Return spring and disc brake

Abstract

The present invention comprises: fixed sections (100) that are fixed to a friction pad (8); first extending sections (101) that are formed in a plate shape and extend from the fixed sections (100) in a direction away from the friction pad (8); a second extending section (102) that is formed in a plate shape and extends from the first extending section (101) in the pressing direction of the friction pad (8); a contact section (103) that is formed in a plate shape and contacts a carrier (5) extending from the second extending section (102) and attached to a non-rotating section of a vehicle; edge sections being surfaces that extend in the thickness direction of the first extending sections (101), the second extending section (102), and the contact section (103); and cover sections (104, 105) that cover at least a portion of the edge sections.

Description

[Technical Field]

[0001] The present invention relates to a return spring and a disc brake. This application claims priority based on Japanese Patent Application No. 2021-154447, filed on September 22, 2021, the contents of which are incorporated herein by reference. [Background technology]

[0002] BACKGROUND ART Some disc brakes use a return spring that is integrally formed by punching a steel plate having spring properties and then bending it using a press or other means (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2014-196829 Summary of the Invention [Problem to be solved by the invention]

[0004] When servicing the disc brakes, there is a risk that fingers may get caught on the edge of the return spring, making maintenance difficult.

[0005] An object of the present invention is to provide a return spring and a disc brake that can improve maintainability. [Means for solving the problem]

[0006] According to a first aspect of the present invention, the return spring comprises a fixed portion fixed to the friction pad, a first extension portion formed in a plate shape and extending from the fixed portion in a direction away from the friction pad, a second extension portion formed in a plate shape and extending from the first extension portion in a pressing direction of the friction pad, a contact portion formed in a plate shape and extending from the second extension portion to contact a carrier attached to a non-rotating part of the vehicle, an edge portion which is a surface extending in the plate thickness direction between the first extension portion, the second extension portion, and the contact portion, and a cover portion which covers at least a portion of the edge portion.

[0007] According to a second aspect of the present invention, a disc brake includes a friction pad and a return spring having a fixed portion fixed to the friction pad, a first extension portion formed in a plate shape and extending from the fixed portion in a direction away from the friction pad, a second extension portion formed in a plate shape and extending from the first extension portion in a pressing direction of the friction pad, a contact portion formed in a plate shape and extending from the second extension portion to contact a carrier attached to a non-rotating part of a vehicle, an edge portion which is a surface extending in the plate thickness direction between the first extension portion, the second extension portion, and the contact portion, and a cover portion which covers at least a portion of the edge portion. [Effects of the Invention]

