Pad-Spring Assembly for Brake Caliper

Abstract

An axial direction (XX) that coincides with or is parallel to the rotation axis of a brake disc of a disc brake, a radial direction (RR) that is perpendicular to the axial direction (XX), and a tangential direction (TT) that is perpendicular to both the axial direction (XX) and the radial direction (RR) are defined; the radial direction (RR) defines a radially inward direction (RI) directed towards the axis of rotation of the brake disc and a radially outward direction (RO) opposite to the radially inward direction (RI), The assembly comprises: At least one brake pad (2) including a friction material (3) and a support plate (4) supporting said friction material (3); at least one resilient device (5) adapted to apply an axially (XX) directed resilient biasing action to said brake pad (2) to move it away from said brake disc when braking action has ceased; the support plate (4) comprises a surface (6) facing the disc, in intimate association with the friction material (3), and a plate back surface (7) axially opposite the surface (6) facing the disc, adapted to face a thrust means (8) of the brake caliper (10) which may be associated with the assembly (1); the friction material (3) comprises a radially inner edge adapted to face the rotation axis of the brake disc and a radially outer edge (13) radially opposite the radially inner edge, the radially outer edge (13) of the friction material (3) defines a radially outer dimension level of the friction material (3) having a tangential extension (13') on the disk-facing surface (6) of the support plate (4); the disc-facing surface (6) of the support plate (4) comprises at least one free surface (9) that is free from contact with the friction material (3) and is adapted to face a braking surface of the brake disc that may be associated with the assembly (1), the free portion (9) being located radially inward with respect to the at least one tangential extension (13') of the radially outer edge (13) of the friction material (3); the free surface (9) of the disc-facing surface (6) of the support plate (4) of the brake pad (2) comprises at least one through-opening edge (16) at least partially delimiting a through-opening (17) in the axial direction (XX) through the support plate (4) of the brake pad (2), The at least one elastic device (5) has a body, the body comprising: at least one coupling (21, 21') adapted to connect to the body of the brake caliper (10) that may be associated with the assembly (1); and at least one support (22) resting against the through-opening edge (16) of the free surface (9) of the support plate (4) axially transverse to the through-opening (17) of the support plate (4) so ​​as to apply a resilient biasing action directly to the through-opening edge (16) of the through-opening (17) in the axial direction (XX). Pad and spring assembly (1) for the brake caliper (10) of a disc brake.

Description

Technical Field

[0001] The present invention relates to a pad - spring assembly for a brake caliper.

[0002] Furthermore, the present invention relates to a brake caliper for a disc brake including the assembly.

Background Art

[0003] In a disc brake, the brake caliper is generally arranged to straddle the outer peripheral edge of a brake disc adapted to rotate about a rotation axis defining an axial direction (X - X). In a disc brake, a radial direction (R - R) substantially orthogonal to the axial direction (X - X) and a tangential direction (T - T) or circumferential direction (T - T) orthogonal to both the axial direction (X - X) and the radial direction (R - R) are further defined.

[0004] The brake pad generally includes a pad to which a friction material is fixed and which is adapted to be pressed against a facing braking surface of a braking band of the brake disc. The plate may sometimes include an audible wear indicator embedded in the friction material, which has a function of making a sound by rubbing against the braking band of the disc when the friction material becomes thinner in the axial direction due to long - term use.

[0005] The axial direction (X - X), the radial direction (R - R), and the tangential direction (T - T) or circumferential direction (T - T) are defined on the brake pad even in a configuration where the brake pad is not attached to the brake caliper, for example, when it is associated with at least one elastic device.

[0006] Known types of pads are of the so-called hanging-on-pin type, providing eyelets made in the pad plate and adapted to receive pins specifically envisioned and intended to hold the pads within the caliper body. In this type of pad, the braking action is transmitted from the material to the plate surrounding the eyelet and then to the caliper body.

[0007] Different types of pads are of the so-called sitting-on-caliper-body type, being housed in specific pockets obtained in the caliper body, and at the start of the braking operation of the vehicle, the braking action is transmitted to the caliper body by the side surface of the pad plate hitting the opposing abutment surface of the caliper body pocket. The pins attached to this type of pad function as sliding axial guides that guide the approach and separation movements of the pad towards and away from the disc.

[0008] Normally, the caliper body is made of metal such as aluminum, or an aluminum alloy such as aluminum and lithium, or steel, and can be made by casting, but can also be made by machining using chip forming technology or even forging.

[0009] In a floating caliper body associated with a fixed disc, the floating part of the caliper body has a cylinder (or cylinders) adapted to house a hydraulic piston that can apply a thrust action to the facing pad, and while sliding on the bracket, i.e., the fixed part of the caliper, it contacts the braking surface of the disc and acts on a second clutch pad that contacts the opposing brake disc surface to apply a braking action to the vehicle.

[0010] In a known caliper body associated with a fixed disc, cylinders adapted to house pistons, preferably hydraulic pistons, are present on both axially opposing sides of the caliper body, applying a thrust action to the brake pads and contacting the respective opposing disc braking surfaces to apply a braking action to the vehicle.

