Floating Caliper

Abstract

To provide a floating type caliper with a design plate capable of improving productivity and workability of assembling the design plate.SOLUTION: A floating type caliper comprises a caliper body 3, a first pad 61 arranged between a claw part 32 and a disc rotor R, a first pad support 7 that slidably supports the first pad 61 in the axial direction of the disc rotor R, a mount 2 into which the first pad support 7 and a second pad support 8 are assembled, and a design plate 9 arranged so as to face the outer surface of the claw part 32. When the axial direction of the disc rotor R is defined as a rotor axis direction, the design plates 9, 9A are attached to the first pad supports 7, 7A so that the movement of the design plates 9, 9A with respect to the first pad supports 7, 7A at least in the rotor axis direction is restricted.SELECTED DRAWING: Figure 18

Description

[Technical field]

[0001] The present invention relates to a floating caliper. [Background technology]

[0002] A floating caliper includes a caliper body having a cylinder portion that houses a piston and a claw portion that is arranged opposite the cylinder portion. The claw portion is arranged on the outer surface of the vehicle and is arranged so as to be visible from outside the vehicle. Therefore, in order to improve the design of the caliper and protect the parts, a design plate that covers the outer surface of the claw portion has been conventionally installed on the caliper body. For example, in the disc brake device described in Japanese Patent No. 5148545, a design plate is screwed to the caliper body. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 5148545 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in a configuration in which the design plate is fixed to the caliper body by screws, it is necessary to form screw holes and manage the torque when fastening the screws. Machining and design changes to the mount and caliper body are major tasks. In addition, separate equipment is required for torque management. In order to prevent damage and loosening of the screws, it is necessary to tighten the screws with an appropriate torque when removing and attaching the design plate. As such, the conventional configuration has room for improvement in terms of the productivity of floating-type calipers with design plates and the ease of assembling the design plates.

[0005] An object of the present invention is to provide a floating-type caliper that can improve the productivity of a floating-type caliper having a design plate and the ease of assembling the design plate. [Means for solving the problem]

[0006] The floating caliper of the present invention is a floating caliper comprising: a caliper body having a cylinder portion that slidably accommodates a piston, a claw portion that is arranged opposite the cylinder portion via a disc rotor, and a bridge portion that connects the cylinder portion and the claw portion across the disc rotor; a first pad that is arranged between the claw portion and the disc rotor, a second pad that is arranged between the piston and the disc rotor, a first pad support that supports the first pad slidably in the axial direction of the disc rotor, a second pad support that supports the second pad slidably in the axial direction of the disc rotor, a mount to which the first pad support and the second pad support are assembled, and a design plate that is arranged opposite the outer surface of the claw portion, wherein when the axial direction of the disc rotor is the rotor axial direction, the design plate is attached to the first pad support so that movement of the design plate at least in the rotor axial direction relative to the first pad support is restricted. Effect of the Invention

[0007] According to the present invention, the design plate can be held on the caliper body by processing the design plate and the first pad support without processing the mount and the caliper body. By using the first pad support assembled to the mount to hold the design plate, additional processing of screw holes in the mount and the caliper body is not required. In addition, screw fastening work is not required when assembling the design plate, and torque management is also not required. In this way, according to the present invention, it is possible to improve the productivity of floating-type calipers having design plates and the workability of assembling the design plate. [Brief description of the drawings]

[0008] [Figure 1] 1 is a configuration diagram of a disc brake device according to a first embodiment. FIG. [Diagram 2] FIG. 2 is a cross-sectional view taken along line II-II of FIG. [Diagram 3] FIG. 1 is a perspective view of a disc brake device according to a first embodiment. [Figure 4] FIG. 2 is a perspective view showing a state before a design plate is assembled to the disc brake device of the first embodiment. [Diagram 5] FIG. 2 is a perspective view of a design plate according to the first embodiment. [Figure 6] FIG. 2 is a rear view of the disc brake device of the first embodiment. [Figure 7] FIG. 4 is a plan view of a first pad support in the first embodiment. [Figure 8] FIG. 4 is a side view of the first pad support of the first embodiment. [Figure 9] FIG. 4 is a rear view of the first pad support of the first embodiment. [Figure 10] FIG. 2 is a perspective view of a first pad support according to the first embodiment. [Figure 11] 5A to 5C are schematic diagrams showing modified examples of the arm portion and the engagement portion of the first embodiment. [Figure 12] FIG. 13 is a perspective view of a recess in the first modified example. [Figure 13] 13 is a conceptual diagram for explaining a recess and a plate portion of the first modified example. FIG. [Figure 14] 13 is a conceptual diagram for explaining a recess and a plate portion of the first modified example. FIG. [Figure 15] 13 is a conceptual diagram for explaining a recess and a position restriction surface of Modification 2. FIG. [Figure 16] 13 is a conceptual diagram for explaining a recess and a restricting portion according to Modification 3. FIG. [Figure 17] 13 is a conceptual diagram showing an example of an arm portion having a recess and a connection portion. FIG. [Figure 18] FIG. 11 is a perspective view of a floating caliper according to a second embodiment. [Figure 19] FIG. 11 is a perspective view showing a floating caliper in a state before a design plate is assembled in a second embodiment. [Figure 20] FIG. 11 is a perspective view of a design plate according to a second embodiment. [Figure 21] FIG. 11 is a perspective view of a first pad support according to the second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. Each of the drawings used in the description is a conceptual diagram. In addition, in the description, the axial direction of the disc rotor R is referred to as the "rotor axial direction", the radial direction of the disc rotor R is referred to as the "rotor radial direction", and the circumferential direction of the disc rotor R is referred to as the "rotor circumferential direction". In addition, the vehicle body side of the disc rotor R is referred to as the inner side, and the outer side (vehicle surface side) of the disc rotor R is referred to as the outer side. In other words, one axial side of the disc rotor R is the outer side, and the other axial side of the disc rotor R is the inner side. Note that Figs. 1 and 2 are schematic diagrams for explaining the configuration of the disc brake device 100, and the design plate 9 and the engagement portion 72 are omitted. Figs. 1 and 2 are schematic diagrams, and therefore some parts do not match the appearance of other figures.

