Brake assembly with guide pin assembly

Abstract

A brake assembly having a guide pin assembly is provided. [Solution] A brake assembly comprising a brake carrier, a brake caliper, and a guide pin assembly. The guide pin assembly slidably connects the brake caliper to the brake carrier. The guide pin assembly comprises an integrated cap bushing, a sleeve, and a fastener. The fastener connects the sleeve to the brake carrier. The integrated cap bushing is movable relative to the sleeve.

Description

Technical Field

[0004]

[0001] The present invention relates to a brake assembly and a guide pin assembly.

Background Art

[0002] A guide assembly for a disc brake is disclosed in (Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Patent Document 2

Summary of the Invention

Means for Solving the Problems

[0004] The present invention relates to a brake assembly. The brake assembly comprises a brake carrier, a brake caliper, and a guide pin assembly. The brake caliper defines a bore. The bore extends along an axis. The guide pin assembly slidably connects the brake caliper to the brake carrier. The guide pin assembly comprises an integrated cap bushing, a sleeve, and a fastener. The integrated cap bushing is at least partially received within the bore. The integrated cap bushing is fixed to the brake caliper. The integrated cap bushing is an integrated component comprising a tubular wall and a cap. The tubular wall surrounds and at least partially defines a cavity. The cavity extends along an axis. The tubular wall has an end face. The end face is located opposite the cap. The cap extends from the tubular wall. The cap closes the end of the integrated cap bushing. The sleeve is received in the cavity. The sleeve engages with the tubular wall so that the integrated cap bushing can move along its axis relative to the sleeve. The fastener is located inside the sleeve. The fastener connects the sleeve to the brake carrier.

[0005] The tubular wall may further comprise an outer surface. The outer surface may be oriented away from the axis. The outer surface may engage with the brake caliper within the bore. The cap may further comprise an outer cap surface. The outer cap surface may be oriented away from the axis. The outer cap surface may engage with the brake caliper within the bore. The outer cap surface may be positioned further from the axis than the outer surface of the tubular wall surface. The outer cap surface and the outer surface of the tubular wall surface may be positioned at a common radial distance from the axis.

[0006] The brake caliper may further comprise a threaded region. The threaded region may be located within the bore. The integrated cap bushing may further comprise a threaded portion. The threaded portion may engage with the threaded region to secure the integrated cap bushing to the brake caliper. The threaded portion of the integrated cap bushing may be located on the cap. The threaded portion of the integrated cap bushing may be located on the tubular wall.

[0007] The integrated cap bushing can be secured to the brake caliper by a fastener. The fastener may be located within the bore.

[0008] The brake caliper may further comprise a brake caliper groove. The brake caliper groove may surround the bore. The brake caliper groove may extend away from the axle. The brake caliper groove may extend from the bore. The cap may further comprise an outer cap. The outer cap may face away from the axle. The cap may further comprise a cap groove. The cap groove may extend from the outer cap toward the axle. A fastener may be received in the brake caliper groove and the cap groove.

[0009] The integrated cap bushing can be secured to the brake caliper by a fastener located on the outside of the bore. The cap may further comprise a cap flange. The cap flange may be located on the outside of the bore. The cap flange may extend away from the axis. A fastener can secure the cap flange to the brake caliper.

[0010] The brake caliper may further include a recess. The recess may extend away from the axis. The recess may extend from the bore. The integrated cap bushing may further include a projection. The projection may extend away from the axis. The projection may be received in the recess. The projection may secure the integrated cap bushing to the brake caliper.

[0011] The fastener, sleeve, and integrated cap bushing may cooperate to define a chamber. The chamber may be positioned axially between the fastener and the cap. The chamber may contain lubricating oil.

[0012] The integrated cap bushing may be spaced away from the brake carrier. The integrated cap bushing may not be in contact with the brake carrier. The sleeve may engage with the brake carrier.

[0013] The brake assembly may further include a flexible boot. The flexible boot may extend between the brake carrier and the brake caliper. The flexible boot may further include a mounting rim. The mounting rim of the flexible boot may be positioned in the bore. The mounting rim may be fixed between the integrated cap bushing and the brake caliper.

[0014] The brake caliper may further include a brake caliper boot groove. The brake caliper boot groove may surround the bore. The brake caliper boot groove may extend from the bore. The brake caliper boot groove may extend away from the axle. The mounting rim for the flexible boot may be located within the brake caliper boot groove.

[0015] The tubular wall may further comprise a guide surface. The guide surface may extend from the end face of the tubular wall toward the outside of the tubular wall. The flexible boot may engage with the guide surface. The guide surface may be positioned at an oblique angle with respect to the end face. The guide surface may be positioned at an oblique angle with respect to the outside. The guide surface may extend away from the axis as it extends away from the end face.

[0016] The tubular wall may further include a stepped surface. The stepped surface may extend from the end of the guide surface to the outside of the tubular wall. The mounting rim may engage with the stepped surface.