[0011] When a driver of a vehicle steps on the brake pedal, pressure is applied to the brake fluid, and that pressure is applied through a pipe to the brake fluid present in the hydraulic circuit within the caliper body, reaching the cylinder, and that pressure is applied to the lower surface of the piston. As a result, the piston is forced to close against the brake pad, and then that pad abuts against the braking surface of the disk.

[0012] The caliper body deforms as a function of the torque applied in a direction forming a torque arm with respect to the fixed point on the support of the caliper body by the operation of the piston that causes the pad to abut against the braking surface of the disk. These torques deform the caliper body tangentially, radially, and also axially with respect to the disk, increasing the piston stroke, and as a result, increasing the stroke of the control pedal of the braking system.

[0013] When the braking operation stops, the caliper body returns to its undeformed shape, approaching the braking surface of the disk. At the same time, the piston of the cylinder - piston assembly receives a thrust force away from the disk by the action of a piston retraction device, which is usually a seal integrated into the dust boot of the piston, as shown in applicant's documents US2013 - 192936 and US2014 - 231190.

[0014] Normally, such a piston retraction device (known as a roll - back device) is provided at the interface between the piston and each cylinder, and when the braking control stops, it is designed to retract the piston by a limited predetermined amount within its cylinder, moving it away from each pad.

[0015] In this situation, the approach of the caliper body to the disk determines an undesirable but slight contact between the brake pad and the disk braking surface, thereby determining a continuous slight friction and a braking action also called residual braking torque even when the braking command has stopped.

[0016] Such residual braking torque, due to the frictional action between the pads and the disc braking surfaces, generates a slight but audible noise, causes undesirable wear of the pads and the brake disc, meaning that more frequent maintenance is required for their replacement, and also means that there is a minimum fuel consumption for supplying the minimum energy required to overcome this residual torque to the drive unit, and is therefore often considered undesirable.

[0017] For these reasons, it is known to associate with a spring brake pad that applies a direct axial (X-X) bias to the brake pad by cooperating with the parts of the brake caliper body, moving the brake pad away from the brake disc when the braking operation stops and bringing it into contact with the piston already retracted by the retraction device. During braking, such a biasing action in the direction away from the disc is overcome by the thrust action applied by the piston. On the other hand, when braking is released, i.e., when the braking operation ends, the spring applies a thrust axially and moves the pad away from the braking surface of the brake disc, thus avoiding contact between the pad and the brake disc when braking is not required.

[0018] For example, in document WO2015-155708 by the present applicant, a solution with a cross-shaped spring is shown, which is coupled at the top to a bridge of the caliper body arranged to straddle the disc and has an advantageously inclined portion adapted to push the radially outer part of the brake pad away from the disc. Such a spring uses the same inclined portion to act on the radially outer edge of the brake pad and push the brake pad radially outwards. The cross-shaped spring coupled to this type of caliper bridge needs to act on the radially outer peripheral part of the brake pad and will necessarily give a local axial thrust, which can cause a displacement of the pad with respect to the braking surface of the disc facing the brake pad, generate non-uniform wear of the friction material of the pad to correct this, and may limit the life of the brake pad.

[0019] For example, as shown in US2014-0305753, a spring solution operating on an extension of the side surface extending in the tangential direction from the side surface of the brake pad is also known. In this case, the spring leaf is folded such that one end is coupled to the brake pad and the opposite end is coupled to the body of the caliper, and a portion is folded back and extended in the tangential direction on the side surface of the plate. In such a solution, it is necessary to increase the tangential dimension of the pad to accommodate the ear portion of the pad and to accommodate the folded-back portion of the spring, and it is necessary to secure free space adjacent to the pad in the tangential direction within the caliper body.

[0020] Another known type of spring, as shown in EP0716246 and WO92-18785 for example, is disposed on the back surface of the brake pad and is composed of a leaf-shaped body that couples to the piston or an undercut instead of the elongated vehicle wheel-facing portion of the caliper body of the floating brake caliper. For example, document US2002-096404 shows a spring solution of a leaf-shaped spring adapted to be coupled by an undercut to the wall of an annular groove provided in the piston.

[0021] A further spring solution that can be associated by firmly coupling to the piston is shown in document US2015-323024 by the applicant, which discloses a spring solution including a plurality of petals adapted to press against the axial wall of such a cavity when inserted into each substantially cylindrical lightweight cavity of the piston.

[0022] The spring solution coupled to the piston body has the advantage of applying an elastic biasing action to the brake pad applied to the rear zone of the pad that presses one or more pistons, thus providing the possibility of acting substantially on the center of gravity of the brake pad.

[0023] However, such known solutions are not without drawbacks, since the contact area between the back of the brake pad and the facing thrust means (e.g., the piston of a cylinder - piston assembly) decreases. Furthermore, such a spring coupled to the piston necessarily limits the cooling capacity of the piston and, by extension, the cooling capacity of the brake fluid housed within the cylinder. Additionally, such a spring can damage the dust boot that protects the cylinder - piston assembly from the ingress of dust and impurities, which can lead to the need for frequent maintenance.

[0024] There is a strong felt need to provide a spring solution for moving the brake pad away from the braking surface of the disc when the braking operation stops, and for abutting against a piston that is adapted to keep the pad substantially parallel to the braking surface of the brake disc while simultaneously avoiding imposing a permanent bond or connection to the piston body.