[0010] First Embodiment As shown in Figures 1 and 2, the disc brake device 100 includes a disc rotor R that rotates together with the wheel, and a floating caliper 1. The floating caliper 1 of the first embodiment includes a mount 2, a caliper body 3, a slide pin 4, a first pad 61, a second pad 62, a first pad support 7, a second pad support 8, and a design plate 9, as shown in Figures 1, 2, 3, and 4.

[0011] The mount 2 is a metal member (torque member) attached to a non-rotating member of the vehicle body. The mount 2 includes a pair of bridge portions 21 arranged side by side in the rotor circumferential direction, a pair of outer-side torque receiving portions 22, an outer-side bridging portion 23, a pair of inner-side torque receiving portions 24, and an inner-side bridging portion 25. The pair of bridge portions 21 straddle the disc rotor R in the rotor axial direction on the outer side in the rotor radial direction. The pair of outer-side torque receiving portions 22 extend from one end of the pair of bridge portions 21 toward the inner side in the rotor radial direction. The outer-side bridging portion 23 bridges between the tip portions of the pair of outer-side torque receiving portions 22. The pair of inner-side torque receiving portions 24 extend from the other end of the pair of bridge portions 21 toward the inner side in the rotor radial direction. The inner-side bridging portion 25 bridges between the tip portions of the pair of inner-side torque receiving portions 24.

[0012] A pin guide hole 21a extending in the rotor axial direction is formed in each of the pair of bridge portions 21. A slide pin 4 is inserted into the pin guide hole 21a so as to be slidable in the rotor axial direction. The caliper body 3 is attached to the mount 2 via the slide pin 4 so as to be relatively movable in the rotor axial direction.

[0013] The caliper body 3 is a metal member (e.g., an aluminum member) and includes a bridge portion 31, a claw portion 32, a cylinder portion 33, and a pair of fastening portions 34. The bridge portion 31 straddles the disc rotor R in the rotor axial direction on the outer side in the rotor radial direction, and connects the claw portion 32 and the cylinder portion 33.

[0014] The claw portion 32 constitutes an outer side portion of the caliper body 3. The claw portion 32 is formed with a recess 321 recessed from an end portion on the inner side in the rotor radial direction to the outer side in the rotor radial direction at a position corresponding to the piston 10. The recess 321 is provided to facilitate the formation of a cylinder hole 331, which will be described later, in the manufacture of the caliper body 3. By forming the recess 321, a tool can be moved in the rotor axial direction without interference from the claw portion 32, and the cylinder hole 331 extending in the rotor axial direction can be easily formed. The recess 321 in the first embodiment is formed in an arc shape so as to bulge outward in the rotor radial direction.

[0015] The cylinder portion 33 constitutes an inner portion of the caliper body 3. The cylinder portion 33 faces the claw portion 32 in the rotor axial direction via the disc rotor R. A cylinder hole 331 that opens to the outer side is formed in the cylinder portion 33. A piston 10 is housed in the cylinder hole 331 so as to be slidable in the rotor axial direction. In the caliper body 3, a hydraulic pressure chamber 33a is defined by the cylinder portion 33 and the piston 10. The piston 10 moves in the rotor axial direction in response to the hydraulic pressure in the hydraulic pressure chamber 33a.

[0016] Thus, the caliper body 3 has a cylinder portion 33 that slidably accommodates the piston 10, a claw portion 32 that is arranged opposite the cylinder portion 33 via the disc rotor R, and a bridge portion 31 that connects the cylinder portion 33 and the claw portion 32 across the disc rotor R.

[0017] The pair of fastening portions 34 each extend from the cylinder portion 33 to a position facing the pin guide hole 21a. That is, the tip of the fastening portion 34 on one side in the rotor circumferential direction faces the pin guide hole 21a on one side in the rotor circumferential direction. The tip of the fastening portion 34 on the other side in the rotor circumferential direction faces the pin guide hole 21a on the other side in the rotor circumferential direction. Each fastening portion 34 has a fastening hole that penetrates in the rotor axial direction and has a screw thread formed on its inner circumferential surface.

[0018] The slide pins 4 are partially bolt-shaped metal members (so-called slide pin bolts) attached to the fastening portions 34. The base end of one slide pin 4 is fastened to one fastening portion 34. The base end of the other slide pin 4 is fastened to the other fastening portion 34. The tip end of each slide pin 4 is housed in the corresponding pin guide hole 21a so as to be relatively movable in the axial direction. A boot 5 is attached to a portion of each slide pin 4.

[0019] A first pad 61 and a second pad 62 (hereinafter also referred to as "pads 61, 62") are brake pads, and are attached to the mount 2 via a corresponding first pad support 7 and a second pad support 8, respectively, so as to be slidable in the rotor axial direction. As shown in FIG. 2, the pads 61, 62 are disposed opposite each other in the rotor axial direction via the disc rotor R. Each of the pads 61, 62 has a friction material 601 that applies a braking force to the disc rotor R by being in sliding contact with the disc rotor R, and a back plate 602 that supports the back surface of the friction material 601.