[0017] The present invention also relates to an integrated cap bushing for a brake caliper. The integrated cap bushing comprises a tubular wall and a cap. The tubular wall surrounds and at least partially defines the cavity. The tubular wall has an end face. A cap is located opposite the end face. The cap extends from the tubular wall. The cap closes the end of the tubular wall. The integrated cap bushing is a single, integrated component. [Brief explanation of the drawing]

[0018] [Figure 1] This is a perspective view of an example brake assembly and brake rotor. [Figure 2] This is a cross-sectional view along cutting line 2-2. [Figure 3] It is an enlarged view of a part of FIG. 2 showing an example of a guide pin assembly. [Figure 4] It is an enlarged view showing a second example of a guide pin assembly. [Figure 5] It is an enlarged view showing a third example of a guide pin assembly. [Figure 6] It is an enlarged view showing a fourth example of a guide pin assembly. [Figure 7] It is an enlarged view showing a fifth example of a guide pin assembly. [Figure 8] It is an enlarged view showing a sixth example of a guide pin assembly.

BEST MODE FOR CARRYING OUT THE INVENTION

[0019] If necessary, detailed embodiments of the present invention are disclosed herein. However, it should be understood that the disclosed embodiments are merely examples of the present invention that can be embodied in various alternative forms. The figures are not necessarily to scale, and some features may be exaggerated or minimized to show details of specific components. Therefore, the specific structural and functional details disclosed herein should not be construed in a limiting sense, but should merely be understood as a representative basis for teaching those skilled in the art to utilize the present invention in various forms.

[0020] Also, in order to describe various elements, terms such as first, second, etc. may be used in some examples in this specification, but it should also be understood that these elements should not be limited by these terms. These terms are merely used to distinguish one element from another. For example, without departing from the scope of the various described embodiments, the first element may be referred to as the second element, and similarly the second element may be referred to as the first element. The first element and the second element are both elements, but not the same element.

[0021] The terms used in the descriptions of the various embodiments are intended solely to describe specific embodiments and are not intended to limit them. Where used in the descriptions of the various embodiments and the accompanying claims, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly indicates otherwise. Furthermore, the terms "and / or" as used herein will be understood to refer to and encompass any possible combination of one or more of the enumerated items relating to the description. In addition, the terms "includes," "includes," "comprises," and / or "comprising," as used herein, identify the presence of described features, integers, steps, operations, elements, and / or components, but will not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0022] Referring to Figure 1, an example of a brake assembly 10 is shown. The brake assembly 10 may be provided as part of a cargo loading device for a vehicle such as a truck, bus, agricultural machinery, military transport or weapons vehicle, or for land, air or sea vehicles. The brake assembly 10 is configured as a disc brake. The brake assembly 10 comprises a brake carrier 20 and a brake caliper 22. The brake assembly 10 also comprises a pair of brake pad assemblies 24 and a retainer bracket 26. Referring mainly to Figure 2, the brake assembly 10 may also comprise at least one guide pin assembly 28 and a flexible boot 30.

[0023] Referring to Figures 1 and 2, the brake carrier 20 is configured to be mounted on a vehicle. For example, the brake carrier 20 may be mounted directly or indirectly to the axle assembly or steering knuckle. The brake carrier 20 may be stationary and may not move relative to the vehicle component to which it is mounted. In some configurations, the brake carrier 20 is configured to receive and support the brake pad assembly 24 in such a manner that it allows the brake pad assembly 24 to move toward and away from the brake rotor 40 while suppressing the rotation of the brake pad assembly 24.

[0024] The brake carrier 20 may include a rotor opening from which the brake rotor 40 can extend. The brake rotor 40 is rotatable about the brake rotor axis 42 and spaced apart from the brake carrier 20. For example, the brake carrier 20 may straddle the brake rotor 40 and may help position the brake assembly 24 on both sides of the brake rotor 40.

[0025] Referring to Figure 2, the brake carrier 20 may include one or more fastener holes 50. The fastener holes 50 may facilitate the mounting of the corresponding guide pin assembly 28. The fastener holes 50 may have any suitable configuration. In some configurations, the fastener holes 50 have threads. The fastener holes 50 may be configured as through holes.

[0026] Referring to Figures 1 and 2, the brake caliper 22 is movably or slidably positioned on the brake carrier 20. The brake caliper 22 facilitates the positioning of the brake pad assembly 24 relative to the brake rotor 40. For example, the brake caliper 22 may be configured to position the pad assembly 24 engaged with both sides of the brake rotor 40, thereby facilitating braking of the brake rotor 40, facilitating the retraction of the brake pad assembly, or disengaging the brake rotor 40. In some configurations, the brake caliper 22 comprises a caliper housing 60 and a caliper bridge 62.

[0027] The caliper housing 60 may be movably positioned on the brake carrier 20. For example, the caliper housing 60 may be slidably positioned on a pair of guide pin assemblies 28 which may be fixedly positioned on the brake carrier 20. The caliper housing 60 may facilitate the mounting of a brake actuator and may define an internal cavity that can accommodate, or partially accommodate, various components that facilitate the movement of the brake pad assembly 24, such as an operating shaft, yoke, tappet, piston, and wear adjustment mechanism. Examples of such components are described in (Patent Document 2), which is thus fully incorporated by reference. Furthermore, it should be noted that the present invention is not limited to configurations such as those described in (Patent Document 2).

