat surface (surface), 81...mounting portion, 91...elastic portion, 92...protrusion (contact portion), Ax...central axis, Dh1...horizontal direction (first direction), Dv1, Dv2...vertical direction (second direction), P1...first position, P2...second position.

Claims

1. Brake pads and a support member having a first surface facing a rotor and a second surface located opposite to the first surface, the support member supporting the brake pad so as to be movable in an axial direction along a central axis of rotation of the rotor; a pad support including an intervening portion interposed between the brake pad and the support member, and a support plate supported by the second surface and connected to the intervening portion; a spring having an attachment portion attached to the brake pad, an abutment portion that abuts against the surface of the support plate, and an elastic portion provided between the attachment portion and the abutment portion, wherein when the brake pad moves toward the rotor, the elastic force of the elastic portion pushes the brake pad away from the rotor, the abutment portion is at a first position on the surface when the brake pad is away from the rotor, and when the brake pad is in contact with the rotor, the abutment portion is at a second position on the surface that is spaced from the first position in a first direction along the surface, and the abutment portion is supported on the surface so as to be movable between the first position and the second position; A brake caliper comprising:

2. the abutment portion is supported on the surface of the support plate so as to be movable along the surface of the support plate and in a second direction intersecting the first direction; The brake caliper of claim 1.

3. The abutment portion protrudes from the elastic portion. The brake caliper of claim 1.

4. the surface of the support plate is inclined with respect to the first surface so that the first position is farther from the first surface than the second position in the axial direction; The brake caliper of claim 1.

5. the pad support has a holding plate supported on the first surface and connected to the interposition portion, and holds the support member between the holding plate and the holding plate. The brake caliper of claim 1.

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