[0020] The first pad 61, which is an outer pad, is disposed between the claw portion 32 of the caliper body 3 and the disc rotor R. The second pad 62, which is an inner pad, is disposed between the piston 10 and the disc rotor R. When the hydraulic chamber 33a is pressurized, the piston 10 and the second pad 62 are pressed toward the disc rotor R, and the cylinder portion 33 is pressed in a direction away from the disc rotor R. As a result, the caliper body 3 moves relative to the mount 2 due to the sliding of the slide pin 4, the claw portion 32 and the first pad 61 approach the disc rotor R, and the pair of friction materials 601 sandwich the disc rotor R. In this way, the floating type caliper 1 applies a frictional braking force to the disc rotor R.

[0021] The first pad support 7 and the second pad support 8 are plate-shaped metal members attached to the mount 2. A pair of first pad supports 7 and a pair of second pad supports 8 are attached to the mount 2. The two first pad supports 7 are assembled to the outer-side torque receiving portion 22 so as to sandwich the first pad 61 in the rotor circumferential direction. In addition, the two second pad supports 8 are assembled to the inner-side torque receiving portion 24 so as to sandwich the second pad 62 in the rotor circumferential direction.

[0022] The first pad support 7 positions the first pad 61. The second pad support 8 positions the second pad 62. The first pad support 7 and the second pad support 8 are also called retainers. The mount 2 supports the pads 61, 62 via the first pad support 7 and the second pad support 8 so that they can slide in the rotor axial direction. The first pad 61 slides relative to the first pad support 7, and the second pad 62 slides relative to the second pad support 8.

[0023] Thus, the floating caliper 1 comprises a pair of first pad supports 7 that support the first pad 61 so that it can slide in the rotor axial direction, a pair of second pad supports 8 that support the second pad 62 so that it can slide in the rotor axial direction, and a mount 2 to which the pair of first pad supports 7 and the pair of second pad supports 8 are assembled.

[0024] The design plate 9 is disposed opposite to the outer surface (one end surface in the rotor axial direction) of the claw portion 32 for the purpose of improving the design of the floating-type caliper 1 and protecting the components. The design plate 9 in the first embodiment is, for example, a resin or metal part, and is attached to the mount 2 via the first pad support 7.

[0025] (Details of the design plate and first pad support) 5 and 6, the design plate 9 includes a plate portion 91 disposed opposite the outer surface of the claw portion 32, and a pair of arm portions 92 protruding from the plate portion 91. Each arm portion 92 protrudes toward the disc rotor R from a surface 91a (hereinafter referred to as the "rear surface") of the plate portion 91 that faces the claw portion 32. In other words, each arm portion 92 protrudes from the rear surface 91a of the plate portion 91 in the rotor axial direction.

[0026] One arm portion 92 is formed at one end of the plate portion 91 in the rotor circumferential direction so as to correspond to one of the first pad supports 7. The other arm portion 92 is formed at the other end of the plate portion 91 in the rotor circumferential direction so as to correspond to the other of the first pad supports 7. Each arm portion 92 has a recess 921 capable of accommodating an engagement portion 72, which will be described later. Each arm portion 92 is formed with a recess 921 recessed toward one side in the rotor axial direction. The recess 921 opens toward the other side in the rotor axial direction. The recess 921 is a portion that forms a recessed portion of the arm portion 92, and can also be called a recess forming portion. In other words, the recess 921 has a side surface (peripheral surface) and a bottom surface.

[0027] A through hole 921a is formed in the recess 921 of each arm portion 92, into which a protrusion 723, described later, is inserted. The through hole 921a penetrates the side surface of the recess 921, and communicates the inside and outside of the recess 921. The through hole 921a is formed in the side surface on one side in the rotor circumferential direction in the recess 921 on one side in the rotor circumferential direction, and is formed in the side surface on the other side in the rotor circumferential direction in the recess 921 on the other side in the rotor circumferential direction. That is, the through hole 921a in the first embodiment is formed in the side surface on the side away from the first pad 61 in the rotor circumferential direction (hereinafter also referred to as the "rotor circumferentially separated side"). The pair of arm portions 92 are formed line-symmetrically to each other.

[0028] As shown in Figures 7, 8, 9, and 10, each first pad support 7 is a continuous plate-like member formed by bending a single metal plate. In other words, each first pad support 7 is a curved metal plate member. Each first pad support 7 includes a main body portion 71 that is attached to the mount 2, and an engagement portion 72 that protrudes from the main body portion 71 and engages with the arm portion 92.

[0029] The main body 71 is formed in a U-shape and fitted into the recess 221 of the outer torque receiving portion 22. The main body 71 is formed with a plurality of guide portions 71a and spring portions 71b. The guide portions 71a and the spring portions 71b each protrude from one end portion of the main body 71 in the rotor axial direction (the end portion on the plate portion 91 side). The spring portions 71b have a folded portion that is curved toward the other side in the rotor axial direction so as to form a leaf spring. The spring portions 71b press the first pads 61 outward in the rotor radial direction. The first pads 61 are in slidable contact with the main body 71 including the spring portions 71b.

[0030] The engaging portion 72 engages with the arm portion 92 while being accommodated in the recess 921 of the arm portion 92 and pressing against the inner surface of the recess 921. The engaging portion 72 is formed to have a tightening margin with respect to the recess 921. The engaging portion 72 protrudes from one end of the main body portion 71 in the rotor axial direction. More specifically, the engaging portion 72 includes a base end portion 721, a curved portion 722, and a protruding portion 723. The base end portion 721 protrudes from the main body portion 71 toward the rotor circumferential direction so as not to interfere with the assembly of the first pad 61.