[0028] Referring primarily to Figure 3, the caliper housing 60 defines one or more bores 70. The bores 70 are configured to receive a corresponding guide pin assembly 28. In some configurations, a pair of bores 70 are provided, located near the opposite lateral side of the brake caliper 22. The bores 70 may be configured as through holes. Each bore 70 may extend along a corresponding shaft 72. The shaft 72 may extend parallel to or substantially parallel to the brake rotor shaft 42. As used herein, the term “substantially parallel” means the same as or very close to parallel, including features or axes that are within ±3° of being parallel to each other. In some configurations, the bore 70 may have a cylindrical configuration in which the bore 70 is defined by a bore surface 74 of the brake caliper 22 or the caliper housing 60. The bore surface 74 may extend around the shaft 72. The bore surface 74 may be positioned radially with respect to the shaft 72, or at a substantially constant radial distance from the shaft 72.

[0029] Referring to Figures 1 and 2, the caliper bridge 62 extends from the caliper housing 60. The caliper bridge 62 may be formed integrally with the caliper housing 60 or it may be fixedly positioned on the caliper housing 60. For example, the caliper bridge 62 may be provided as a separate component that can be joined to the caliper housing 60 by one or more fasteners such as bolts. In at least one configuration, the caliper bridge 62 may cooperate with the caliper housing 60 to define at least partially an opening 64 that can facilitate the insertion and removal of the brake pad assembly 24.

[0030] The brake pad assembly 24 is configured to engage with the wheel hub on which the brake rotor 40 is mounted, and with the brake rotor 40 to facilitate braking of the associated vehicle wheel. The brake pad assembly 24 is also capable of engaging with the brake rotor 40 to slow the rotation of the associated wheel around the rotor axis 42. One brake pad assembly 24 may be positioned between the caliper housing 60 and the brake rotor 40 and may be referred to as the in-vehicle brake pad assembly 24. The in-vehicle brake pad assembly 24 is located to the right of the brake rotor 40 based on the view shown in Figure 2. The other brake pad assembly 24 may be positioned on the opposite side of the brake rotor 40, between the caliper bridge 62 and the brake rotor 40, and may be referred to as the out-of-vehicle brake pad assembly 24. The out-of-vehicle brake pad assembly 24 is located to the left of the brake rotor 40 based on the view shown in Figure 2. Each brake pad assembly 24 may include a back plate 80 and friction material 82.

[0031] The backplate 80 is a structural component of the brake pad assembly 24. The backplate 80 may be configured as a plate and may be made from any suitable material, such as metal or a metal alloy. In at least one configuration, the side of the backplate 80 of the in-vehicle brake pad assembly 24 facing away from the friction material 82 may engage with or contact a tappet that may be extendable from the cavity of the caliper housing 60 to actuate the in-vehicle brake pad assembly 24 to engage with the brake rotor 40. The side of the backplate 80 of the out-of-vehicle brake pad assembly 24 facing away from the friction material 82 may engage with or contact the caliper bridge 62.

[0032] The friction material 82 is positioned on the side of the back plate 80 that may face the brake rotor 40. The friction material 82 may come into contact with the brake rotor 40 during vehicle braking.

[0033] Referring to Figures 1 and 2, the retainer bracket 26 may be coupled to the brake caliper 22, if provided. For example, the retainer bracket 26 may extend across the brake pad assembly 24 and the opening 64 of the brake caliper 22 to help hold the brake pad assembly 24 within the brake carrier 20 when the retainer bracket 26 is fixed to the brake caliper 22. The retainer bracket 26 may be detached from or removed from the brake caliper 22 to allow removal or insertion of the brake pad assembly 24 through the opening 64.

[0034] Referring to Figures 2 and 3, an example of a guide pin assembly 28 is shown. The guide pin assembly 28 slidably connects the brake caliper 22 to the brake carrier 20 so that the brake caliper 22 can slide along the axis 72 relative to the brake carrier 20. In some configurations, and as best shown in relation to Figure 3, the guide pin assembly 28 includes a fastener 90, a sleeve 92, and an integrated cap bushing 94.

[0035] The fastener 90 is configured to secure or permanently connect the sleeve 92 to the brake carrier 20. The fastener 90 may have any suitable configuration. For example, the fastener 90 may be configured as a bolt, such as a carriage bolt, that can be received in a fastener hole 50 of the brake carrier 20. The fastener 90 may also be partially received in the bore 70 of the caliper housing 60, or it may extend along or around the shaft 72. The fastener 90 may be located within the sleeve 92.

