Brake caliper

Abstract

To provide a brake caliper capable of restraining falling-off of a part for covering a spring as one example.SOLUTION: A brake caliper according to an embodiment includes, for example, an integrally formed caliper body including a stopper, a first convex portion protruding from the stopper in a protruding direction, and a cylinder separated from the stopper in the protruding direction, a first brake pad and a second brake pad located between the stopper and the cylinder, a mounting movably supporting the caliper body, the first brake pad, and the second brake pad, and a spring attached to the first brake pad or the mounting, biasing the first brake pad, covered by the stopper in the protruding direction, and located between the first convex portion and a center of the mounting in a circumferential direction around the central axis.SELECTED DRAWING: Figure 1

Description

[Technical Field]

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

[0002] A floating-type brake caliper is known, which includes a mounting, a caliper body, a piston, two brake pads, and a spring. The piston is fitted into a bore in the caliper body and presses one of the brake pads against the disc rotor. The caliper body moves relative to the mounting due to a reaction force, and presses the other brake pad against the disc rotor.

[0003] The spring is attached to the mounting or the brake pad and biases the brake pad by elastic force. For example, the brake caliper may further include a cover that protects the spring (Patent Document 1). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2022-098061 Summary of the Invention [Problem to be solved by the invention]

[0005] However, with conventional configurations, there is a possibility that the cover may fall off.

[0006] Therefore, the present invention has been made in view of the above, and provides a brake caliper that can prevent the part covering the spring from falling off. [Means for solving the problem]

[0007] As an example, a brake caliper according to an embodiment of the present invention includes a caliper body having a stopper, a first protrusion protruding from the stopper in a protruding direction along a central axis of rotation of a disc rotor, a cylinder spaced from the stopper in the protruding direction, and a caliper bridge connecting the stopper and the cylinder, which are integrally formed with the caliper body; a first brake pad positioned between the stopper and the cylinder; a second brake pad positioned between the stopper and the cylinder and spaced from the first brake pad in the protruding direction; a mounting that supports the caliper body, the first brake pad, and the second brake pad movably along the central axis; a piston supported by the cylinder and configured to press the second brake pad; and a spring attached to at least one of the first brake pad and the mounting, biasing the first brake pad, being covered by the stopper in the protruding direction, and being located between the first protrusion and the center of the mounting in the circumferential direction around the central axis. Therefore, as an example, the stopper can protect the spring by covering the spring in the protruding direction. Furthermore, the first convex portion is located circumferentially outward of the spring. That is, the first convex portion covers the spring in the circumferential direction or covers the gap between the stopper and the mounting in the circumferential direction. Therefore, the first convex portion can protect the spring in the circumferential direction, for example. Therefore, the brake caliper can suppress deformation of the spring due to, for example, flying objects. Because the first convex portion is formed integrally with other parts of the caliper body, it can suppress detachment due to, for example, operation or vibration of the brake caliper. [Brief explanation of the drawings]

[0008] [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 cross-sectional view showing a part of the disk rotor of the first embodiment. [Figure 3]FIG. 3 is a cross-sectional view schematically showing a part of the disc brake device of the first embodiment taken along line F3-F3 in FIG. [Figure 4] FIG. 4 is a partially cutaway front view of the brake caliper of the first embodiment. [Figure 5] FIG. 5 is a plan view showing the brake caliper of the first embodiment. [Figure 6] FIG. 6 is a side view showing the brake caliper of the first embodiment. [Figure 7] FIG. 7 is a perspective view showing the brake caliper of the first embodiment. [Figure 8] 8 is a cross-sectional view showing a part of the brake caliper of the first embodiment taken along line F8-F8 in FIG. [Figure 9] FIG. 9 is a perspective view showing the pad support of the first embodiment. [Figure 10] FIG. 10 is a cross-sectional view schematically showing the brake caliper of the first embodiment taken along line F10-F10 in FIG. [Figure 11] FIG. 11 is a plan view showing a brake caliper according to the second embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] (First embodiment) The first embodiment will be described below with reference to FIGS. 1 to 10. 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.

[0010] In the following description, "inhibit" is defined as, for example, preventing an event, action, or effect from occurring or reducing the magnitude of an event, action, or effect.

[0011] FIG. 1 is a front view schematically showing 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.

[0012] 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.

[0013] 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.

[0014] Fig. 2 is a cross-sectional view showing a portion of the disc rotor 11 of the first embodiment. As shown in Fig. 2, the disc rotor 11 is fixed to a hub 13 that supports a wheel. The hub 13 is rotatably supported by a knuckle 14 of a suspension that is supported on the body of the vehicle 1. The disc rotor 11 rotates integrally with the hub 13 and the wheel around a central axis Ax.

[0015] As shown in Figure 2, the axial direction includes an inward direction Di and an outward direction Do. The inward direction Di is an example of a protrusion direction. The inward direction Di is a direction along the central axis Ax. The outward direction Do is the opposite direction of the inward direction Di.

[0016] The inward direction Di substantially refers to the inside of the vehicle 1 in the vehicle width direction. The outward direction Do substantially refers to the outside of the vehicle 1 in the vehicle width direction. The vehicle width direction is the left-right direction of the vehicle 1. Note that as the wheels turn, the axial direction, the inward direction Di, and the outward direction Do tilt relative to the vehicle width direction.

[0017] The disc rotor 11 has two side surfaces 11i and 11o. Each of the side surfaces 11i and 11o is formed to be approximately flat. The side surface 11i faces inward Di. The side surface 11o is located opposite the side surface 11i and faces outward Do. In other words, the central axis Ax extends in a direction perpendicular to the side surfaces 11i and 11o.

[0018] FIG. 3 is a cross-sectional view schematically showing a portion of the disc brake device 10 of the first embodiment taken along line F3-F3 in FIG. 1. As shown in FIG. 3, the brake caliper 12 is a floating-type brake caliper. The brake caliper 12 has a mounting 21, two brake pads 22i and 22o, two pistons 23, and a caliper body 24. FIG. 3 shows one of the two pistons 23. The brake pad 22i is an example of a first brake pad. The brake pad 22o is an example of a second brake pad.