[0031] The curved portion 722 extends from the base end portion 721 to one side in the rotor axial direction, and is curved in a U-shape so as to be able to press against the inner surface of the recessed portion 921. The curved portion 722 constitutes a leaf spring. It can also be said that the engagement portion 72 has a leaf spring portion (curved portion 722) that presses against the inner surface of the recessed portion 921. More specifically, the curved portion 722 includes a first portion 722a, a second portion 722b, and a third portion 722c.

[0032] The first portion 722a extends from the base end portion 721 to one side in the rotor axial direction. The second portion 722b is curved in an arc shape so as to turn back from the first portion 722a to the other side in the rotor axial direction. The third portion 722c extends from the second portion 722b to the other side in the rotor axial direction. The third portion 722c is inclined so as to move away from the first portion 722a as it moves toward the other side in the rotor axial direction.

[0033] In the first embodiment, the first portion 722a is located on the rotor circumferentially more distant side than the third portion 722c. Before the engagement portion 72 is inserted into the recess 921, the maximum width of the curved portion 722 in the rotor circumferential direction is larger than the opening width of the recess 921 in the rotor circumferential direction. In other words, the engagement portion 72 is formed to have a tightening margin in the rotor circumferential direction with respect to the recess 921. An opening 722d penetrating in the rotor circumferential direction is formed in the end portion of the curved portion 722 on the rotor circumferentially more distant side (i.e., the first portion 722a).

[0034] The protruding portion 723 protrudes from the curved portion 722 in an elastically deformable manner. More specifically, the protruding portion 723 protrudes from a portion 722e of the curved portion 722 that defines the opening 722d toward the other rotor axial direction and toward the rotor circumferentially distant side. The protruding portion 723 overlaps with a portion of the opening 722d in the rotor circumferential direction. The protruding portion 723 is formed at a position corresponding to the through hole 921a of the recess 921. The opening 722d can also be called a punched portion, and the protruding portion 723 can also be called a return portion or a hook portion.

[0035] When the design plate 9 and the first pad support 7 are assembled, the curved portion 722 and the protruding portion 723 are inserted into the recessed portion 921 while being elastically deformed. When the protruding portion 723 reaches the through hole 921a and is inserted into the through hole 921a by the restoring force, the protruding portion 723 and the recessed portion 921 engage with each other. This engagement structure can be called a snap fit. The pair of arm portions 92 engage with the pair of engaging portions 72. In this manner, the design plate 9 is held by the first pad support 7. That is, the design plate 9 is assembled to the mount 2 via the first pad support 7. In addition, when the protruding portion 723 and the recessed portion 921 are engaged with each other, the curved portion 722 presses the inner surface of the recessed portion 921 by the restoring force.

[0036] When removing the design plate 9 from the first pad support 7, the worker inserts, for example, a rod-shaped member into the through hole 921a from the outside of the arm portion 92 and uses the rod-shaped member to press the protruding portion 723. The worker can pull out the arm portion 92 from the engaging portion 72 while elastically deforming the protruding portion 723 with the rod-shaped member to release the engagement.

[0037] (Effects of the first embodiment) The design plate 9 of the first embodiment includes an arm portion 92, and the first pad support 7 includes an engagement portion 72. According to this configuration, the design plate 9 can be held on the caliper body 3 by processing the design plate 9 and the first pad support 7, without processing the mount 2 and the caliper body 3. By using the first pad support 7 assembled to the mount 2 to hold the design plate 9, additional processing of screw holes in the mount 2 and the caliper body 3 is not required. In addition, screw fastening work is not required when assembling the design plate 9, and torque management is also not required. Thus, according to the first embodiment, it is possible to improve the productivity of the floating-type caliper 1 having the design plate 9 and the ease of assembling the design plate 9.

[0038] The engaging portion 72 in the first embodiment is engaged with the arm portion 92 while being accommodated in the recess 921 and pressing the inner surface of the recess 921. With this configuration, the abutting state between the recess 921 and the engaging portion 72 is maintained even after assembly, and rattling between the arm portion 92 and the engaging portion 72 is suppressed.

[0039] The engaging portion 72 of the first embodiment includes a curved portion 722 and a protruding portion 723, and a through hole 921a is formed in the recess 921. With this configuration, the engaging portion 72 and the arm portion 92 can be engaged with each other with a simple configuration. Furthermore, since the recess 921 is provided with the through hole 921a, an operator can deform the protruding portion 723 from the outside through the through hole 921a, facilitating the operation of releasing the engagement state. Furthermore, since the first pad support 7 is formed of a metal plate member, the processing and design change of the engaging portion 72 is relatively easy.

[0040] The protruding portion 723 in the first embodiment protrudes from a portion that defines the opening 722d of the curved portion 722. According to this configuration, the protruding portion 723 can be bent via the opening 722d during manufacturing, making manufacturing easier.

[0041] The arm portion 92 in the first embodiment protrudes in the rotor axial direction from the back surface 91a of the plate portion 91. With this configuration, the arm portion 92 is less visible from outside the vehicle (the front surface of the design plate 9), and the effect of the arm portion 92 on the design of the design plate 9 can be suppressed.

[0042] (others) The present invention is not limited to the above embodiment. For example, the protrusion 723 may not be formed on the curved portion 722, and a protrusion may be formed on the through hole 921a of the recess 921. For example, as shown in FIG. 11, the protrusion 922 formed on the through hole 921a of the recess 921 may be configured to be inserted into the opening 722d of the curved portion 722 through elastic deformation during assembly. This causes the arm portion 92 to engage with the engaging portion 72. That is, the protrusion (hook portion) for engagement may be formed on either the arm portion 92 or the engaging portion 72. Also, a recess may be formed on the engaging portion 72, and the arm portion 92 may be accommodated in the recess to engage the engaging portion 72 with the arm portion 92.