[0036] The sleeve 92 is at least partially received within the bore 70 and integrated cap bushing 94 of the caliper housing 60. The sleeve 92 receives the fastener 90. For example, the sleeve 92 may be configured as a hollow tube that can surround the fastener 90. The hollow portion of the sleeve 92 that receives the fastener 90 may be sized to be slightly larger than the fastener 90 to allow insertion and rotation of the fastener 90 for assembly, but the sleeve 92 may be positioned approximately centered with respect to the shaft 72.

[0037] The sleeve 92 may have a first end and a second end. The first end may engage with or contact the brake carrier 20. The second end may be located on the opposite side of the first end. In some configurations, the hollow portion of the sleeve 92 may have a larger diameter at the second end than at the first end. For example, the head of the fastener 90 may be received within the larger diameter region of the hollow portion and engage with a stepped surface extending to the smaller diameter region of the hollow portion, preventing the sleeve 92 from moving axially away from the brake carrier 20. Thus, the sleeve 92 may be fixedly positioned relative to the brake carrier 20 or stationary when fastened to the brake carrier 20 by the fastener 90. In some configurations, the sleeve 92 has an outer surface 100.

[0038] The outer surface 100 faces away from the shaft 72. The outer surface 100 is at least partially received within the bore 70 of the caliper housing 60. The outer surface 100 may be the outer circumferential surface of the sleeve 92 and may be spaced apart from the bore surface 74. For example, the outer surface 100 may be positioned at a substantially constant radial distance from the shaft 72. The outer surface 100 may engage with or contact the integrated cap bushing 94.

[0039] The integrated cap bushing 94 is at least partially received within the bore 70 of the caliper housing 60. The integrated cap bushing 94 may engage with the brake caliper 22, be separated from the brake carrier 20, or neither contact nor engage with the brake carrier 20. The integrated cap bushing 94 is an integrated component that can be made from any suitable material, such as a polymer material or a metal alloy. In some configurations, the integrated cap bushing 94 comprises a tubular wall 120, a cap 122, and a cavity 124.

[0040] The tubular wall 120 is at least partially received within the bore 70. For example, the tubular wall 120 may surround the shaft 72 or be spaced away from the shaft 72. The tubular wall 120 may engage with and surround the sleeve 92. The tubular wall 120 may at least partially define the cavity 124. In some configurations, the tubular wall 120 comprises an end face 130, an outer face 132, an inner face 134, a guide face 136, and a stepped face 138.

[0041] The end face 130 is positioned at the end of the tubular wall 120, which is located opposite the cap 122. Thus, the end face 130 may face toward the brake carrier 20 and be spaced away from the brake carrier 20. In one or more configurations, the end face 130 may be positioned substantially perpendicular to the axis 72. The term “substantially perpendicular” is used herein to specify a feature or axis that is the same as or very close to perpendicular, and includes features that are within ±3° of being perpendicular to each other. The end face 130 may or may not be received within the bore 70.

[0042] The outer part 132 faces away from the shaft 72. In some configurations, the outer part is the outer circumferential surface of the tubular wall 120 and may be positioned at a substantially constant radial distance from the shaft 72. At least a portion of the outer part 132 is received within the bore 70 and contacts or engages with the brake caliper 22.

[0043] The inner part 134 is positioned on the opposite side of the outer part 132. Therefore, the inner part 134 faces the axis 72. The inner part 134 may engage with or contact the sleeve 92.

[0044] The guide surface 136, if provided, can facilitate the insertion of the integrated cap bushing 94 into the bore 70, or facilitate the attachment of the flexible boot 30, or both. In some configurations, the guide surface 136 extends from the end face 130 toward the cap 122. In some configurations, the guide surface 136 extends toward or to the outward 132. The guide surface 136 may be positioned at an oblique angle to the end face 130, the outward 132, or both. In some configurations, the guide surface 136 extends away from the shaft 72 as it extends away from the end face 130.

[0045] The stepped surface 138, if provided, may extend from the guide surface 136 to the outer side 132. For example, the stepped surface 138 may extend from the end of the guide surface 136 to the outer side 132 away from the axis 72. In some configurations, the stepped surface 138 is positioned substantially perpendicular to the axis 72, the outer side 132, or both.

[0046] The cap 122 closes the end of the integrated cap bushing 94, which is located on the opposite side of the end face 130. In some configurations, the cap 122 extends from the shaft 72 to the tubular wall 120. The cap 122 may be located within the bore 70, partially within the bore 70, or not located within the bore 70. The cap 122 is formed integrally with the tubular wall 120, thereby eliminating a potential leakage path between the cap 122 and the tubular wall 120. In some configurations, the cap 122 comprises a cap end wall 140 and an outer cap 142.

[0047] The cap end wall 140 is located at the end of the integrated cap bushing 94, which is positioned opposite the end face 130. The cap end wall 140 may be spaced apart from the fastener 90, the sleeve 92, or both. The cap end wall 140 may intersect the shaft 72 and may extend to the outside of the cap 142.