[0019] The mounting 21 is attached to, for example, the knuckle 14. In other words, the mounting 21 is fixed to the body of the vehicle 1. The mounting 21 supports the two brake pads 22i, 22o and the caliper body 24 so that they can move axially relative to the mounting 21.

[0020] Fig. 4 is a partially cutaway front view of the brake caliper 12 of the first embodiment. Fig. 5 is a plan view of the brake caliper 12 of the first embodiment. Fig. 6 is a side view of the brake caliper 12 of the first embodiment. Fig. 7 is a perspective view of the brake caliper 12 of the first embodiment.

[0021] As shown in FIG. 5, the mounting 21 includes an inner mounting 31, an outer mounting 32, and two mounting bridges 33. In this embodiment, the inner mounting 31, the outer mounting 32, and the mounting bridges 33 are integrally formed. The mounting 21 may be disassembled. The mounting 21 is manufactured by casting a metal such as iron. The mounting 21 may also be manufactured using other materials and other methods.

[0022] 7, the inner mounting 31 is formed, for example, in a substantially U-shape that is open radially outward. The inner mounting 31 has two inner support portions 41 and an inner bridge 42. The inner support portion 41 may also be referred to as a torque receiving portion.

[0023] The two inner support portions 41 are spaced apart from each other in the circumferential direction. The two inner support portions 41 extend approximately parallel to each other in the radial direction. The inner support portions 41 are attached to the knuckle 14 by, for example, bolts.

[0024] Each of the two inner support portions 41 has an inner surface 41a. The inner surface 41a faces substantially in the circumferential direction. The inner surface 41a of one inner support portion 41 and the inner surface 41a of the other inner support portion 41 face each other.

[0025] The inner bridge 42 extends in a substantially circumferential direction between the two inner support portions 41. The inner bridge 42 is connected to the inner surfaces 41a of the two inner support portions 41. The inner bridge 42 connects the ends of the two inner support portions 41 on the inside in the radial direction.

[0026] As shown in Fig. 6, the inner mounting 31 is spaced inwardly from the outer mounting 32 in the Di direction. As shown in Fig. 4, the outer mounting 32 is formed, for example, in a generally U-shape that opens radially outward. The outer mounting 32 has two outer support portions 45 and an outer bridge 46. The outer support portion 45 may also be referred to as a torque receiving portion.

[0027] The two outer support portions 45 are spaced apart from each other in the circumferential direction, extend substantially parallel to each other in the radial direction, and have an inner surface 45a and an outer surface 45b.

[0028] The inner surface 45a and the outer surface 45b each face approximately in the circumferential direction. The inner surface 45a of one outer support part 45 and the inner surface 45a of the other outer support part 45 face each other. The outer surface 45b is located on the opposite side of the inner surface 45a. The outer surface 45b forms the end of the mounting 21 in the circumferential direction.

[0029] As shown in Fig. 6, each of the two outer support portions 45 further has an outer surface 45c and an inner surface 45d. The outer surface 45c generally faces in the outward direction Do. The inner surface 45d is located opposite the outer surface 45c. The inner surface 45d generally faces in the inward direction Di. The inner surface 45d faces the inner mounting 31 via a gap.

[0030] 4, the outer bridge 46 extends in a substantially circumferential direction between the two outer support portions 45. The outer bridge 46 is connected to the inner surfaces 45a of the two outer support portions 45. The outer bridge 46 connects the ends of the two outer support portions 45 on the inner side in the radial direction.

[0031] As shown in FIG. 7, recesses 51i are provided in each of the inner support portions 41 of the inner mounting 31. The two recesses 51i are formed in mirror symmetry in the circumferential direction. However, the recesses 51i are not limited to this example. The recesses 51i are recessed in the circumferential direction from the inner surface 41a. The recesses 51i penetrate the inner support portion 41 in the axial direction. The recesses 51i are spaced radially outward from the inner bridge 42.

[0032] As shown in Fig. 4, recesses 51o are provided in each of the outer support portions 45 of the outer mounting 32. The shapes of the two recesses 51o are substantially the same as the shapes of the two recesses 51i. Therefore, the two recesses 51o are also formed in mirror symmetry in the circumferential direction. However, the recesses 51o are not limited to this example.

[0033] The recess 51o is recessed in the circumferential direction from the inner surface 45a. The recess 51o axially penetrates the outer support part 45. Therefore, the recess 51o is open to the outer surface 45c and the inner surface 45d. The recess 51o is spaced radially outward from the outer bridge 46.

[0034] Each of the inner support part 41 and the outer support part 45 has a concave surface 55. The concave surface 55 of the inner support part 41 defines a recess 51i. The concave surface 55 of the outer support part 45 defines a recess 51o.

[0035] Figure 8 is a cross-sectional view showing a part of the brake caliper 12 of the first embodiment taken along line F8-F8 in Figure 3. As shown in Figure 8, the concave surface 55 has three flat surfaces 55a, 55b, and 55c.

[0036] The flat surfaces 55a and 55b each extend substantially in the circumferential direction. The flat surface 55a is spaced radially outward from the flat surface 55b. The flat surface 55c extends substantially in the radial direction between the ends of the flat surfaces 55a and 55b in the circumferential direction. That is, the concave surface 55 is formed substantially in a U-shape.

[0037] 5, the two mounting bridges 33 each connect the inner mounting 31 and the outer mounting 32. Specifically, the two mounting bridges 33 connect the two inner support parts 41 and the two outer support parts 45.

[0038] 6, the mounting bridges 33 are connected to the radially outer ends of the inner support part 41 and the outer support part 45, and extend substantially in the axial direction. That is, the two mounting bridges 33 are spaced apart from each other in the circumferential direction and extend substantially parallel to each other.