[0008] According to the present invention, it is possible to improve maintainability. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a plan view showing a disc brake according to a first embodiment. [Figure 2] 2 is a perspective view showing a carrier, an outer friction pad, and a return spring of the disc brake of the first embodiment. FIG. [Figure 3] FIG. 2 is a plan view showing the carrier, outer friction pads, and return springs of the disc brake of the first embodiment. [Figure 4] FIG. 2 is a perspective view showing an outer friction pad and a return spring of the disc brake of the first embodiment. [Figure 5]FIG. 2 is a plan view showing an outer friction pad and a return spring of the disc brake of the first embodiment. [Figure 6] FIG. 2 is a front view showing an outer friction pad and a return spring of the disc brake according to the first embodiment. [Figure 7] FIG. 2 is a perspective view showing a return spring according to the first embodiment. [Figure 8] FIG. 2 is a perspective view showing a return spring according to the first embodiment. [Figure 9] FIG. 2 is a front view showing the return spring of the first embodiment. [Figure 10] XX cross-sectional view of FIG. 9 showing the return spring of the first embodiment. [Figure 11] FIG. 10 is a perspective view showing a return spring according to a second embodiment. [Figure 12] FIG. 10 is a perspective view showing a return spring according to a second embodiment. [Figure 13] FIG. 10 is a front view showing a return spring according to a second embodiment. [Figure 14] 14 is a cross-sectional view taken along the line XIV-XIV in FIG. 13, showing the return spring of the second embodiment. [Figure 15] FIG. 10 is a perspective view showing a return spring according to a third embodiment. [Figure 16] FIG. 10 is a perspective view showing a return spring according to a third embodiment. [Figure 17] FIG. 10 is a front view showing a return spring according to a third embodiment. [Figure 18] 18 is a cross-sectional view taken along the line XVIII-XVIII in FIG. 17, showing the return spring of the third embodiment. [Figure 19] FIG. 10 is a perspective view showing a return spring according to a fourth embodiment. [Figure 20] FIG. 10 is a front view showing a return spring according to a fourth embodiment. [Figure 21] 21 is a cross-sectional view taken along the line XXI-XXI in FIG. 20 showing the return spring of the fourth embodiment. [Figure 22] FIG. 10 is a perspective view showing a return spring according to a fifth embodiment. [Figure 23] FIG. 10 is a front view showing a return spring according to a fifth embodiment. [Figure 24] 24-24 cross-sectional view of the return spring of the fifth embodiment shown in FIG. 23. [Figure 25] FIG. 13 is a perspective view showing a return spring according to a sixth embodiment. [Figure 26] FIG. 13 is a front view showing a return spring according to a sixth embodiment. [Figure 27] 27 is a cross-sectional view taken along the line XXVII-XXVII in FIG. 26, showing the return spring of the sixth embodiment. [Figure 28] FIG. 13 is a perspective view showing a carrier, an inner friction pad, an outer friction pad, and an inner return spring of a disc brake according to a seventh embodiment. [Figure 29] FIG. 13 is a rear view showing the carrier, the inner friction pad, and the inner return spring of the disc brake of the seventh embodiment. [Figure 30] 29 showing the carrier, inner friction pad, outer friction pad, inner return spring, and outer return spring of the disc brake of the seventh embodiment. FIG. [Figure 31] FIG. 13 is a perspective view showing a return spring according to a seventh embodiment. [Figure 32] FIG. 13 is a perspective view showing a return spring according to a seventh embodiment. [Figure 33] FIG. 13 is a plan view showing a return spring according to a seventh embodiment. [Figure 34] FIG. 13 is a bottom view showing the return spring of the seventh embodiment. [Figure 35] FIG. 13 is a front view showing a return spring according to a seventh embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0010] [First embodiment] A first embodiment will be described below with reference to Figures 1 to 10. A disc brake 1 of the first embodiment is for a vehicle such as an automobile and applies braking force to the vehicle. Specifically, the disc brake 1 is for a four-wheeled automobile.

[0011] As shown in FIG. 1, a disc brake 1 brakes a vehicle by stopping the rotation of a circular disc 2 that rotates together with a wheel (not shown).

[0012] The disc brake 1 includes a carrier 5, a caliper 6, a pair of boots 7, a pair of friction pads 8 and 9, and four return springs 11, 12, 13, and 14.

[0013] Hereinafter, the central axis of the disk 2 will be referred to as the disk axis. The direction in which the disk axis extends will be referred to as the disk axial direction. The radial direction of the disk 2 will be referred to as the disk radial direction. The circumferential direction of the disk 2 within the carrier 5 and caliper 6, i.e., the direction of rotation, will be referred to as the disk rotation direction. The center side of the disk 2 in the disk radial direction will be referred to as the disk radial inner side. The opposite side of the center of the disk 2 in the disk radial direction will be referred to as the disk radial outer side. The center side of the disk rotation direction within the carrier 5 and caliper 6 will be referred to as the disk rotation inner side. The opposite side of the center in the disk rotation direction within the carrier 5 and caliper 6 will be referred to as the disk rotation outer side. A disk radial line that passes through the center of the carrier 5 and caliper 6 in the disk rotation direction when not braking and the disk axis, and runs along the disk radial direction, will be referred to as the radial reference line. This radial reference line is perpendicular to the disk axis. The outer side of the vehicle in which the disc brake 1 is provided in the vehicle width direction is referred to as the outer side, and the inner side of the vehicle width direction is referred to as the inner side.