[0048] The outer cap 142 faces away from the shaft 72 and may surround the shaft 72. In some configurations, the outer cap 142 is positioned further from the shaft 72 than the outer 132 of the tubular wall 120. The outer cap 142 may engage with the brake caliper 22 within the bore 70. In other configurations, such as the one shown in Figure 8, the outer cap 142 does not extend further from the shaft 72 than the outer 132 of the tubular wall 120. For example, in Figure 8, the outer 132 of the tubular wall 120 and the outer cap 142 are positioned at a common radial distance from the shaft 72. The outer 132 and the outer cap 142 may be positioned at a common radial distance from the shaft 72 in the configurations shown in Figures 3-7. Similarly, the outer cap 142 may extend further from the shaft 72 than the outer 132 in the configuration shown in Figure 8.

[0049] The cavity 124 is located inside the integrated cap bushing 94. The cavity 124 may extend along the axis 72. For example, the cavity 124 may extend from the end face 130 to the cap end wall 140. In some configurations, the cavity 124 has a cylindrical shape. The fastener 90 and sleeve 92 are received within the cavity 124.

[0050] The fastener 90, sleeve 92, and integrated cap bushing 94 may cooperate to define a chamber 150. The chamber 150 may be part of a cavity 124. The chamber 150 may be positioned between the fastener 90 and the cap 122 along the axis 72. For example, the chamber 150 may be positioned between the fastener 90 and the cap end wall 140 along the axis 72 and may be surrounded by the tubular wall 120, the cap 122, or both. The chamber 150 is configured to receive or contain a lubricant 152 such as grease. The lubricant 152 may fill or partially fill the chamber 150 and facilitate the sliding movement of the integrated cap bushing 94 along the sleeve 92. For example, some of the lubricant 152 may enter the small gap between the outer surface 100 of the sleeve 92 and the inner surface 134 of the tubular wall 120 and facilitate the sliding movement between them.

[0051] The integrated cap bushing 94 is fixed to the brake caliper 22. Therefore, once inserted, the integrated cap bushing 94 is fixedly positioned relative to the brake caliper 22, or positioned in a stationary state, and thus the brake caliper 22 and the integrated cap bushing 94 are movable together along the axis 72 relative to the brake carrier 20, fastener 90 and sleeve 92.

[0052] The brake caliper 22 and integrated cap bushing 94 may be movable between a retracted position and an extended position relative to the brake carrier 20, fastener 90, and sleeve 92. When braking or a braking force is applied, such as by a brake actuator, the brake caliper 22 and integrated cap bushing 94 may move from the retracted position to the extended position. For example, the in-vehicle brake pad assembly 24 may be moved from a retracted position, where the in-vehicle brake pad assembly 24 can be separated from the brake rotor 40, to a position where it is in contact with the brake rotor 40. When the in-vehicle brake pad assembly 24 is in contact with the brake rotor 40, a reaction force may move the brake caliper 22 and integrated cap bushing 94 along axis 72 in a first direction relative to the brake carrier 20, fastener 90, and sleeve 92, acting to engage the out-of-vehicle brake pad assembly 24 with the opposite side of the brake rotor 40, thereby assisting in slowing the rotation of the brake rotor 40 and the associated vehicle wheel. The brake caliper 22 and the integrated cap bushing 94 can be moved from the extended position to the retracted position when braking or braking force is reduced or no longer applied.

[0053] The integrated cap bushing 94 can be secured to the brake caliper 22 in several ways.

[0054] In the configuration shown in Figure 3, the integrated cap bushing 94 is secured to the brake caliper 22 by an interference fit. The interference fit may be provided between the brake caliper 22 and the tubular wall 120, between the brake caliper 22 and the cap 122, or a combination thereof.

[0055] Referring to Figures 4 and 5, a configuration is shown in which the integrated cap bushing 94 is secured to the brake caliper 22 by a fitting thread. The fitting thread can be provided at any suitable position.

[0056] In the configuration shown in Figure 4, the mating threads are associated with the cap 122. The brake caliper 22 may include a threaded region 160. The threaded region 160 may be located within the bore 70, spiral around the shaft 72, and may include one or more threads facing toward the shaft 72. The integrated cap bushing 94 may include a threaded portion 162 that fits with the threaded region 160. The threaded portion 162 may spiral around the shaft 72 and may include one or more threads facing away from the shaft 72. The threaded portion 162 of the integrated cap bushing 94 mates with the threaded region 160 of the brake caliper 22, securing the integrated cap bushing 94 to the brake caliper 22. The threaded portion 162 may be located at least partially within the bore 70 once the integrated cap bushing 94 is introduced.

[0057] In the configuration shown in Figure 5, the mating threads are associated with the tubular wall 120. For example, the integrated cap bushing 94 may include a threaded portion 162 provided on the tubular wall 120. The threaded portion 162 may include one or more threads that spiral around the shaft 72 and point away from the shaft 72. The threaded portion 162 mates with the threaded region 160 of the brake caliper 22, securing the integrated cap bushing 94 to the brake caliper 22. The threaded region 160, the threaded portion 162, or both may extend along the shaft 72 to a length longer or shorter than shown, and may be positioned along the shaft 72 at a different location than shown. For example, the threaded region 160 and the threaded portion 162 may be located adjacent to the cap 122 or near the end face 130. By providing threaded regions 160 and threaded portions 162 along a short axial distance, after the majority of the integrated cap bushing 94 is inserted into the bore 70, the mating threads can engage, allowing the integrated cap bushing 94 to rotate in order to tighten and secure it to the brake caliper 22.