[0025] Accordingly, there is a felt need to provide a spring solution that removes or at least minimizes the residual braking torque, while simultaneously reducing the risk of misalignment between the brake pad and the braking surface of the facing disc, and promoting even wear of the friction material over long - term use.

SUMMARY OF THE INVENTION

MEANS FOR SOLVING THE PROBLEM

[0026] The object of the present invention is to solve the drawbacks of the prior art and to provide a solution to the needs described herein with reference to the prior art.

[0027] These and other objects are achieved by the assembly according to claim 1 and the brake caliper according to claim 9.

[0028] Some advantageous embodiments are the subject of the dependent claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Further features and advantages of the caliper body will become apparent from the following description of its preferred embodiments with reference to the accompanying drawings, which are given by way of example and not by way of limitation.

[0030]

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DETAILED DESCRIPTION OF THE INVENTION

[0031] According to a general embodiment, a pad-spring assembly 1 or assembly 1 for a brake caliper 10 for a disc brake is provided.

[0032] The assembly 1 includes at least one brake pad 2 and at least one elastic device 5.

[0033] In a disc brake, an axial direction X-X that coincides with or is parallel to the axis of rotation of a disc (not shown) of the disc brake, a radial direction R-R that is orthogonal to the axial direction X-X, and a tangential direction T-T that is orthogonal to both the axial direction X-X and the radial direction R-R are defined. Preferably, the radial direction R-R is incident on the axis of rotation of the brake disc.

[0034] The radial direction R-R defines a radially inward direction RI that is directed toward the axis of rotation of the brake disc and a radially outward direction RO that is opposite to the radially inward direction RI.

[0035] The axial direction X-X, the radial direction R-R, and the tangential direction T-T, and the radially inward direction RI and the radially outward direction RE are defined on the brake pad 2 also when it is considered that the brake pad 2 is not associated with the brake caliper 10 and when it is considered that the brake pad 2 is associated with at least one elastic device 5.

[0036] At least one brake pad 2 includes a friction material 3 adapted to be pressed against the exposed braking surface of the disc brake to apply a braking operation and a support plate 4 that supports the friction material 3.

[0037] At least one elastic device 5 is adapted to apply an elastic biasing action in the axial direction X-X to the brake pad 2 so as to move away from the brake disc when the braking operation stops. In this way, it is possible to minimize the generation of undesirable residual braking torque.

[0038] The support plate 4 includes a surface facing the disc 6 that is closely associated with the friction material 3 and a plate back surface 7 that is on the opposite side in the axial direction to the surface facing the disc 6 and is adapted to directly or indirectly face the thrust means 8 of the brake caliper 10 that can be associated with the assembly 1. Preferably, the surface facing the disc 6 is partially covered with at least one layer of the friction material 3.

[0039] Preferably, the thrust means 8 of the brake caliper 10 includes at least one piston 8 of at least one cylinder-piston assembly. Preferably, at least one cylinder of at least one cylinder-piston assembly associated with the piston 8 is entirely formed within the caliper body 40 of the brake caliper 10. The at least one piston 8 is hydraulically and / or electromechanically operable.

[0040] The friction material 3 includes a radially inner edge adapted to face the axis of rotation of the brake disc, and a radially outer edge 13 that is radially opposite to the radially inner edge.

[0041] The radially outer edge 13 of the friction material 3 defines at least one radially outer dimensional level of the friction material 3 having a tangential extension line 13' on a plane including the surface 6 of the support plate 4 facing the disc. In other words, the surface 6 of the support plate 4 facing the disc defines a horizontal plane that includes it, although the support plate 4 has discontinuities such as through holes and / or through slots. In other words, the radially outer dimensional level of the friction material 3 means that it is defined on a plane that coincides with and is parallel to the surface of the plate facing the disc 6, although the surface facing the disc has discontinuities such as the through opening 17.

[0042] According to one embodiment, the radially outer dimensional level of the friction material 3 is defined by drawing at least one tangential extension line 13' parallel to the tangential direction T-T from the radially outer edge 13 of the friction material 3 evaluated at the length farthest from the axis of rotation of the brake disc that may be associated with the assembly 1. In other words, the radially outer dimensional level of the friction material is determined by the radially outermost peripheral portion of the friction material 3.

[0043] According to a preferred embodiment, the surface 6 of the support plate 4 facing the disk is free of contact with the friction material 3 and includes at least one free portion 9 or free surface 9 adapted to face the braking surface of the brake disk that may be associated with the assembly 1. The free portion 9 is located radially inwardly with respect to at least one tangential extension line 13' of the radially outer edge 13 of the friction material 3. In other words, at least one free portion 9 of the surface 6 of the support plate 4 of the brake pad 2 facing the disk is delimited in the radially outer direction RO by at least one of the radially outer edge 13 and / or its tangential extension line 13', preferably by the tangential extension line 13' of the radially outer edge. In other words, the friction material 3 has at least one recess so as to face at least one free portion 9 of the surface 6 of the support plate 4 facing the disk. The friction material recess defines at least one recess edge surface 15 on the friction material 3 that faces in the radially outer direction RO and is located most radially inwardly of the tangential extension line 13' of the radially outer edge of the friction material 3.