[0039] 3, the disc rotor 11 is located between an inner mounting 31 and an outer mounting 32. The inner mounting 31 is spaced inwardly from the disc rotor 11 (Di). Furthermore, the outer mounting 32 is spaced outwardly from the disc rotor 11 (Do).

[0040] The mounting bridge 33 extends substantially in the axial direction across the disc rotor 11 at a position spaced radially outward from the disc rotor 11. In other words, the mounting 21 is disposed so as to straddle the disc rotor 11.

[0041] The two brake pads 22i, 22o are spaced apart from each other in the axial direction. The brake pad 22i is spaced apart from the brake pad 22o in the inward direction Di. The disc rotor 11 is located between the two brake pads 22i, 22o.

[0042] The two brake pads 22i, 22o are formed in mirror symmetry with respect to each other in the axial direction. Furthermore, the brake pads 22i, 22o are formed in mirror symmetry with respect to each other in the circumferential direction. However, the brake pads 22i, 22o are not limited to this example.

[0043] 7, the brake pad 22i is disposed between two inner support portions 41. The two inner support portions 41 support the brake pad 22i so as to be axially movable along the central axis Ax relative to the mounting 21. The brake pad 22i is spaced radially outward from the inner bridge 42.

[0044] 4, the brake pad 22o is disposed between two outer support portions 45. The two outer support portions 45 support the brake pad 22o so that the brake pad 22o is axially movable along the central axis Ax relative to the mounting 21. The brake pad 22o is spaced radially outward from the outer bridge 46.

[0045] The disc brake device 10 brakes the disc rotor 11 and the wheel by pressing the brake pads 22i and 22o against the side surfaces 11i and 11o of the disc rotor 11. As shown in Fig. 3, each of the two brake pads 22i and 22o has a back plate 61, a friction material 62, and a shim 63.

[0046] The back plate 61 is disposed substantially perpendicular to the axial direction and is formed in a plate shape extending substantially in the circumferential direction. The back plate 61 has a mounting surface 61a and a back surface 61b. The mounting surface 61a faces the disc rotor 11. The back surface 61b is located on the opposite side of the mounting surface 61a.

[0047] As shown in Fig. 8, the back plate 61 further has two side surfaces 61c and two protrusions 61d. Fig. 8 shows one side surface 61c and one protrusion 61d.

[0048] The two side surfaces 61c are provided at both circumferential ends of the back plate 61. The side surface 61c of the brake pad 22i faces the inner side surface 41a of the inner support part 41. The side surface 61c of the brake pad 22o faces the inner side surface 45a of the outer support part 45. Note that Fig. 8 shows the side surface 61c of the brake pad 22o.

[0049] The two protrusions 61d protrude in the circumferential direction from the two side surfaces 61c. In other words, the two protrusions 61d are provided at both ends of the back plate 61 in the circumferential direction. The protrusions 61d of the brake pad 22i are fitted into the recessed portions 51i. The protrusions 61d of the brake pad 22o are fitted into the recessed portions 51o.

[0050] 4 and 7, the brake caliper 12 further includes two pad supports 71i, two pad supports 71o, and two compression springs 72i, 72o. Fig. 4 shows one of the pad supports 71o. Fig. 7 shows one of the pad supports 71i. The pad support 71o and the compression spring 72o are examples of springs.

[0051] The two pad supports 71i are fitted into the two recesses 51i and attached to the inner mounting 31. The pad supports 71i are interposed between the protrusions 61d of the brake pads 22i and the recessed surfaces 55 of the inner support portion 41, respectively.

[0052] 8, the two pad supports 71o are fitted into the two recesses 51o and attached to the outer mounting 32. The pad supports 71o are respectively interposed between the protrusions 61d of the brake pads 22o and the recessed surfaces 55 of the outer support part 45.

[0053] The two pad supports 71i are formed in mirror symmetry with respect to each other in the circumferential direction. The shapes of the two pad supports 71o are substantially the same as the shapes of the two pad supports 71i. That is, the two pad supports 71o are also formed in mirror symmetry with respect to each other in the circumferential direction.

[0054] Fig. 9 is a perspective view showing one pad support 71o of the first embodiment. As shown in Fig. 9, pad supports 71i and 71o each have an intervening wall 75 and two spring portions 76 and 77. The spring portions 76 and 77 are leaf springs, but may be other types of springs.

[0055] The intervening wall 75 is formed in a generally U-shape and has an outer wall 81, an inner wall 82, and a side wall 83. As shown in Fig. 8, the outer wall 81 and the inner wall 82 each extend in a generally circumferential direction. The outer wall 81 is spaced radially outward from the inner wall 82. The side wall 83 extends in a generally radial direction between an end of the outer wall 81 and an end of the inner wall 82 in the circumferential direction.

[0056] The protrusion 61d is located between the outer wall 81 and the inner wall 82. The outer wall 81 is located between the protrusion 61d and the flat surface 55a of the recessed surface 55 and is supported by the flat surface 55a. The inner wall 82 is located between the protrusion 61d and the flat surface 55b of the recessed surface 55 and is spaced apart from the recessed surface 55. The side wall 83 is located between the protrusion 61d and the flat surface 55c of the recessed surface 55 and is supported by the flat surface 55c.

[0057] As shown in Fig. 9, the spring portion 76 is connected to the side wall 83. As shown in Fig. 8, the tip of the spring portion 76 protrudes radially inward from the inner wall 82. The spring portion 76 abuts against the flat surface 55b of the concave surface 55, and pushes the intervening wall 75 radially outward by its elastic force. As a result, the spring portion 76 presses the outer wall 81 against the flat surface 55a of the concave surface 55.

[0058] As shown in Fig. 9, the spring portion 77 has a curved portion 85 and an abutting portion 86. The curved portion 85 is bent in a substantially U-shape. One end of the curved portion 85 is connected to the inner wall 82. The abutting portion 86 extends in a substantially straight line from the other end of the curved portion 85. As shown in Fig. 8, the abutting portion 86 is located between the inner wall 82 and the protrusion 61d, and abuts against the end of the protrusion 61d on the radially inner side.