[0058] The integrated cap bushing 94 can be secured to the brake caliper 22 by a fastener or fastening feature. Several examples of configurations employing a fastener are shown in Figures 6 and 7.

[0059] In the configuration shown in Figure 6, the integrated cap bushing 94 is fixed to the brake caliper 22 by a fastener 170 located within the bore 70. The brake caliper 22 may include a brake caliper groove 172. The brake caliper groove 172 may surround the shaft 72 and the bore 70. The brake caliper groove 172 may extend from the bore 70 in a direction away from the shaft 72. The integrated cap bushing 94 may include an integrated cap bushing groove 174. The integrated cap bushing groove 174 may surround the shaft 72. The integrated cap bushing groove 174 may be provided on the tubular wall 120, the cap 122, or both. In the configuration shown, the integrated cap bushing groove 174 may be provided on the cap 122 and extend from the outside of the cap 142 toward the shaft 72. The fastener 170 can be received in the brake caliper groove 172 and the integrated cap bushing groove 174. The fastener 170 can have any suitable configuration. For example, the fastener 170 may be configured as a clip, a snap ring, or something similar.

[0060] Figure 7 shows another example of an integrated cap bushing 94 fixed to a brake caliper 22 located within a bore 70. In the example shown, the brake caliper 22 includes a recess 180. The recess 180 extends from the bore 70 in a direction away from the shaft 72. The recess 180 may or may not surround the shaft 72. The integrated cap bushing 94 includes a projection 182. The projection 182 may extend away from the shaft 72 and may be received within the recess 180 to secure the integrated cap bushing 94 to the brake caliper 22. The recess 180 and the projection 182 may be provided in any suitable location. For example, the projection 182 may be provided on the cap 122 as shown, or on the tubular wall 120. The configuration shown in Figure 7 may also be reversed, in which case the projection 182 may be provided on the brake caliper 22 and the recess 180 may be provided on the integrated cap bushing 94.

[0061] In the configuration shown in Figure 8, the integrated cap bushing 94 is secured to the brake caliper 22 by a fastener that is not located inside the bore 70. Therefore, the fastener 190 is located inside the brake caliper 22 outside the bore 70. For example, the cap 122 may include a cap flange 192. The cap flange 192 is located outside the bore 70 and may extend away from the shaft 72. In some configurations, the cap flange 192 may protrude away from the shaft 72 and / or overlap with a portion of the brake caliper 22. The fastener 190 can secure the cap flange 192 to the brake caliper 22. The fastener 190 may be a separate component from the cap flange 192 or may be integrated with the cap flange 192. For example, the fastener 190 may be a threaded fastener such as a bolt or screw, or a non-threaded fastener such as a pin or clip, extending through a hole or slot in the cap flange 192 and into a corresponding fastener receiving hole 194 in the brake caliper 22. In another example, the fastener 190 may be formed integrally with the cap flange 192. For example, the fastener 190 may be a projection such as a clip or pin that can extend from the cap flange 192 into the fastener receiving hole 194 in the brake caliper 22. Such a fastener 190 may be secured in any suitable way, such as by a compression fit, a fitting feature (e.g., a latch, hook, spline, projection, recess, etc.), or similar. It is conceivable that multiple cap flanges 192 and fasteners 190 may be provided, and that the fasteners 190 may have the same or different configurations.

[0062] Referring primarily to Figure 3, the flexible boot 30 may extend between the brake carrier 20 and the brake caliper 22, or between the guide pin assembly 28 and the brake caliper 22. The flexible boot 30 is configured to flex in response to the movement of the brake caliper 22. For example, the flexible boot 30 may expand or unfold when the brake caliper 22 moves in a first direction along axis 72 relative to the brake carrier 20, and may contract or fold when the brake caliper 22 moves in a second direction, i.e., in the opposite direction relative to the brake carrier 20. The flexible boot 30 may comprise one or more mounting rims 200. One mounting rim 200 may be fixed to the brake carrier 20, and another mounting rim 200 may be fixed to the brake caliper 22. For clarity, only the mounting rim 200 that engages with the brake caliper 22 is numbered.

[0063] The flexible boot 30 can be secured in various ways. In the shown configuration, the flexible boot 30 is shown secured between the integrated cap bushing 94 and the brake caliper 22; however, the flexible boot 30 may not be secured between the integrated cap bushing 94 and the brake caliper 22. For example, the mounting rim 200 of the flexible boot 30 may not contact or engage with the integrated cap bushing 94 and may be secured by a fastener such as a ring that press-fits into the brake caliper 22 and a ring that captures the mounting rim 200 between the ring and the brake caliper 22.