[0043] The engagement between the arm portion 92 and the engagement portion 72 may be realized by a snap-fit ​​structure other than the above (for example, a hook portion and a recess). For example, a resin snap-fit ​​member may be provided on the plate portion 91 and the first pad support 7. The arm portion 92 may protrude from a portion other than the back surface 91a of the plate portion 91. The engagement portion 72 may be formed so as not to press the inner surface of the recess 921. In other words, the engagement portion 72 may be formed without a tightening margin with respect to the recess 921, and may be configured to engage with the arm portion 92 by, for example, the protrusion 723. The design plate 9 can be held by engagement alone.

[0044] Furthermore, the through hole 921a of the recess 921 can be formed on any side surface of the recess 921. Furthermore, the engagement portion 72 may not include the base end portion 721, and the curved portion 722 may extend from the main body portion 71 in the rotor axial direction. In this case, for example, the positions of the first portion 722a and the third portion 722c are opposite to those in the above embodiment. Furthermore, the design plate 9 may include a portion that extends from the peripheral end portion of the plate portion 91 in the rotor axial direction and covers the caliper body 3.

[0045] Moreover, the engaging portion 72 is not limited to the position in the above embodiment, and can extend from any portion of the main body portion 71. The engaging portion 72 may be formed on only one of the pair of first pad supports 7. However, from the viewpoint of improving the holding force, it is preferable that the engaging portion 72 is formed on both of the pair of first pad supports 7, and a pair of arm portions 92 corresponding to the engaging portions 72 is formed on the plate portion 91. The floating-type caliper 1 may be provided with three or more arm portions 92 and three or more engaging portions 72. As described above, even with the configurations described in the other items, the design plate 9 can be held on the caliper body 3 without additional processing and screwing work on the mount 2 and the caliper body 3.

[0046] In the above embodiment, the flat portion of the engagement portion 72 of the first pad support 7 (excluding curved portions such as the curved portion 722) is formed to intersect (for example, perpendicular to) a virtual line extending in the rotor circumferential direction, but may be formed to intersect (for example, perpendicular to) a virtual line extending in the rotor radial direction. That is, the virtual line perpendicular to the flat portion of the engagement portion 72 extends in the rotor circumferential direction in the above embodiment, but may extend in the rotor radial direction. In the former configuration (the configuration of the first embodiment), the first pad support 7 is easily bent in the rotor circumferential direction and difficult to bend in the rotor radial direction, but in the latter configuration, the first pad support 7 is easily bent in the rotor radial direction and difficult to bend in the rotor circumferential direction. Also, one first pad support 7 may have the former configuration, and the other first pad support 7 may have the latter configuration.

[0047] In addition, the engagement direction (insertion direction) between the recess 921 and the engagement portion 72 of the first pad support 7 is not limited to the rotor axial direction as in the above embodiment, but may be, for example, the rotor circumferential direction or the rotor radial direction. For example, the recess 921 and the engagement portion 72 may be formed so that the design plate 9 is assembled to the engagement portion 72 by sliding or rotating parallel to the plate portion 91.

[0048] (Variation 1) As a first modification of the first embodiment, a mode in which the recess 921 and the plate portion 91 are formed from different materials will be described. In the first modification, the recess 921 is formed from a material that is more heat resistant than the plate portion 91. Heat resistance can be said to be the degree (temperature) of high temperature at which physical properties can be maintained when exposed to the high temperature. The higher the heat resistance, the more physical properties (e.g., shape) can be maintained at high temperatures. As an example, high heat resistance can be said to be a high glass transition point.

[0049] 12, 13, and 14, the design plate 9 is formed by insert molding in which the recess 921 is inserted into the plate portion 91. In other words, the design plate 9 of the first modification is configured by integrating the recess 921 and the plate portion 91, which are separate members.

[0050] The recess 921 is formed of a material having higher heat resistance than the plate portion 91. For example, the material of the plate portion 91 is a material classified as an engineering plastic, and the material of the recess 921 is a material classified as an engineering plastic that has higher heat resistance than the material of the plate portion 91.

[0051] In the first modification, as shown in FIG. 14, the entire arm portion 92 defines the recess 921. It is not necessary that the entire arm portion 92 defines the recess 921. In this case, the arm portion 92 includes the recess 921 and a connection portion 923 that connects the recess 921 and the plate portion 91 (see FIG. 17). In this case, the connection portion 923 may be formed of a material different from that of the recess 921. In this manner, the arm portion 92 includes the recess 921 in at least a portion. The other configurations of the first modification are similar to those of the first embodiment, and therefore description thereof will be omitted. Although not shown, the above configuration is adopted in the arm portions 92 on both sides in the rotor circumferential direction.

[0052] According to the first modification, the plate portion 91 and the recessed portion 921 are formed from different materials, so that the material can be selected according to the function and performance required for each portion of the design plate 9. In the first modification, a material with higher heat resistance than the plate portion 91 is used for the material of the recessed portion 921, so that the function (shape) of the recessed portion 921 can be maintained even if heat is transferred from the mount 2, which is prone to high temperatures, to the recessed portion 921 via the first pad support 7. In other words, deformation of the recessed portion 921 due to high heat and the like are suppressed, and the engagement between the first pad support 7 and the recessed portion 921 is more reliably maintained.

[0053] Furthermore, in selecting the material for the plate portion 91 that does not directly contact the mount 2 or the first pad support 7, design can be prioritized over heat resistance. In other words, according to the first modification, it is possible to increase the degree of freedom in selecting the material for the plate portion 91 that constitutes the design surface visible from outside the vehicle. Note that the recess 921 (arm portion 92) and the plate portion 91 may each be made of, for example, resin or metal.