[0044] Advantageously, the free surface 9 of the surface of the support plate 4 of the brake pad 2 facing the disk 6 includes at least one through-opening edge 16 that at least partially delimits an axial X-X through-opening 17 passing through the support plate 4 of the brake pad 2. In this way, the brake pad 2 includes at least one through-opening 17 that axially connects the plate back surface 7 and the free surface 9. Preferably, the through-opening 17 passes through the brake pad 2. Preferably, the through-opening 17 opens in the friction material recess 3.

[0045] According to a preferred embodiment, the free surface 9 of the support plate 4 includes an opening margin surface that at least partially surrounds the through-opening edge 16 and preferably surrounds the through-opening edge 16 radially inwardly, i.e., in the radially inner direction RI. In this way, the support portion 22 is prevented from interfering with the friction material 3 during an operating state, for example, during braking.

[0046] According to one embodiment, as shown in FIG. 10 for example, the through-opening 17 is a through-hole surrounded by a closed peripheral edge.

[0047] Preferably, the closed peripheral edge of the through-opening 17 is partially drawn on the free surface 9. In other words, the closed peripheral edge of the through-opening 17 crosses the tangential extension line 13' of the radially outer edge 13 of the friction material 3.

[0048] According to one embodiment, as shown in FIG. 13 for example, the through-opening 17 is a through-slot surrounded by an open peripheral edge, and preferably, the open peripheral edge of the through-opening 17 communicates in the radially outward direction RO.

[0049] More advantageously, at least one elastic device 5 has a body including at least one connecting portion 21, 21' adapted to connect to the body of the brake caliper 10 that can be associated with the assembly 1, and at least one support portion 22 that is stationary with respect to the opening edge 16 of the free surface 9 of the support plate 4 that axially crosses the through-opening 17 of the support plate 4. In other words, at least one support portion 22 extends at least in the axial direction X-X, and preferably also in the radial direction R-R, and abuts against the through-opening edge 16 drawn on the free portion 9 of the surface of the support plate 4 of the brake pad 2 facing the disc 6 through the through-opening 17.

[0050] In this way, it is possible to apply an elastic biasing action in the axial direction X-X to the brake pad 2 to move the brake pad 2 away from the brake disc with which it can be associated.

[0051] In the operating state, during the braking operation, the brake pad 2 is pushed by the thrust means 8 and abuts against the accessible braking surface of the brake disc. At the same time, when an axial thrust operation is applied to the support portion 22 of the elastic device 5 that elastically changes and deforms itself, the brake pad 2 contacts the accessible braking surface of the brake disc. Preferably, during the braking operation, the through-opening edge 16 slides on the support portion 22 of the elastic device 5, thereby elastically deforming in the radially outward direction RO while remaining in contact with it. When the braking control stops, the spring support portion 22 applies an elastic biasing action to move the brake pad 2 away from the disc.

[0052] Preferably, the through-opening edge 16 faces in the radially outward direction RO. Preferably, the through-opening edge 16 delimits the through-opening 17 in the radially inward direction RI.

[0053] Preferably, at least one elastic device 5 has a body that further includes at least one arm 23 that preferably extends in the radial direction R-R between the support portion 22 of the body of the elastic device 5 and the connecting portions 21, 21'.

[0054] In this way, it is possible to apply a direct elastic biasing action in the axial direction X-X between the caliper body 40 of the brake caliper 10 and the brake pad 2 for the purpose of moving the brake pad 2 away from the associated brake disc.

[0055] At least one arm 23, even if it is possible to do so, does not necessarily directly connect the support portion 22 to the connecting portions 21, 21', but still enables the elastic device 5 to apply at least a direct elastic biasing action in the axial direction X-X between the brake caliper body 10 and the brake pad 2.

[0056] According to one embodiment, at least one arm 23 extends such that at least one of its parts faces and / or contacts the plate back surface 7 of the support plate 6 of the brake pad 2.

[0057] According to one embodiment, at least one arm 23 extends radially outward with respect to the tangential extension line 13' of the radially outer edge 13 of the friction material 3. According to one embodiment, the body of the elastic device 5 comprises at least one further connecting part 25, 25', for example an arm, which connects the connecting parts 21, 21' to at least one arm 23, thereby bringing the connecting parts 21, 21' to an axial level formed between the radial extensions of the braking surfaces of the brake disc associated with the assembly 1, preferably forming an arched path. According to one embodiment, the elastic device 5 comprises a cross-shaped body and at least two axially opposed arms 23, each ending in at least one support part 22, for axially biasing the two opposing brake pads 2 away from the brake disc in the axial direction X-X. In this way, the assembly 1 further comprises at least one further pair of opposing brake pads 2 so as to include two opposing brake pads 2 adapted to be pressed against the opposing braking surfaces of the brake disc that can be associated with the assembly 1.

[0058] According to one embodiment, the assembly 1 further comprises a separate elastic device 5, and both of the two elastic devices 5 arranged side by side in the tangential direction act on the same brake pad 2 and / or the same pair of opposing brake pads 2 with their contact parts 22.