[0059] In the pad support 71i, the curved portion 85 is connected to an end of the inner wall 82 in the inward direction Di. The abutting portion 86 extends obliquely with respect to the axial direction. The end of the abutting portion 86 in the outward direction Do is farther from the central axis Ax than the end of the abutting portion 86 in the inward direction Di.

[0060] As shown in Fig. 9, in the pad support 71o, the curved portion 85 is connected to the end of the inner wall 82 in the outward direction Do. The curved portion 85 protrudes in the outward direction Do from the outer mounting 32 beyond the outer surface 45c of the outer support part 45. The abutting portion 86 extends obliquely with respect to the axial direction. The end of the abutting portion 86 in the inward direction Di is farther from the central axis Ax than the end of the abutting portion 86 in the outward direction Do.

[0061] 8, the spring portion 77 biases the convex portion 61d radially outward by the elastic force of the curved portion 85, pressing the convex portion 61d against the outer wall 81. The convex portion 61d is supported by the flat surface 55a of the concave surface 55 via the outer wall 81. As a result, the pad supports 71i and 71o hold the back plate 61 in the radial direction.

[0062] Furthermore, the spring portion 77 biases the convex portion 61d of the brake pad 22i in the inward direction Di by the elastic force of the curved portion 85, so as to move the convex portion 61d axially away from the disc rotor 11. That is, the spring portion 76 of the pad support 71i biases the convex portion 61d of the brake pad 22i in the inward direction Di. The spring portion 76 of the pad support 71o biases the convex portion 61d of the brake pad 22o in the outward direction Do.

[0063] Figure 10 is a cross-sectional view of the brake caliper 12 of the first embodiment, taken along line F10-F10 in Figure 8. As shown in Figure 10, the compression springs 72i and 72o are leaf springs, but may be other types of springs. Each of the compression springs 72i and 72o has an attachment portion 91, a curved portion 92, and an abutment portion 93.

[0064] The mounting portion 91 of the compression spring 72i is attached to the protrusion 61d of the brake pad 22i. The mounting portion 91 of the compression spring 72o is attached to the protrusion 61d of the brake pad 22o. The compression springs 72i and 72o are attached to the protrusion 61d on the leading side, for example.

[0065] The curved portion 92 is bent in a substantially U-shape. One end of the curved portion 92 is connected to the mounting portion 91. The other end of the curved portion 92 is connected to the abutting portion 93. The curved portion 92 of the compression spring 72o may protrude beyond the outer surface 45c of the outer support portion 45 in the outward direction Do from the outer mounting 32. The abutting portion 93 is located between the side wall 83 and the protrusion 61d, and abuts against the side wall 83.

[0066] The compression spring 72i biases the brake pad 22i in the circumferential direction by the elastic force of the curved portion 92. The compression spring 72o biases the brake pad 22o in the circumferential direction by the elastic force of the curved portion 92. The compression springs 72i and 72o press the trailing-side convex portion 61d against the side wall 83, thereby holding the back plate 61 in the circumferential direction.

[0067] 3, the friction material 62 is fixed to a mounting surface 61a of the back plate 61. The friction material 62 is located between the mounting surface 61a and the disc rotor 11. The shim 63 is attached to a rear surface 61b of the back plate 61.

[0068] The pistons 23 are formed in a generally cylindrical shape extending in the axial direction. The two pistons 23 are spaced apart from each other in the circumferential direction. The shape and position of the pistons 23 are not limited to this example. The number of pistons 23 is not limited to two, and may be one, or three or more.

[0069] 5, the caliper body 24 has a cylinder 101, a stopper 102, a caliper bridge 103, and two first protrusions 104. The stopper 102 may also be referred to as a claw.

[0070] The caliper body 24 is integrally formed. That is, the cylinder 101, the stopper 102, the caliper bridge 103, and the first protrusion 104 are integrally formed with one another. The caliper body 24 is manufactured by casting, for example, an aluminum alloy. However, the caliper body 24 may be manufactured using other materials and other methods.

[0071] The cylinder 101 has a cylinder block 111 and two support protrusions 112. As shown in Figure 3, the cylinder block 111 has an inner surface 111a. The inner surface 111a faces generally in the outward direction Do. The inner surface 111a faces the brake pads 22i.

[0072] Two cylinder bores 115 are provided in the cylinder block 111. The cylinder bores 115 are recesses that open to the inner surface 111a. For example, the cylinder bores 115 are formed by closing the end in the inward direction Di of a hole that penetrates the cylinder block 111 in the axial direction. The two cylinder bores 115 are spaced apart from each other in the circumferential direction. The cross section of the cylinder bores 115 is formed to be approximately circular.

[0073] The two pistons 23 are arranged in the two cylinder bores 115 so as to be capable of reciprocating in the axial direction. As a result, the cylinder 101 of the caliper body 24 supports the pistons 23 so as to be capable of moving axially relative to the cylinder 101. A fluid chamber 116 is defined by the pistons 23 and the cylinder block 111. The fluid chamber 116 is included in the cylinder bore 115.

[0074] The brake caliper 12 further includes, for example, two piston seals 117. The piston seals 117 are formed, for example, from synthetic rubber in a substantially annular shape. The piston seals 117 are provided in the cylinder bores 115 and seal the gaps between the pistons 23 and the cylinder block 111 so that the pistons 23 can move axially. That is, the piston seals 117 seal the fluid chambers 116.

[0075] 5, the two support projections 112 protrude circumferentially from both ends of the cylinder block 111. The support projections 112 are spaced apart from the inner support portion 41 of the mounting 21 in the inward direction Di.

[0076] The brake caliper 12 further has two guide pins 118. The two guide pins 118 are attached to the two support protrusions 112. The guide pins 118 are attached to the support protrusions 112 so as to protrude in the outward direction Do from the support protrusions 112.

[0077] The two guide pins 118 are inserted into, for example, two guide holes provided in the mounting 21. As a result, the mounting 21 supports the caliper body 24 via the guide pins 118 so that the caliper body 24 can move in the axial direction.