[0054] (Variation 2) As a second modification of the first embodiment, a mode in which each recess 921 has a position restriction surface 921b as shown in Fig. 15 will be described. The second modification can be applied to, for example, the configuration of the first embodiment or the configuration of the first modification. Therefore, the other configuration of the second modification is omitted since the above description can be referred to.

[0055] When the design plate 9 is attached to the first pad support 7, the position restriction surface 921b is in contact with the mount 2. The position restriction surface 921b is, for example, planar, and is the other end surface in the rotor axial direction of the recess 921 (arm portion 92). The annular opening end surface of each recess 921 is in contact with the surface of the mount 2 (one end surface in the rotor axial direction) except for the recessed portion 20a of the mount 2. The recessed portion 20a is a portion in which a part of the first pad support 7 is accommodated. The recessed portion 20a may be provided on the opening end surface of the recess 921.

[0056] The position restriction surface 921b and the mount 2 are in contact with each other in both the recess 921 on one side of the rotor circumferential direction and the recess 921 on the other side of the rotor circumferential direction. The surface of the mount 2 with which the position restriction surface 921b is in contact is, for example, planar. In this case, the planar position restriction surface 921b and the planar surface of the mount 2 are in contact with each other. This ensures an efficient contact area. Note that the surface of the position restriction surface 921b and / or the surface of the mount 2 is not limited to being planar, and may be, for example, curved or have one or more convex portions. The position restriction surface 921b and the mount 2 are not limited to being in surface contact with each other, and may be in point contact with each other, for example.

[0057] The first pad support 7 and the design plate 9 may swing relative to the mount 2 in response to the movement of the vehicle. For example, the design plate 9 may swing in an arc shape with the fixed end of the first pad support 7 relative to the mount 2 as a fulcrum. However, according to the second modification, the position restriction surface 921b is in contact with the mount 2, so that the arc shape swing, i.e., the swinging movement in the rotor circumferential direction while approaching the mount 2, is suppressed. Furthermore, when the position restriction surface 921b tries to move (slide), a frictional force is generated between the position restriction surface 921b and the mount 2, suppressing the movement.

[0058] In this way, according to the modified example 2, the swing (vibration) of the design plate 9 can be suppressed, and the engagement between the design plate 9 and the first pad support 7 can be more reliably maintained. In addition, by suppressing the swing, the deformation (bending) of the first pad support 7 is suppressed, and the durability of the first pad support 7 is improved. In addition, by applying the modified example 2 to the modified example 1, the position restriction surface 921b is also formed of a material with high heat resistance, so that the shape can be maintained against the high heat of the mount 2 in contact. Note that the position restriction surface 921b may be formed to protrude from a part of the opening end surface of the recess 921, for example. In addition, the position restriction surface 921b may be formed so as to contact the caliper body 3. In addition, the part of the recess 921 that forms the position restriction surface 921b and the other parts may be formed of different materials.

[0059] (Variation 3) As a third modification of the first embodiment, a mode in which a restricting portion 93 is provided for each recess 921 of the second modification will be described as shown in Fig. 16. Description of the configuration other than the restricting portion 93 will be omitted. Each restricting portion 93 extends in the rotor axial direction from a side surface of the recess 921 (for example, around the through hole 921a) so as to contact a side surface of the mount 2.

[0060] Each regulating portion 93 contacts a side surface of the mount 2 on the rotor circumferentially separated side (the side farther from the first pad 61: see FIG. 9). That is, the two regulating portions 93 are arranged to sandwich the mount 2 in the rotor circumferential direction. Specifically, one regulating portion 93 contacts a side surface of the mount 2 (outer-side torque receiving portion 22) on one side in the rotor circumferential direction. The other regulating portion 93 contacts a side surface of the mount 2 (outer-side torque receiving portion 22) on the other side in the rotor circumferential direction. It can be said that each regulating portion 93 has a position regulating surface 93a that contacts the mount 2.

[0061] According to the third modification, the restricting portion 93 is in contact with the mount 2, which suppresses the swinging of the design plate 9 relative to the mount 2. This improves the durability of the first pad support 7. In addition, at least two restricting portions 93 are arranged to sandwich the mount 2, which suppresses swinging to either side in the rotor circumferential direction.

[0062] The two restricting portions 93 may be formed so as to contact the side surface of the mount 2 on the first pad side in the rotor circumferential direction (see FIG. 9). In other words, the two restricting portions 93 may be disposed so as to be sandwiched between a pair of outer-side torque receiving portions 22. This configuration also makes it possible to suppress rocking to either side in the rotor circumferential direction. The restricting portions 93 may be formed so as to contact the caliper body 3. The restricting portions 93 may be formed so as to contact the end surface of the mount 2 in the rotor radial direction.

[0063] <Second embodiment> The second embodiment will be described with reference to Figures 18, 19, 20, and 21. The floating caliper 1A of the second embodiment has a mount 2, a caliper body 3, a slide pin 4, a first pad 61, a second pad 62, a first pad support 7A, a second pad support 8, and a design plate 9A, as in the first embodiment. Hereinafter, the second embodiment will be described mainly in terms of the parts that are different from the first embodiment (the first pad support 7A and the design plate 9A), and the description of the other parts will be omitted. In the description of the second embodiment, the description and drawings of the first embodiment and each modified example can be referred to. Since the drawings of the first embodiment can be referred to, the reference numerals are omitted appropriately in the drawings of the second embodiment.

[0064] The design plate 9A of the second embodiment includes a plate portion 91 whose outer surface constitutes a design surface 91b, and a side wall 94 extending from the outer periphery of the plate portion 91 toward the mount 2 side (the other side in the rotor axial direction). The plate portion 91 is a portion disposed opposite the outer surface of the claw portion 32, and is formed in a flat shape. The design surface 91b is the outer surface of the plate portion 91 (one end surface in the rotor axial direction). Note that the design surface 91b is not limited to being flat, and may, for example, have projections and recesses formed thereon, or may be curved.