[0059] According to one embodiment, at least one arm 23 extends in the radially outer direction RO from the support part 22 of the elastic device 5 between the plate back 7 and the body of the brake caliper 10 that can be associated with the assembly 1.

[0060] According to a preferred embodiment, the through-opening edge 16 includes an arched contact length 18 such that the contact part 22 of the elastic device 5 can contact with a minimum contact area, ideally with a single contact point between the elastic device 5 and the through-opening edge 16. In this way, it is possible to apply an axial elastic bias to the brake pad at any time.

[0061] According to one embodiment, as shown, for example, in FIG. 23, the through-opening edge 16 is associated with a slide 11 that extends between the plate back surface 7 and the free surface 9 of the support plate 4. Preferably, the slide 11 is inclined by a predetermined inclination angle with respect to the axial direction X-X. According to a preferred embodiment, the slide 11 is inclined towards the axis of rotation of a brake disk that can be associated with the assembly 1. According to a preferred embodiment, the slide 11 is inclined in a radially inward direction RI towards the opening edge 16, in other words, it is inclined in the radially inward direction RI that moves along the axial direction X-X from the plate back surface 7 towards the free surface 9 of the surface of the support plate 4 facing the disk 6. Preferably, the predetermined inclination angle is substantially equal to the angle 20 formed between the support part 22 and the arm 23 of the elastic device 5.

[0062] According to one embodiment, the through-opening 17 is surrounded by an eyelet 19 having a radially outward eyelet side portion 30.

[0063] According to one embodiment, the eyelet 19 that is axially offset with respect to the plate back surface 7 is desirably axially offset towards a brake disk that can be associated with the assembly 1, thereby forming a resting portion seat 38 that is adapted to receive a part of the support part 22 of the elastic device 5.

[0064] According to one embodiment, the support part 22 includes a radially inner surface 46 that abuts on the through-opening edge 16 and an opposite radially outer surface 47. Preferably, the radially outer surface 47 abuts on the radially outer edge 30 of the eyelet 19.

[0065] According to a preferred embodiment, at least one arm 23 of the elastic device 5 ends with a free end 24 that defines a support portion 22. According to a preferred embodiment, the free end 24 that defines the support portion 22 projects at least axially from the arm 23. In this way, the support portion 22 can abut against the radially inner edge 16 of the friction material 3 that is arranged radially inwardly with respect to the tangential extension 13' of the radially inner edge 13 of the friction material 3 without interfering with the footprint of the piston on the plate back 7 of the brake pad 2.

[0066] The term "footprint of the piston" means one or more regions where the piston 8 acts directly or indirectly on the plate back 7 of the support plate of the brake pad 2 during the braking operation. In other words, at least one footprint of the piston 8 is defined axially as the region of the brake pad 2 where the thrust means 8 acts during the braking operation.

[0067] For example, as shown in FIG. 19, preferably, a radially dimensioned piston band 27 defined by the radial dimension of the piston footprint is defined on the plate back 7 of the support plate 4 of the brake pad 2. According to one embodiment, the piston footprint defines an outer radial piston level 28 that substantially coincides with an extension parallel to the tangential direction T-T on the plate back 7 at the radial position of the piston footprint evaluated at the point furthest from the axis of rotation of the disc. According to one embodiment, the piston footprint defines an inner radial piston level 29 that substantially coincides with an extension parallel to the tangential direction T-T on the plate back 7 at the radial position of the piston footprint evaluated at the position closest to the axis of rotation of the disc. According to one embodiment, the radially dimensioned piston band 27 is delimited in the radial direction R-R by the outer radial piston level 28 and the inner radial piston level 29.

[0068] The radial dimension piston band 27, the outer radial piston level 28, and the inner radial piston level 29 are also defined on the surface facing the disk 6 of the support plate 4 by the axial extension through the support plate 4.

[0069] Preferably, the through-opening edge 16 of the free surface 9 of the support plate 4 of the brake pad 2 in contact with the support portion 22 of the elastic element 5 is radially inside the outer radial piston level 28 and is preferably included within the piston band 27 of the radial dimension.

[0070] According to one embodiment, the free end 24 projects axially in the X-X axis from the arm 23, thereby forming an angle 20 with the arm 23. According to a preferred embodiment, the angle 20 is greater than 90°. Preferably, the angle 20 is configured between 120° and 180°, and preferably, the angle 20 is substantially equal to 135°.

[0071] According to a preferred embodiment, at least one arm 23 of the elastic device 5 is preferably made in the form of a leaf made of spring steel.

[0072] Preferably, the arm 23 and the support portion 22 are integrally made.

[0073] According to a preferred embodiment, at least one connecting portion 21, 21' of the elastic device 5 is adapted to be coupled to a part of the brake caliper body 2 that can be associated with the assembly 1, preferably to at least one brake caliper bridge of the brake caliper body 10.

[0074] According to one embodiment, the support plate 4 of the brake pad 2 includes a plate radially inner edge 31 adapted to face the axis of rotation of the disk of the associated disk brake, and an opposite plate radially outer edge 32 opposite the plate radially inner edge 31. Preferably, on the surface of the support plate 4 facing the disk 6, a radially outer plate edge 32 is provided that defines a radially outer plate edge portion 33 between the radially outer plate edge 13 of the friction material 3 and the radially outer plate edge 32. According to one embodiment, the plate radially outer edge 32 delimits at least one wear sensor seat 34 adapted to receive at least a part of a wear notification device of the friction material. According to one embodiment, the plate radially outer edge 33 delimits at least one damper seat 35 adapted to receive at least a part of a device for adjusting the vibration frequency of the brake pad, such as an additional mass.