[0064] A mounting rim 200 associated with the brake caliper 22 can be fixed between the integrated cap bushing 94 and the brake caliper 22. For example, the mounting rim 200 may be located within the bore 70 and may at least partially surround or extend around the integrated cap bushing 94 so that the mounting rim 200 is sandwiched or fixed between the brake caliper 22 and the tubular wall 120. In some configurations, the mounting rim 200 is received within a brake caliper boot groove 202. The brake caliper boot groove 202 surrounds the bore 70 and extends from the bore 70 in a direction away from the axis 72. In some configurations, the mounting rim 200 of the flexible boot 30 engages with a guide surface 136 and optionally with a stepped surface 138.

[0065] The brake assembly 10 can be assembled by attaching the sleeve 92 to the brake carrier 20 with a fastener 90. Lubricant 152 can be injected into the cavity 124 of the integrated cap bushing 94, thereby positioning the lubricant 152 near the cap end wall 140. The amount of lubricant 152 to be injected can be measured or measured so that a sufficient amount of lubricant 152 is provided and so that this amount of lubricant can be contained by the chamber 150. The integrated cap bushing 94 can be inserted into the bore 70 in the brake caliper 22 before or after the lubricant 152 is injected.

[0066] Next, the integrated cap bushing 94 and the brake caliper 22 can be aligned with the sleeve 92 so that the sleeve 92 can be inserted into the cavity 124 of the integrated cap bushing 94. Relative movement along the axis 72 can be provided between the sleeve 92 and the integrated cap bushing 94 to insert or position the sleeve 92 within the integrated cap bushing 94. Insertion of the sleeve 92 can facilitate the distribution of lubricant 152 between the sleeve 92 and the inside 134 of the tubular wall 120 of the integrated cap bushing 94. Alignment and insertion can be assisted by the tapered shape of the guide surface 136 of the integrated cap bushing 94.

[0067] In a configuration in which the flexible boot 30 is positioned within the bore 70 of the brake caliper 22 and sandwiched between the integrated cap bushing 94 and the brake caliper 22, the mounting rim 200 of the flexible boot 30 is inserted into the bore 70 and, if provided, into the brake caliper boot groove 202, after which the integrated cap bushing 94 can be fully inserted or secured, thereby allowing the integrated cap bushing 94 to help secure the flexible boot 30, thereby reducing or eliminating the need for additional fasteners. The guide surface 136 may act as a wedge and may also engage with the mounting rim 200 and exert a force against the mounting rim 200, which pushes the mounting rim radially outward as the integrated cap bushing 94 moves toward the brake carrier 20 along the axis 72, thereby securing the mounting rim 200 in the brake caliper boot groove 202.

[0068] Brake assemblies and guide pin assemblies as described employ a cap integrated with the tubular wall, rather than providing a separate component such as a cap that press-fits into the end of the bore of the brake caliper and does not support or slide along the sleeve. Integrated cap bushings have fewer potential lubricant leak paths, can better contain lubricant, can better separate lubricant from external contaminants, and can help prevent lubricant degradation. Furthermore, integrated cap bushings can avoid problems associated with separate components such as misalignment and improper installation of the cap during assembly or maintenance, which can lead to improper sealing, leakage, or cap damage. By preventing or reducing lubricant degradation and leakage, smoother axial movement of the brake caliper relative to the brake carrier may be promoted, which in turn may help reduce or avoid resistance and uneven wear of the brake pad friction material, thereby reducing resistance and helping to improve the lifespan of the brake pad assembly. One-piece cap bushings can be configured to allow lubrication to be injected into the bushing before installation, thereby providing lubrication near the sliding surfaces of the sleeve and the one-piece cap bushing without having to disassemble the fastener and sleeve from the brake carrier, thereby reducing maintenance time and associated costs and labor. Furthermore, one-piece cap bushings can be removed and reinstalled without the need to disassemble the brake caliper, detach the brake caliper from the brake carrier, or remove the sleeve and fastener from the brake carrier, or any combination thereof, allowing preventive maintenance or inspections to be performed more effectively.

[0069] While exemplary embodiments have been described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the terms used herein are descriptive rather than limiting, and it should be understood that various modifications are possible without departing from the spirit and scope of the invention. Furthermore, features of various embodiments can be combined to form further embodiments of the invention. [Explanation of symbols]

[0070] 10 Brake Assembly 20 Brake Carrier 22 Brake calipers 24 Brake Pad Assembly 26 Retainer Bracket 28 Guide pin assembly 30 Flexible Boots 40 Brake rotors 42 Brake rotor shaft 50 fastener holes 60 Caliper Housing 62 Caliper Bridge 64 openings 70 Bore 72 axes 74 Bore surface 80 Backplate 82 Friction materials 90 Fastener 92 sleeves 94 Integrated cap bushing 100 Exterior 120 Tubular wall 122 Cap 124 Cavity 130 End face 132 Outside 134 Inside 136 Guide surface 138 Step surface 140 Cap end wall 142 Outside of the cap 150 Chambers 152 Lubricating oil 160 threaded area 162 Threaded part 170 Fastener 172 Brake caliper groove 174 Integrated cap bushing groove 180 recess 182 Protrusion 190 Fastener 192 Cap flange 194 Fastener receiving holes 200 Mounting Rim 202 Brake caliper boot groove