[0065] The side wall 94 is formed over the entire outer circumferential edge of the plate portion 91. In detail, the side wall 94 includes a first side wall portion 941 forming a side surface on one side in the rotor circumferential direction, a second side wall portion 942 forming a side surface on the other side in the rotor circumferential direction, a third side wall portion 943 forming a side surface on the inner side in the rotor radial direction, and a fourth side wall portion 944 forming a side surface on the outer side in the rotor radial direction.

[0066] A through hole 95 is formed in each of the first side wall portion 941 and the second side wall portion 942. In this example, the rotor circumferential central portion of the fourth side wall portion 944 protrudes less from the plate portion 91 than both ends in the rotor circumferential direction. The entire design plate 9A is formed of a material having high heat resistance, for example, like the recess 921 in the first modified example. The material of the design plate 9A is a material having high heat resistance, for example, among materials classified as engineering plastics.

[0067] As in the first embodiment, the first pad support 7A is a metal member that positions the first pad 61. The two first pad supports 7A are attached to the outer-side torque receiving portion 22 so as to sandwich the first pad 61 in the rotor circumferential direction. Since the two first pad supports 7A have symmetrical shapes, the first pad support 7A on the other side in the rotor circumferential direction will be described as an example.

[0068] The first pad support 7A includes a main body portion 71 that is assembled to the mount 2, and a protruding engagement portion 73 that protrudes from the main body portion 71 and engages with the through hole 95. The main body portion 71 is formed in a U-shape, and is fitted into the outer-side torque receiving portion 22. A detailed configuration of the main body portion 71 can be referred to a known configuration or the first embodiment, so a description thereof will be omitted.

[0069] The protruding engagement portion 73 extends from one end of the main body portion 71 in the rotor axial direction in a direction (the other side in the rotor circumferential direction and one side in the rotor axial direction) away from the first pad 61. More specifically, the protruding engagement portion 73 includes a first portion 731 extending from the main body portion 71 to one side in the rotor axial direction, and a second portion 732 extending from the first portion 731 to the other side in the rotor circumferential direction.

[0070] The first portion 731 is formed in a planar shape with a perpendicular line extending in the rotor circumferential direction. When the first portion 731 is attached to the design plate 9A, the first portion 731 is elastically deformed, for example, in the rotor circumferential direction by a worker or the like (which may be a work robot) and disposed inside the design plate 9A.

[0071] The second portion 732 is curved so as to be folded back toward one side in the rotor circumferential direction and formed in a leaf spring shape. The second portion 732 can also be called a curved portion or a leaf spring portion. The second portion 732 is pressed into the through hole 95 by an operator or the like when assembled to the design plate 9A. The second portion 732 is elastically deformed in the through hole 95 so that the width in the rotor axial direction becomes smaller from the original shape. In other words, the second portion 732 engages with the side wall 94 in the through hole 95 while pressing the side wall 94 (second side wall portion 942) by the restoring force of the spring. By engaging the protruding engagement portion 73 with the through hole 95, the movement of the design plate 9A in the rotor circumferential direction, the rotor radial direction, and the rotor axial direction relative to the first pad support 7A is restricted.

[0072] In this way, the design plate 9A is attached to the first pad support 7A so that movement at least in the rotor axial direction (here, the direction perpendicular to the design surface 91b) relative to the first pad support 7A (and the mount 2) is restricted. The configuration in which the first pad support (7, 7A) restricts the movement of the design plate (9, 9A) is also valid in the first embodiment and each modified example. The design surface 91b is the surface opposite to the back surface 91a of the plate portion 91 in the first embodiment.

[0073] Furthermore, the design plate 9A is attached to the first pad support 7A so that movement in the rotor circumferential direction and the rotor radial direction (here, directions parallel to the design surface 91b) relative to the first pad support 7A is also restricted. In this manner, the configuration in which the first pad support (7, 7A) restricts movement of the design plate (9, 9A) is also valid in the first embodiment and each modified example.

[0074] When removing the decorative plate 9A from the first pad support 7A, an operator, for example, presses the protruding engagement portion 73 in the through hole 95 from the outside of the decorative plate 9A with a rod-shaped member, and pushes the protruding engagement portion 73 out of the through hole 95.

[0075] (Effects of the second embodiment) According to the second embodiment, the design plate 9A can be assembled to the floating caliper by attaching (engaging, fitting, and fixing) the design plate 9A to each first pad support 7A. This provides the same effects as the first embodiment. Since the movement of the design plate 9A relative to the first pad support 7A in at least both directions in the rotor axial direction is restricted, the design plate 9A is prevented from approaching or moving away from the mount 2, and the design plate 9A is less likely to come off the floating caliper 1A. Furthermore, since the movement of the design plate 9A relative to the first pad support 7A in the rotor circumferential direction and rotor radial direction is restricted, the design plate 9A is fixed more reliably, and there is no need to fix it to other parts, and the ease of assembly is further improved. According to the second embodiment, the assembly of the design plate 9A can be completed only by fixing the design plate 9A to the first pad support 7A.

[0076] Moreover, according to the second embodiment, the design plate 9A only requires the through hole 95 to be machined, making manufacturing easier. Furthermore, since the through hole 95 is provided in the side wall 94, no design restrictions are imposed on the design surface 91b, increasing the degree of freedom in design production. Furthermore, since the through hole 95 is provided in the side wall 94, the direction in which the protruding engagement portion 73 is pressed in is shifted from the rotor axial direction. This makes it difficult for the design plate 9A to come off the floating-type caliper 1A due to vibration or impact in the rotor axial direction.