[0075] According to one embodiment, a portion of the plate radially outer edge 33 delimits at least one pin seat 36 adapted to receive at least one sliding pin 37 of the brake caliper 10 adapted to guide the movement of the brake pad 2 relative to the brake caliper body 10 both during and after the braking operation. Preferably, at least one sliding pin 37 also functions as a radial restraint against the radial elastic biasing action applied by the elastic device 5. According to one embodiment, the support portion 22 of the elastic device also applies a direct biasing action in the radially inward direction RI to the edge of the through opening 16. Preferably, a sliding pin 37 cooperating with the wall of the pin seat 36 is provided so that the direct biasing action in the radially inward direction RI is counteracted.

[0076] According to one embodiment, the friction material 3 further includes at least one lateral edge 14 adapted to face in the tangential direction T-T and to face the brake caliper 10 associated with the assembly 1.

[0077] According to one embodiment, at least one lateral edge 14 defines the outer diameter dimension level of the friction material 3 having the extension line 14' in the tangential direction on the surface facing the disk 6 of the support plate 4. According to one embodiment, the extension line 14' can also be parallel to the brake pad 2 of the definable intermediate axis instead of being parallel to the radial direction R-R.

[0078] According to one embodiment, the free surface 9 is delimited in the radially outward direction RO at the radially outer dimension level and is delimited in the tangential direction T-T by the outer dimension of the friction material 3 in the tangential direction and by the friction material 3.

[0079] According to one embodiment, the free surface 9 is delimited in the radially outward direction RO by the radially outer dimension level and in the tangential direction T-T by the friction material 3.

[0080] According to a general embodiment, a disc brake 10 is provided that includes a caliper body 40 adapted to be disposed across a brake disc that can be associated with a brake caliper 10 according to any one of the preceding embodiments and at least one pad - spring assembly 1.

[0081] Preferably, the brake caliper 10 further includes thrust means 8 adapted to press at least one brake pad 2 against the facing braking surface of a brake disc that can be associated with the brake caliper 10. Preferably, the thrust means includes at least one piston 8 that operates hydraulically and / or electromechanically, and the at least one piston 8 is associated with at least one retraction device 12, or roll - back device 12, adapted to retract the piston 8 relative to the caliper body 40 with a predetermined component when the brake command stops. Preferably, the retraction device 12 also functions as a knock - back device that pulls the piston 8 out of the caliper body 40 by a predetermined component if necessary.

[0082] According to one embodiment, the thrust means 8 of the brake caliper 10 defines a piston band 27 of the piston footprint and radial dimension.

[0083] The caliper body 40 includes a pair of opposing elongated portions 41, 42, each adapted to face directly or indirectly, using at least one brake pad 2, one of the opposing braking surfaces of a brake disk that can be associated with the brake caliper 10.

[0084] The caliper body 40 further includes at least one caliper bridge 43, 44 that connects the elongated portions 41, 42 arranged across the associated disk brake.

[0085] Preferably, at least one caliper bridge 43 or 44 is at least three caliper bridges, in which case the at least three caliper bridges delimit a radial caliper body opening 45 therebetween.

[0086] Preferably, the at least three caliper bridges include at least one central bridge 43 and at least one pair of side bridges 44 that are tangentially opposed to the central bridge 43.

[0087] According to one embodiment, at least one connecting portion 21, 21' of at least one elastic device 5 of the assembly 1 is connected to at least two caliper bridges 43, 44, preferably the central bridge 43 and the side bridge 44, disposed inside at least one radial caliper opening 45. Preferably, two separate elastic devices 5 are provided arranged side by side in the tangential direction such that both are connected to the central bridge 43 and each is connected to one of the end bridges 44.

[0088] According to a preferred embodiment, the caliper body 40 is a fixed caliper body having opposing thrust means 8 for the brake pads received in the opposing elongated portions 41, 42.

[0089] In certain embodiments, separately or together, the above-described features make it possible to obtain an assembly that simultaneously satisfies the above-mentioned contrasting requirements and the above-mentioned desired advantages. In particular, - It is possible to balance the brake pads away from the disc, thereby preventing displacement between the brake pads and the braking surface of the brake disc. - It is also possible to balance the brake pads away from the disc while avoiding placing a spring between the brake pads and the pistons to enhance the heat exchange characteristics of the pistons. - It is possible to prevent the spring from wasting the volume between the pads.

[0090] Those skilled in the art can make many changes and adaptations to the above-described embodiments or replace them with other functionally equivalent elements without departing from the scope of the appended claims to meet accidental requirements.