[0014] The carrier 5 is a seamless, integrally molded product formed by casting. As shown in Fig. 2, the carrier 5 has an inner beam portion 21, a pair of inner side walls 22, 23, a pair of pin insertion portions 24, 25, a pair of outer side walls 26, 27, a pair of outer protrusions 28, 29, and an outer beam portion 30. The carrier 5 has a mirror-symmetrical shape.

[0015] The carrier 5 has its inner beam portion 21 attached to a non-rotating portion of the vehicle. The inner beam portion 21 is disposed on one side of the disk 2 in the disk axial direction and attached to the non-rotating portion of the vehicle. Here, the non-rotating portion of the vehicle to which the carrier 5 is attached is disposed on the inner side of the disk 2. The inner beam portion 21 attached to this non-rotating portion is also disposed on the inner side of the disk 2. Below, the carrier 5 will be described in a state in which it is attached to the non-rotating portion of the vehicle.

[0016] As shown in Fig. 3, the inner beam portion 21 extends in one direction and is disposed so as to extend in the direction of disc rotation. As shown in Fig. 2, the inner beam portion 21 is provided with a pair of mounting boss portions 32 (only one of which is shown) on both sides in the direction of disc rotation, each of which has a mounting hole 31 (only one of which is shown) that runs along the disc axis. The pair of mounting boss portions 32 of the inner beam portion 21 are attached to a non-rotating portion of the vehicle by mounting bolts that are screwed into the respective mounting holes 31.

[0017] Of the pair of inner side wall portions 22, 23, one inner side wall portion 22 extends radially outward from one end portion in the disc rotation direction of the inner beam portion 21. Moreover, of the pair of inner side wall portions 22, 23, the other inner side wall portion 23 extends radially outward from an end portion of the inner beam portion 21 opposite the inner side wall portion 22 in the disc rotation direction.

[0018] Hereinafter, in the direction connecting the pair of inner sidewalls 22, 23, which is the same as the disc rotation direction, the inner sidewall 22 side will be referred to as the first side in the disc rotation direction, and the inner sidewall 23 side will be referred to as the second side in the disc rotation direction. The first side in the disc rotation direction and the second side in the disc rotation direction are opposite sides in the disc rotation direction. The pair of inner sidewalls 22, 23, like the inner beam portion 21, are arranged on the inner side of the disc 2 as shown in FIG. 1.

[0019] As shown in Figure 3, the inner side wall 22 has a surface 35 facing the inner side on its inner side. The surface 35 is flat and extends perpendicular to the disc axis. The inner side wall 22 has an inner surface 36 facing inward in the disc rotation direction on its inner side in the disc rotation direction. The inner surface 36 extends along the disc axis and a radial reference line.

[0020] The inner sidewall 23 has, on its inner side, a surface 37 facing the inner side. The surface 37 is flat and extends perpendicular to the disk axis. The surface 35 and the surface 37 are disposed on the same plane. The inner sidewall 23 has, on its inner side in the disk rotation direction, an inner surface 38 facing inward in the disk rotation direction. The inner surface 38 extends along the disk axis and a radial reference line.

[0021] As shown in Fig. 2, one of the pair of pin insertion portions 24, 25, the pin insertion portion 24, is connected to the end portion on the outer side in the disk radial direction of the inner side wall portion 22 on the first side in the disk rotation direction. The pin insertion portion 24 extends outward beyond the inner side wall portion 22 along the disk axial direction and also protrudes toward the inner side. The portion of the pin insertion portion 24 that extends outward from the inner side wall portion 22 straddles the outer periphery of the disk 2 as shown in Fig. 1.

[0022] 2, the other pin insertion portion 25 of the pair of pin insertion portions 24, 25 is connected to the end portion on the outer side in the disk radial direction of the inner side wall portion 23 on the second side in the disk rotation direction. The pin insertion portion 25 extends outward beyond the inner side wall portion 23 along the disk axial direction and also protrudes toward the inner side. The portion of the pin insertion portion 25 that protrudes outward from the inner side wall portion 23 straddles the outer periphery of the disk 2 as shown in FIG.