[0078] The cylinder 101 is spaced inward from the stopper 102 in the inward direction Di. The stopper 102 is disposed substantially perpendicular to the axial direction and is formed in a plate shape extending substantially in the circumferential direction. As shown in FIG. 3, the inner surface 111a of the cylinder block 111 faces the stopper 102. Therefore, the cylinder bore 115 opens toward the stopper 102.

[0079] The disc rotor 11 and the two brake pads 22i, 22o are located between the cylinder block 111 of the cylinder 101 and the stopper 102. The cylinder 101 is spaced inwardly Di from the disc rotor 11. The stopper 102 is spaced outwardly Do from the disc rotor 11.

[0080] The caliper bridge 103 connects the cylinder block 111 of the cylinder 101 to the stopper 102. The caliper bridge 103 is connected to an end of the cylinder block 111 and an end of the stopper 102 on the radially outer side.

[0081] The caliper bridge 103 is spaced radially outward from the disc rotor 11 and the brake pads 22i, 22o. Therefore, the caliper bridge 103 is spaced farther from the central axis Ax than the pad support 71o and the compression spring 72o. As described above, the caliper body 24 is disposed so as to straddle the disc rotor 11.

[0082] 5, in the circumferential direction, the caliper bridge 103 is located between two mounting bridges 33, between two inner support portions 41, and between two outer support portions 45. In the circumferential direction, the length (width) of the caliper bridge 103 is shorter than the distance between the two mounting bridges 33, shorter than the distance between the two inner support portions 41, and shorter than the distance between the two outer support portions 45.

[0083] 4, the stopper 102 is longer in the circumferential direction than the caliper bridge 103. The stopper 102 is also longer in the circumferential direction than the outer mounting 32. The stopper 102 has a base 121 and two extensions 122.

[0084] The base 121 is connected to the caliper bridge 103. The base 121 extends radially inward from the caliper bridge 103. In other words, the base 121 is a portion of the stopper 102 whose circumferential length is equal to that of the caliper bridge 103.

[0085] The base 121 covers the brake pad 22o in the inward direction Di. The base 121 also covers the cylinder bore 115 in the inward direction Di. In other words, the base 121 and the cylinder bore 115 overlap each other in a projection view seen in the inward direction Di.

[0086] The two extension portions 122 extend substantially in the circumferential direction from both circumferential ends of the base portion 121, beyond both circumferential ends of the caliper bridge 103. The extension portions 122 cover the outer support portion 45, the recessed portion 51o, the protruding portion 61d of the brake pad 22o, the pad support 71o, and the compression spring 72o in the inward direction Di.

[0087] In this embodiment, the extension portion 122 extends circumferentially from the base portion 121 beyond both ends of the outer mounting 32 in the circumferential direction. That is, the extension portion 122 extends substantially circumferentially from the base portion 121 beyond the outer surface 45b of the outer support portion 45. However, the extension portion 122 is not limited to this example.

[0088] 5, the stopper 102 further has an inner surface 102a and an outer surface 102b. The inner surface 102a faces generally in an inward direction Di. The outer surface 102b is located opposite the inner surface 102a and faces generally in an outward direction Do.

[0089] Each of the base 121 and the two extensions 122 has a portion of the inner surface 102a and a portion of the outer surface 102b. In other words, the inner surface 102a and the outer surface 102b are provided across the base 121 and the two extensions 122.

[0090] The inner surface 102a of the base 121 abuts against the shim 63 of the brake pad 22o. The inner surface 102a may be temporarily separated from the brake pad 22o. The inner surface 102a of the extension 122 faces the outer support part 45, the recess 51o, the protrusion 61d of the brake pad 22o, the pad support 71o, and the compression spring 72o with gaps between them. That is, the stopper 102 is separated in the outward direction Do from the pad support 71o and the compression spring 72o.

[0091] A gap G is provided between the inner surface 102a of the extension portion 122 and the outer surface 45c of the outer support portion 45. The gap G is open to the outside of the brake caliper 12 in the radial and circumferential directions. The gap G also communicates with the recess 51o.

[0092] The curved portion 85 of the spring portion 77 of the pad support 71o and the curved portion 92 of the compression spring 72o protrude in the outward direction Do from the outer surface 45c of the outer support part 45. Therefore, parts of the pad support 71o and the compression spring 72o are located in the gap G.

[0093] The outer surface 102b of the stopper 102 is a substantially uniform flat or curved surface extending in a substantially circumferential direction. Since the uniform outer surface 102b is formed relatively widely in the circumferential direction across the base portion 121 and the extension portion 122, letters, figures, and patterns can be easily arranged on the outer surface 102b. The uniform outer surface 102b also contributes to a simple, geometric design of the brake caliper 12. Note that the outer surface 102b is not limited to this example and may have, for example, irregularities.

[0094] The two first protrusions 104 protrude inward in the Di direction from the inner surfaces 102a of the two extensions 122. The two first protrusions 104 are located at both ends of the stopper 102 in the circumferential direction. In other words, the two first protrusions 104 are spaced apart from each other in the circumferential direction.

[0095] The first protrusion 104 is located on the outer side of the mounting 21 in the circumferential direction. That is, the first protrusion 104 is located farther from the center C of the mounting 21 in the circumferential direction than the end (outer surface 45b) of the mounting 21. In other words, the mounting 21 is located between two first protrusions 104 in the circumferential direction.

[0096] In the circumferential direction, the first protrusion 104 is spaced apart from the mounting 21. Therefore, even if, for example, the inner surface 102a of the stopper 102 comes into contact with the outer surface 45c of the outer support part 45, the first protrusion 104 remains spaced apart from the mounting 21. Note that the first protrusion 104 may be able to come into contact with the mounting 21.

[0097] The pad support 71o and the compression spring 72o are located in the circumferential direction between the first protrusion 104 and the center C of the mounting 21. In other words, the pad support 71o and the compression spring 72o are located between the two first protrusions 104 around the central axis Ax.