Description of Reference Numerals

[0091] 1 Pad - spring assembly, or assembly 2 Brake pad 3 Friction material 4 Support plate 5 Elastic device 6 Lateral disc of the support plate 7 Plate back 8 Thrust means, or piston 9 Free portion, or free surface 10 Brake caliper 11 Slide 12 Piston retraction device, or roll - back device 13 Radial outer edge of the friction material 13’ Extension line of the radial outer edge of the friction material 14 Lateral edge of the friction material 14’ Lateral extension line of the friction material 15 Concave surface of the friction material 16 Edge of the through - opening 17 Through-opening 18 Arch length of the through-opening 19 Eyelet 20 Angle 21, 21' Elastic device connecting part 22 Elastic device support part 23 Elastic device arm 24 Free end of the elastic device 25, 25' Further connecting part of the elastic device 27 Radial dimension piston band 28 Outer radial piston level of the support plate 29 Inner radial piston level of the support plate 30 Outer radial eyelet edge 31 Inner radial plate edge 32 Outer radial plate edge 33 Outer radial plate margin 34 Wear sensor sheet 35 Damper sheet 36 Pin sheet 37 Sliding pin 38 Contact part sheet 40 Caliper body 41, 42 Elongated part of the caliper body 43 Central caliper bridge 44 Side caliper bridge 45 Radial caliper opening 46 Inner radial surface of the support part 47 Outer radial surface of the support part X-X axis direction R-R Radial direction T-T Tangential direction RO Radially outward RI Radially inward

Claims

1. A pad spring assembly for a brake caliper (10) of a disc brake, comprising: an axial direction (X-X) that coincides with or is parallel to the axis of rotation of the brake disc of the disc brake, a radial direction (R-R) that is orthogonal to the axial direction (X-X), and a tangential direction (T-T) that is orthogonal to both the axial direction (X-X) and the radial direction (R-R) are defined; the radial direction (R-R) defines a radially inward direction (RI) directed towards the axis of rotation of the brake disc and a radially outward direction (RO) opposite to the radially inward direction (RI); the assembly comprises: at least one brake pad (2) including a friction material (3) and a support plate (4) for supporting the friction material (3); at least one elastic device (5) adapted to apply an elastic biasing action in the axial direction (X-X) to the brake pad (2) so as to move away from the brake disc when the braking operation stops; the support plate (4) includes a surface (6) facing the disc that is closely related to the friction material (3), and a plate back surface (7) that is on the opposite side in the axial direction to the surface (6) facing the disc and is adapted to face the thrust means (8) of the brake caliper (10) that can be related to the assembly (1); the friction material (3) includes a radially inner edge adapted to face the axis of rotation of the brake disc and a radially outer edge (13) on the opposite side in the radial direction to the radially inner edge; the radially outer edge (13) of the friction material (3) defines a radially outer dimension level of the friction material (3) having a tangential extension line (13') on the surface (6) of the support plate (4) facing the disc; the surface (6) of the support plate (4) facing the disc includes at least one free surface (9) that is adapted to face the braking surface of the brake disc that can be related to the assembly (1) and is not in contact with the friction material (3), and the free surface (9) is located radially inward with respect to at least one of the tangential extension lines (13') of the radially outer edge (13) of the friction material (3); The free surface (9) of the surface (6) facing the disk of the support plate (4) of the brake pad (2) includes at least one through-opening edge (16) that at least partially delimits an axial (X-X) through-opening or slot (17) passing through the support plate (4) of the brake pad (2). The at least one elastic device (5) has a body. The body includes at least one connecting portion (21, 21') adapted to connect to the body of the brake caliper (10) that can be associated with the assembly (1). and at least one support portion (22) that axially crosses the through-opening or slot (17) of the support plate (4) so as to directly apply an elastic biasing action axially (X-X) to the through-opening edge (16) of the through-opening or slot (17) and that is stationary with respect to the through-opening edge (16) of the free surface (9) of the support plate (4). Assembly (1). The through-opening edge (16) faces in a radially outward direction (RO) and / or the through-opening edge (16) delimits the through-opening or slot (17) in a radially inward direction (RI). Assembly (1) according to claim 1. The through-opening edge (16) preferably includes an arcuate contact length (18) such that the contact portion (22) of the elastic device (5) can contact with a minimum contact area, ideally with a single contact point coinciding between the elastic device (5) and the through-opening edge (16). Assembly (1) according to claim 1 or 2. The through-opening edge (16) is associated with a slide (11) extending between the plate back surface (7) and the free surface (9) of the support plate (4). The slide is inclined by a predetermined inclination angle with respect to the axial direction (X-X). Assembly (1) according to any one of claims 1 to 3. The predetermined inclination angle is substantially equal to the angle (20) formed between the support portion (22) of the elastic device (5) and the arm (23). Assembly (1) according to claim 4. ​ ​ ​ ​ ​ The slide (11) is inclined towards the axis of rotation of the brake disc that can be associated with the assembly (1). Assembly (1) according to claim 4 or 5.

7. The through-opening or slot (17) is surrounded by an eyelet (19) having a radially outward eyelet side portion (30). Assembly (1) according to any one of claims 1 to 6.

8. The eyelet (19) is axially offset with respect to the back surface (7) of the plate and is preferably axially offset towards the brake disc that can be associated with the assembly (1), thereby forming a contact sheet (38) adapted to receive a part of the support portion (22) of the elastic device (5). Assembly (1) according to claim 7.