Claims

1. Brake assembly, Brake carrier and A brake caliper that defines a bore extending along the axis, The brake caliper is slidably coupled to the brake carrier by a guide pin assembly, and the guide pin assembly is An integrated cap bushing, at least partially received in the bore and fixed to the brake caliper, wherein the integrated cap bushing is an integrated component comprising a tubular wall and a cap, the tubular wall surrounding and at least partially defining a cavity extending along an axis and having an end face located opposite the cap, the cap extending from the tubular wall and closing the end of the integrated cap bushing, A sleeve to be received in the cavity, wherein the integrated cap bushing engages with the tubular wall such that it is movable along the axis relative to the sleeve, A fastener is disposed within the sleeve and connects the sleeve to the brake carrier. A brake assembly equipped with the following features.

2. The brake assembly according to claim 1, wherein the tubular wall further comprises an outer part that faces away from the axis and engages with the brake caliper within the bore, and the cap further comprises a cap outer part that faces away from the axis and engages with the brake caliper within the bore, the cap outer part being positioned further from the axis than the outer part of the tubular wall.

3. The brake assembly according to claim 1, wherein the tubular wall further comprises an outer part facing away from the shaft and engaging with the brake caliper within the bore, and the cap further comprises a cap outer part facing away from the shaft and engaging with the brake caliper within the bore, and the cap outer part and the outer part are positioned at a common radial distance from the shaft.

4. The brake assembly according to claim 1, wherein the brake caliper further comprises a threaded region disposed within the bore, and the integrated cap bushing further comprises a threaded portion that engages with the threaded region and secures the integrated cap bushing to the brake caliper.

5. The brake assembly according to claim 4, wherein the threaded portion of the integrated cap bushing is positioned on the cap.

6. The brake assembly according to claim 4, wherein the threaded portion of the integrated cap bushing is arranged on the tubular wall.

7. The brake assembly according to claim 1, wherein the integrated cap bushing is fixed to the brake caliper by a fastener positioned in the bore.

8. The brake assembly according to claim 7, wherein the brake caliper further comprises a brake caliper groove surrounding the bore and extending from the bore toward the axis, and the cap further comprises an outer cap surface facing toward the axis and a cap groove extending toward the axis from the outer cap surface, and the fastener is received in the brake caliper groove and the cap groove.

9. The brake assembly according to claim 1, wherein the integrated cap bushing is fixed to the brake caliper by a fastener positioned on the outside of the bore.

10. The brake assembly according to claim 9, wherein the cap further comprises a cap flange positioned outside the bore and extending away from the shaft, and the fastener secures the cap flange to the brake caliper.

11. The brake assembly according to claim 1, wherein the brake caliper further comprises a recess extending from the bore away from the shaft, and the integrated cap bushing further comprises a projection extending away from the shaft, the projection being received in the recess, and the integrated cap bushing being fixed to the brake caliper.

12. The brake assembly according to claim 1, wherein the fastener, the sleeve, and the integrated cap bushing cooperate to define a chamber positioned along the axis between the fastener and the cap, the chamber containing lubricating oil.

13. The brake assembly according to claim 1, wherein the sleeve engages with the brake carrier, and the integrated cap bushing is spaced apart from the brake carrier and does not come into contact with the brake carrier.

14. The brake assembly according to claim 1, further comprising a flexible boot extending between the brake carrier and the brake caliper, wherein the mounting rim of the flexible boot is positioned in the bore and fixed between the integrated cap bushing and the brake caliper.

15. The brake assembly according to claim 14, wherein the brake caliper further comprises a brake caliper boot groove surrounding the bore and extending from the bore toward the axis, and the mounting rim of the flexible boot is positioned in the brake caliper boot groove.

16. The brake assembly according to claim 15, wherein the tubular wall further comprises an outer surface facing away from the axis and engaging with the brake caliper within the bore, and a guide surface extending outward from the end face, and the flexible boot engages with the guide surface.

17. The brake assembly according to claim 16, wherein the guide surface is arranged at an oblique angle with respect to the end face and the outer surface.

18. The brake assembly according to claim 16, wherein the guide surface extends away from the shaft as it extends away from the end face.

19. The brake assembly according to claim 18, wherein the tubular wall further comprises a stepped surface extending from the end of the guide surface to the outside.

20. The brake assembly according to claim 19, wherein the mounting rim engages with the stepped surface.

21. This is an integrated cap bushing for brake calipers, A tubular wall surrounding and at least partially defining the cavity, comprising a tubular wall having an end face, A cap is positioned on the opposite side of the end face and extends from the tubular wall. The cap closes the end of the tubular wall, and the integrated cap bushing is an integrated component. Integrated cap bushing.

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