[0098] The first protrusion 104 covers the gap G in the circumferential direction. In this embodiment, the first protrusion 104 covers a part of the gap G in the radial direction. That is, the first protrusion 104 narrows the gap G. Furthermore, the first protrusion 104 covers the curved portions 85, 92 located in the gap G in the circumferential direction.

[0099] In the radial direction, each of the two first protrusions 104 is longer than the pad support 71o and the compression spring 72o. The first protrusions 104 of this embodiment cover the entire pad support 71o and the entire compression spring 72o in the circumferential direction.

[0100] The radially outer end of the first protrusion 104 is farther from the central axis Ax than the radially outer end of the pad support 71o. Furthermore, the radially inner end of the first protrusion 104 is closer to the central axis Ax than the radially inner end of the pad support 71o. In other words, the pad support 71o is positioned in a range that can be completely covered by the first protrusion 104 in the circumferential direction.

[0101] The radially outer end of the first protrusion 104 is farther from the central axis Ax than the radially outer end of the compression spring 72o. Furthermore, the radially inner end of the first protrusion 104 is closer to the central axis Ax than the radially inner end of the compression spring 72o. In other words, the compression spring 72o is positioned in a range that can be completely covered by the first protrusion 104 in the circumferential direction.

[0102] In the axial direction, each of the two first protrusions 104 is shorter than the outer mounting 32. The length of the outer mounting 32 in the axial direction is the distance between the outer surface 45c and the inner surface 45d of the outer support portion 45. Therefore, for example, even if the inner surface 102a of the stopper 102 contacts the outer surface 45c of the outer support portion 45, the end of the first protrusion 104 in the inward direction Di is separated from the disc rotor 11. Note that the length of the first protrusion 104 is not limited to the above example.

[0103] For example, when the driver of the vehicle 1 depresses the brake pedal to brake, the pressure of the brake fluid in the fluid chamber 116 increases. This pressure causes the piston 23 to move outward Do and push the shim 63 of the brake pad 22i. The piston 23 presses the friction material 62 of the brake pad 22i against the side surface 11i of the disc rotor 11.

[0104] When the piston 23 presses the brake pad 22i against the disc rotor 11, the caliper body 24 moves inward Di due to the reaction force. As a result, the base 121 of the stopper 102 presses the friction material 62 of the brake pad 22o against the side surface 11o of the disc rotor 11.

[0105] When the friction material 62 comes into contact with the rotating disc rotor 11, the brake pads 22i, 22o receive a circumferential force due to friction between the disc rotor 11 and the friction material 62. As a result, the protrusion 61d of the brake pad 22i presses against the flat surface 55c of the inner support part 41 via the side wall 83 of the pad support 71i. Also, the protrusion 61d of the brake pad 22o presses against the flat surface 55c of the outer support part 45 via the side wall 83 of the pad support 71o.

[0106] The inner support portion 41 and the outer support portion 45 receive a braking force (braking torque) transmitted via the brake pads 22i and 22o. The mounting 21 transmits the braking torque to the body of the vehicle 1. As a result, the disc brake device 10 brakes the disc rotor 11.

[0107] While the vehicle 1 is traveling, flying objects such as stones or ice blocks kicked up by the tires may fly in the circumferential direction toward the brake caliper 12. However, the first protrusion 104 circumferentially covers the gap G, the pad support 71o, and the compression spring 72o. Therefore, the first protrusion 104 can prevent the flying object from colliding with the curved portion 85 of the pad support 71o or the curved portion 92 of the compression spring 72o. The first protrusion 104 can also prevent the flying object from passing through the gap G and entering the recess 51o.

[0108] In the disc brake device 10 according to the first embodiment described above, the caliper body 24 has a stopper 102, a first protrusion 104, a cylinder 101, and a caliper bridge 103, which are integrally formed. The first protrusion 104 protrudes from the stopper 102 in an inward direction Di along the central axis Ax of rotation of the disc rotor 11. The cylinder 101 is spaced apart from the stopper 102 in the inward direction Di. The caliper bridge 103 connects the stopper 102 and the cylinder 101. The brake pad 22o is located between the stopper 102 and the cylinder 101. The brake pad 22i is located between the stopper 102 and the cylinder 101 and is spaced apart from the brake pad 22o in the inward direction Di. The mounting 21 supports the caliper body 24, the brake pad 22o, and the brake pad 22i so that they can move along the central axis Ax. The piston 23 is supported by the cylinder 101 and configured to press the brake pad 22i. The pad support 71o is attached to the mounting 21. The compression spring 72o is attached to the brake pad 22o. The pad support 71o and the compression spring 72o bias the brake pad 22o. The pad support 71o and the compression spring 72o are covered in the inward direction Di by the stopper 102, and are located between the first protrusion 104 and the center C of the mounting 21 in the circumferential direction about the central axis Ax.

[0109] Therefore, as an example, the stopper 102 covers the pad support 71o and the compression spring 72o in the inward direction Di, thereby protecting the pad support 71o and the compression spring 72o from, for example, stones or ice blocks flying in the inward direction Di. Furthermore, the first protrusion 104 is positioned outward in the circumferential direction from the pad support 71o and the compression spring 72o. That is, the first protrusion 104 covers the pad support 71o and the compression spring 72o in the circumferential direction, or covers the gap G between the stopper 102 and the mounting 21 in the circumferential direction. Therefore, the first protrusion 104 can protect the pad support 71o and the compression spring 72o from, for example, stones or ice blocks flying in the circumferential direction. Therefore, the brake caliper 12 can suppress deformation of the pad support 71o and the compression spring 72o due to, for example, stones or ice blocks, thereby maintaining smooth operation of the brake pad 22o. Because the first protrusion 104 is formed integrally with other portions of the caliper body 24, it is possible to prevent the first protrusion 104 from falling off due to, for example, movement or vibration of the brake caliper 12, and it is also possible to prevent an increase in the number of parts. Furthermore, the first protrusion 104 increases the mass and rigidity of the caliper body 24, thereby suppressing brake squeal of the brake caliper 12. Furthermore, the first protrusion 104 increases the volume and surface area of ​​the caliper body 24, thereby facilitating cooling of the brake caliper 12.