9. The friction material (3) has at least one recess so as to face at least one free surface (9) of the surface (6) of the support plate (4) facing the disc. The recess of the friction material faces upward on the friction material (3) in the radially outer direction (RO) and defines at least one recess edge surface (15) that is located more radially inward than the tangential extension line (13') of the radially outer edge (13) of the friction material (3). Assembly (1) according to any one of claims 1 to 8.

10. The through-opening or slot (17) opens at the recess of the friction material (3). Assembly (1) according to claim 9.

11. The free surface (9) of the support plate (4) at least partially surrounds the through-opening edge (16), preferably including an opening margin surface that surrounds the through-opening edge (16) in the radially inner direction (RI). Assembly (1) according to claim 9 or 10.

12. At least one of the elastic devices (5) has a body, and the body further includes at least one arm (23) that preferably extends in the radial direction (R - R) between the support portion (22) and the connecting portions (21, 21') of the body of the elastic device (5). Assembly (1) according to any one of claims 1 to 11.

13. At least one of said arms (23) has at least one part extending facing or in contact with said plate rear face (7) of said support plate (4) of said brake pad (2). Assembly (1) according to claim 12.

14. At least one of said arms (23) of said elastic device (5) ends at a free end (24) defining said support (22). Said free end (24) defining said support (22) projects at least axially from said arm (23). Assembly (1) according to claim 12 or 13.

15. Said free end (24) projects axially (X-X) from said arm (23), thereby forming an angle (20) with said arm (23). Said angle (20) is greater than 90°, preferably said angle (20) is between 120° and 180°, preferably said angle (20) is substantially equal to 135°. Assembly (1) according to claim 14.

16. Said through-opening (17) is a through-hole surrounded by a closed peripheral edge, or Said through-opening (17) is a through-slot surrounded by an open peripheral edge, preferably the open peripheral edge of said through-opening (17) opens in a radially outward direction (RO). Assembly (1) according to any one of claims 1 to 12.

17. On said plate rear face (7) of said support plate (4) of said brake pad (2), a radially dimensioned piston band (27) defined by the radial dimension of the piston footprint is defined. Said piston footprint defines an outer radial piston level (28) substantially coinciding with an extension parallel to said tangential direction (T-T) on said plate rear face (7) of the radial position of said piston footprint evaluated at the point furthest from the axis of rotation of said disc, or Said piston footprint defines an inner radial piston level (29) substantially coinciding with an extension parallel to said tangential direction (T-T) on said plate rear face (7) of the radial position of said piston footprint evaluated at the position closest to the axis of rotation of said disc. Assembly (1) according to any one of claims 1 to 16.

18. The radial dimension piston band (27) is delimited in the radial direction (R-R) by the outer radial piston level (28) and the inner radial piston level (29). The assembly (1) according to claim 17.

19. The through-opening edge (16) of the free surface (9) of the support plate (4) of the brake pad (2) in contact with the support part (22) of the elastic element (5) is radially inside the outer radial piston level (28), preferably included within the radial dimension piston band (27). The assembly (1) according to claim 17 or 18.

20. The term "piston footprint" means one or more regions where the piston (8) acts directly or indirectly on the plate back (7) of the support plate (4) of the brake pad (2) during braking operation. The assembly (1) according to any one of claims 17 to 19.

21. The elastic device (5) includes a cross-shaped body and at least two axially opposed arms (23) each ending in at least one support part (22) so as to bias at least two opposing brake pads (2) away from the brake disc in the axial direction (X-X), such that the assembly (1) further includes at least one additional pair of opposing brake pads (2) adapted to be pressed against opposing braking surfaces of a brake disc that can be associated with the assembly (1). The assembly (1) according to any one of claims 1 to 20.

22. The assembly (1) further includes a separate elastic device (5), and both of the two elastic devices (5) arranged side by side in the tangential direction are arranged such that their contact parts (22) act on the same brake pad (2) or the same pair of opposing brake pads (2). The assembly (1) according to claim 21.

23. A brake caliper (10) for a disc brake, including a caliper body (40) adapted to be arranged across a brake disc that can be associated with the brake caliper (10) and at least one pad spring assembly (1) according to any one of claims 1 to 22.

24. A brake caliper (10), further comprising thrust means (8) adapted to press at least one brake pad (2) against a facing braking surface of the brake disc that can be associated with the brake caliper (10), wherein the caliper body (40) comprises a pair of opposing elongated portions (41, 42), each adapted to face directly or indirectly, using at least one brake pad (2), one of the opposing braking surfaces of a brake disc that can be associated with the brake caliper (10), and at least one caliper bridge (43, 44) connecting the elongated portions (41, 42) disposed across the associated disc brake, wherein the at least one caliper bridge (43 or 44) is at least three caliper bridges including at least one central bridge (43) and at least a pair of side bridges (44) tangentially opposed to the central bridge (43), wherein the at least three caliper bridges delimit radially caliper body openings (45) from each other, The brake caliper (10) according to claim 23.

25. At least one of the connecting portions (21, 21') of at least one elastic device (5) of the assembly (1) is connected to at least two caliper bridges (43, 44), preferably the central bridge (43) and the side bridge (44), disposed inside at least one of the radial caliper openings (45), The brake caliper (10) according to claim 24.

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