[0077] (Modification of the second embodiment) The present invention is not limited to the above embodiment. For example, the protruding engagement portion 73 may have a protruding portion (claw) similar to the protruding portion 723 of the first embodiment, and the side wall 94 (for example, the inner wall of the through hole 95) may have a recess similar to the recess 921 of the first embodiment. In consideration of removal of the design plate 9A, it is preferable that the recess is formed so that a rod-shaped member can be inserted from the outside.

[0078] Furthermore, the through holes 95 may be provided in the third side wall portion 943, the fourth side wall portion 944, and / or the plate portion 91 instead of (or in addition to) the first side wall portion 941 and the second side wall portion 942. For example, the through holes 95 may be provided at both ends of the plate portion 91 in the rotor circumferential direction. In this case, the protruding engagement portion 73 of each first pad support 7A protrudes from the main body portion 71 to one side in the rotor axial direction, for example. Furthermore, for example, one through hole 95 may be provided in the side wall 94, and the other through hole 95 may be provided in the plate portion 91.

[0079] Also, instead of the through hole 95, the side wall 94 may have a concave recess into which the protruding engagement portion 73 is pressed. This also makes it possible to fix the design plate 9A to the first pad support 7A. In this way, the design plate 9A has an engaged portion (for example, a through hole 95 or a recess) that engages with the protruding engagement portion 73. The design plate 9A of the second embodiment has an engaged portion that engages with the protruding engagement portion 73 when pressed by the protruding engagement portion 73. Also, the side wall 94 is not limited to being formed on the entire outer periphery of the plate portion 91, and may be composed of, for example, only the first side wall portion 941 and the second side wall portion 942. Also, the side wall 94 may not be present.

[0080] Also, as in Modification 1, for example, a part of the side wall 94 in which the through hole 95 is formed may be made of a material having higher heat resistance than the plate portion 91. The portion in which the through hole 95 is formed (for example, side wall portions 941, 942, etc.) may be made of a material different from the other portions (a material having higher heat resistance than the other portions). Also, the configuration of the second embodiment may be appropriately combined with the concept and configuration of the first embodiment and each modification. [Explanation of symbols]

[0081] 1, 1A...floating caliper, 10...piston, 2...mount, 3...caliper body, 31...bridge portion, 32...claw portion, 321...recess, 61...first pad, 62...second pad, 7, 7A...first pad support, 71...main body portion, 72...engagement portion, 722...curved portion, 722d...opening, 723...protruding portion, 73...protruding engagement portion, 8...second pad support, 9, 9A...design plate, 91...plate portion, 91b...design surface, 92...arm portion, 921...recess, 921a...through hole, 921b...position control surface, 94...side wall, 95...through hole (engaged portion), R...disc rotor.

Claims

1. a caliper body including a cylinder portion that slidably accommodates a piston, a claw portion that is disposed opposite the cylinder portion via a disc rotor, and a bridge portion that connects the cylinder portion and the claw portion across the disc rotor; a first pad disposed between the claw portion and the disk rotor; A second pad disposed between the piston and the disk rotor; a first pad support that supports the first pad slidably in an axial direction of the disk rotor; a second pad support that supports the second pad slidably in an axial direction of the disk rotor; a mount to which the first pad support and the second pad support are assembled; A design plate disposed opposite to an outer surface of the claw portion; A floating caliper comprising: If the axial direction of the disk rotor is the rotor axial direction, A floating-type caliper, wherein the design plate is attached to the first pad support such that movement of the design plate relative to the first pad support is restricted at least in the rotor axial direction.

2. If the circumferential direction of the disk rotor is defined as the rotor circumferential direction and the radial direction of the disk rotor is defined as the rotor radial direction, 2. The floating-type caliper according to claim 1, wherein the design plate is attached to the first pad support so that movement of the design plate relative to the first pad support in the rotor circumferential direction and the rotor radial direction is also restricted.

3. The first pad support includes a main body portion assembled to the mount and a protruding engagement portion protruding from the main body portion, The floating-type caliper according to claim 1 or 2, wherein the design plate has an engaged portion that engages with the protruding engaging portion.

4. The design plate includes a plate portion disposed opposite an outer surface of the claw portion and an arm portion protruding from the plate portion, 3. The floating-type caliper according to claim 1, wherein the first pad support comprises a main body portion assembled to the mount, and an engagement portion protruding from the main body portion and engaging with the arm portion.

5. the arm portion has a recess capable of accommodating the engagement portion, 5. The floating-type caliper according to claim 4, wherein the engagement portion is engaged with the arm portion in a state in which the engagement portion is received in the recess and presses an inner surface of the recess.

6. the first pad support is a curved metal plate member, The engaging portion includes a curved portion curved to be able to press against an inner surface of the recess, and a protruding portion protruding from the curved portion to be able to elastically deform, The floating-type caliper according to claim 5 , wherein the recess has a through hole into which the protrusion is inserted.

7. the curved portion has an opening at a position corresponding to the through hole, The floating caliper according to claim 6 , wherein the protrusion protrudes from a portion of the curved portion that defines the opening.

8. 8. The floating-type caliper according to claim 5, wherein the recess and the plate portion are formed of different materials.

9. The floating-type caliper according to claim 8 , wherein the recess is formed of a material having a higher heat resistance than the plate portion.

10. 10. The floating-type caliper according to claim 5, wherein the recess has a position restriction surface that is in contact with the mount or the caliper body.

11. 11. The floating-type caliper according to claim 4, wherein the arm portion protrudes from a surface of the plate portion facing the claw portion toward the disc rotor.

Images