[0110] The first protrusion 104 is farther from the center C of the mounting 21 in the circumferential direction than the end of the mounting 21. Therefore, for example, when the caliper body 24 moves along the central axis Ax relative to the mounting 21, the first protrusion 104 can prevent interference with the mounting 21. Furthermore, the stopper 102 is longer than the mounting 21 around the central axis Ax. Therefore, the stopper 102 increases the mass and rigidity of the caliper body 24, thereby reducing brake squeal of the brake caliper 12. Furthermore, the stopper 102 increases the volume and surface area of ​​the caliper body 24, thereby promoting cooling of the brake caliper 12. Furthermore, the stopper 102 can improve the appearance of the brake caliper 12.

[0111] The mounting 21 has an outer mounting 32, an inner mounting 31, and a mounting bridge 33. The outer mounting 32 supports the brake pad 22o movably along the central axis Ax. The inner mounting 31 is spaced apart from the outer mounting 32 in the inward direction Di and supports the brake pad 22i movably along the central axis Ax. The mounting bridge 33 connects the outer mounting 32 and the inner mounting 31. The pad support 71o is attached to at least one of the brake pad 22o and the outer mounting 32. In the axial direction along the central axis Ax, the first protrusion 104 is shorter than the outer mounting 32.

[0112] Therefore, as an example, the disc rotor 11 is disposed between the outer mounting 32 and the inner mounting 31. Because the first protrusion 104 is shorter than the outer mounting 32, interference with the disc rotor 11 can be suppressed when the caliper body 24 moves along the central axis Ax relative to the mounting 21.

[0113] In a radial direction perpendicular to the central axis Ax, the first protrusion 104 is longer than the pad support 71o and the compression spring 72o. Therefore, as an example, the first protrusion 104 can cover the entire area of ​​the pad support 71o and the compression spring 72o in the circumferential direction about the central axis Ax, or can cover a larger portion of the gap G between the stopper 102 and the mounting 21 in the circumferential direction. Therefore, the first protrusion 104 can more reliably protect the pad support 71o and the compression spring 72o from, for example, stones or ice blocks flying in the circumferential direction.

[0114] (Second embodiment) The second embodiment will be described below with reference to Fig. 11. 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.

[0115] 11 is a plan view showing a brake caliper 12 according to the second embodiment. As shown in FIG. 11, the caliper body 24 of the second embodiment further has two second protrusions 201.

[0116] The two second protrusions 201 protrude inwardly Di from the inner surfaces 102a of the two extensions 122. The two second protrusions 201 are located at the ends of the two extensions 122 on the radially outer side.

[0117] One end of the second protrusion 201 is connected to the end of the first protrusion 104 on the radially outer side. The other end of the second protrusion 201 is connected to the caliper bridge 103. That is, the second protrusion 201 is located between the first protrusion 104 and the caliper bridge 103 in the circumferential direction. Furthermore, the caliper bridge 103 is located between the two second protrusions 201 around the central axis Ax. Note that the second protrusion 201 may be spaced apart from at least one of the caliper bridge 103 and the first protrusion 104.

[0118] The caliper bridge 103 and the second protrusion 201 are farther from the central axis Ax than the recess 51o, the pad support 71o, and the compression spring 72o. The second protrusion 201 covers the gap G from the inside in the radial direction. The second protrusion 201 also covers the curved portions 85 and 92 located in the gap G from the inside in the radial direction.

[0119] In the disc brake device 10 of the second embodiment described above, the caliper bridge 103 is farther from the central axis Ax than the pad support 71o and the compression spring 72o. The caliper body 24 further has a second protrusion 201. The second protrusion 201 is farther from the central axis Ax than the pad support 71o and the compression spring 72o, protrudes inward from the stopper 102, and is located between the first protrusion 104 and the caliper bridge 103 in the circumferential direction.

[0120] Therefore, as an example, the second protrusion 201 is positioned outward of the pad support 71o and the compression spring 72o in the radial direction perpendicular to the central axis Ax. That is, the second protrusion 201 radially covers the pad support 71o and the compression spring 72o, or radially covers the gap G between the stopper 102 and the mounting 21. Therefore, the second protrusion 201 can protect the pad support 71o and the compression spring 72o from, for example, stones or ice blocks flying in the radial direction. Therefore, the brake caliper 12 can suppress deformation of the pad support 71o and the compression spring 72o due to, for example, stones or ice blocks, thereby maintaining smooth operation of the brake pad 22o. Because the second protrusion 201 is integrally formed with other parts of the caliper body 24, it is possible to suppress detachment due to, for example, operation or vibration of the brake caliper 12, and to suppress an increase in the number of parts. Furthermore, the second protrusions 201 increase the mass and rigidity of the caliper body 24, thereby suppressing brake squeal of the brake caliper 12. Furthermore, the second protrusions 201 increase the volume and surface area of ​​the caliper body 24, thereby facilitating cooling of the brake caliper 12.

[0121] As an example, the brake caliper according to at least one embodiment described above includes a caliper body having a stopper, a first protrusion protruding from the stopper in a protruding direction along the central axis of rotation of the disc rotor, a cylinder spaced from the stopper in the protruding direction, and a caliper bridge connecting the stopper and the cylinder, which are integrally formed with the caliper body; a first brake pad positioned between the stopper and the cylinder; a second brake pad positioned between the stopper and the cylinder and spaced from the first brake pad in the protruding direction; a mounting that supports the caliper body, the first brake pad, and the second brake pad movably along the central axis; a piston supported by the cylinder and configured to press the second brake pad; and a spring attached to at least one of the first brake pad and the mounting, biasing the first brake pad, being covered by the stopper in the protruding direction, and being located between the first protrusion and the center of the mounting in the circumferential direction around the central axis. Therefore, for example, by covering the spring in the protruding direction, the stopper can protect the spring from, for example, stones or ice blocks flying in the protruding direction. Furthermore, the first convex portion is located circumferentially outward of the spring. That is, the first convex portion covers the spring in the circumferential direction or the gap between the stopper and the mounting in the circumferential direction. Therefore, the first convex portion can protect the spring from, for example, stones or ice blocks flying in the circumferential direction. Therefore, the brake caliper can suppress spring deformation caused by, for example, stones or ice blocks, and ultimately maintain smooth operation of the first brake pad. Because the first convex portion is formed integrally with other parts of the caliper body, it can suppress detachment due to, for example, brake caliper operation or vibration, and can also suppress an increase in the number of parts. Furthermore, the first convex portion increases the mass and rigidity of the caliper body, thereby suppressing brake squeal of the brake caliper. Furthermore, the first protrusion increases the volume and surface area of ​​the caliper body, thereby facilitating cooling of the brake caliper.

[0122] In the above-described brake caliper, as an example, the first protrusion is farther from the center of the mounting than the end of the mounting in the circumferential direction. Therefore, as an example, when the caliper body moves along the central axis relative to the mounting, the first protrusion can be prevented from interfering with the mounting. Furthermore, the stopper is longer than the mounting around the central axis. Therefore, the stopper increases the mass and rigidity of the caliper body, thereby suppressing brake squeal of the brake caliper. Furthermore, the stopper increases the volume and surface area of ​​the caliper body, thereby promoting cooling of the brake caliper. Furthermore, the stopper can improve the appearance of the brake caliper.

[0123] In the above-described brake caliper, for example, the caliper bridge is farther from the central axis than the spring, and the caliper body further includes a second protrusion that is farther from the central axis than the spring, protrudes from the stopper in the protruding direction, and is positioned between the first protrusion and the caliper bridge in the circumferential direction. Therefore, for example, the second protrusion is positioned outward from the spring in a radial direction perpendicular to the central axis. That is, the second protrusion radially covers the spring or the gap between the stopper and the mounting. Therefore, the second protrusion can protect the spring from, for example, stones or ice flying in the radial direction. Therefore, the brake caliper can suppress deformation of the spring due to, for example, stones or ice, thereby maintaining smooth operation of the first brake pad. The second protrusion is integrally formed with the other parts of the caliper body, which can prevent the second protrusion from coming off due to, for example, the operation or vibration of the brake caliper, and can also prevent an increase in the number of parts. Furthermore, the second protrusion increases the mass and rigidity of the caliper body, which can reduce brake squeal. Furthermore, the second protrusion increases the volume and surface area of ​​the caliper body, which can promote cooling of the brake caliper.

[0124] In the above-described brake caliper, as one example, the mounting includes an outer mounting that supports the first brake pad movably along the central axis, an inner mounting that is spaced from the outer mounting in the protruding direction and supports the second brake pad movably along the central axis, and a mounting bridge that connects the outer mounting and the inner mounting, the spring is attached to at least one of the first brake pad and the outer mounting, and the first protrusion is shorter than the outer mounting in the axial direction along the central axis. Therefore, as one example, the disc rotor is disposed between the outer mounting and the inner mounting. Because the first protrusion is shorter than the outer mounting, interference with the disc rotor when the caliper body moves along the central axis relative to the mounting can be suppressed.

[0125] In the above-described brake caliper, for example, the first protrusion is longer than the spring in a radial direction perpendicular to the central axis. Therefore, for example, the first protrusion can cover the entire area of ​​the spring in the circumferential direction around the central axis, or can cover a larger portion of the gap between the stopper and the mounting in the circumferential direction. Therefore, the first protrusion can more reliably protect the spring from, for example, stones or ice flying in the circumferential direction.

[0126] 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]

[0127] 11...disc rotor, 12...brake caliper, 21...mounting, 22i...brake pad (second brake pad), 22o...brake pad (first brake pad), 23...piston, 24...caliper body, 31...inner mounting, 32...outer mounting, 33...mounting bridge, 45b...outer surface (end), 71o...pad support (spring), 72o...compression spring (spring), 101...cylinder, 102...stopper, 103...caliper bridge, 104...first convex portion, 201...second convex portion, Ax...central axis, Di...inward direction (protruding direction), C...center.

Claims

1. a caliper body having a stopper, a first protrusion protruding from the stopper in a protruding direction along a central axis of rotation of the disc rotor, a cylinder spaced from the stopper in the protruding direction, and a caliper bridge connecting the stopper and the cylinder, the caliper body being integrally formed; a first brake pad positioned between the stopper and the cylinder; a second brake pad positioned between the stopper and the cylinder and spaced apart from the first brake pad in the protruding direction; a mounting that supports the caliper body, the first brake pad, and the second brake pad movably along the central axis; a piston supported in the cylinder and configured to press against the second brake pad; a spring attached to at least one of the first brake pad and the mounting, biasing the first brake pad, covered by the stopper in the protruding direction, and positioned between the first protrusion and the center of the mounting in the circumferential direction around the central axis; A brake caliper comprising:

2. the first protrusion is located farther from the center of the mounting than from the end of the mounting in the circumferential direction; The brake caliper of claim 1.

3. the caliper bridge is spaced farther from the central axis than the spring; the caliper body further includes a second protrusion that is farther from the central axis than the spring, protrudes from the stopper in the protruding direction, and is positioned between the first protrusion and the caliper bridge in the circumferential direction; The brake caliper of claim 1.

4. the mounting includes an outer mounting that supports the first brake pad movably along the central axis, an inner mounting that is spaced from the outer mounting in the protruding direction and supports the second brake pad movably along the central axis, and a mounting bridge that connects the outer mounting and the inner mounting, the spring is attached to at least one of the first brake pad and the outer mounting, In an axial direction along the central axis, the first protrusion is shorter than the outer mounting. The brake caliper of claim 1.

5. The first protrusion is longer than the spring in a radial direction perpendicular to the central axis. The brake caliper of claim 1.

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