[0023] A pin insertion hole (not shown) extending along the disk axial direction is formed in each of the pair of pin insertion portions 24, 25. The pin insertion hole (not shown) of the pin insertion portion 24 is formed from the inner end face of the pin insertion portion 24 to a midpoint within the pin insertion portion 24. The pin insertion hole (not shown) of the pin insertion portion 25 is formed from the inner end face of the pin insertion portion 25 to a midpoint within the pin insertion portion 25.

[0024] A slide pin 41 on the first side in the disk rotation direction of the caliper 6 is slidably fitted into a pin insertion hole (not shown) of the pin insertion portion 24 of the carrier 5. A slide pin 42 on the second side in the disk rotation direction of the caliper 6 is slidably fitted into a pin insertion hole (not shown) of the pin insertion portion 25. As a result, the carrier 5 supports the caliper 6 at the pair of pin insertion portions 24, 25 so that the caliper 6 is slidable in the disk axial direction. In other words, the caliper 6 is provided on the carrier 5 so as to be displaceable in the disk axial direction.

[0025] 2, of the pair of outer side walls 26, 27, one outer side wall 26 extends radially inward from the pin insertion portion 24 on the first side in the disk rotation direction. The outer side wall 26 extends radially inward from the end of the pin insertion portion 24 opposite to the inner side wall 22, i.e., on the outer side.

[0026] Of the pair of outer side walls 26, 27, the other outer side wall 27 extends radially inward from the pin insertion portion 25 on the second side in the disk rotation direction. The outer side wall 27 extends radially inward from the end of the pin insertion portion 25 opposite to the inner side wall 23, i.e., on the outer side.

[0027] The pair of outer side walls 26, 27 are disposed on the outer side of the disk 2, as shown in FIG.

[0028] As shown in Figure 2, the outer side wall 26 has a surface 45 facing the outer side on its outer side. The surface 45 is flat and extends perpendicular to the disk axis. The outer side wall 26 has an inner surface 46 facing inward in the disk rotation direction on its inner side in the disk rotation direction. The inner surface 46 extends along the disk axis and a radial reference line.

[0029] The outer side wall 27 has a surface 47 on its outer side that faces the outer side. The surface 47 is flat and extends perpendicular to the disk axis. The surface 45 and the surface 47 are arranged on the same plane. The outer side wall 27 has an inner surface 48 on its inner side in the disk rotation direction that faces inward in the disk rotation direction. The inner surface 48 extends along the disk axis and a radial reference line.

[0030] Of the pair of outer-side protrusions 28, 29, one outer-side protrusion 28 protrudes outerward from a surface 45 of the outer side wall 26 on the first side in the disc rotation direction. The outer-side protrusion 28 protrudes outerward from an edge portion of the surface 45 of the outer side wall 26 that is outward in the disc rotation direction and inward in the disc radial direction. The outer-side protrusion 28 extends along the disc radial direction at the position of an edge portion of the surface 45 that is outward in the disc rotation direction and inward in the disc radial direction. The outer-side protrusion 28 is inclined with respect to the radial reference line so that it moves further away from the radial reference line as it moves radially outward in the disc direction.

[0031] Of the pair of outer-side protrusions 28, 29, the other outer-side protrusion 29 protrudes outerward from a surface 47 of the outer side wall 27 on the second side in the disk rotation direction. The outer-side protrusion 29 protrudes outerward from an edge portion of the surface 47 of the outer side wall 27 that is outward in the disk rotation direction and inward in the disk radial direction. The outer-side protrusion 29 extends along the disk radial direction at the position of an edge portion of the surface 47 that is outward in the disk rotation direction and inward in the disk radial direction. The outer-side protrusion 29 is inclined with respect to the radial reference line so that it moves further away from the radial reference line as it moves radially outward in the disk direction.

[0032] The outer beam portion 30 extends in the disk rotation direction. The outer beam portion 30 connects the ends of the pair of outer sidewall portions 26, 27 that are on the inner side in the disk radial direction and in the disk rotation direction. The outer beam portion 30, like the pair of outer sidewall portions 26, 27, is disposed on the outer side of the disk 2.

[0033] As described above, the carrier 5 is disposed across the outer periphery of the disk 2 in the disk axial direction and is attached to a non-rotating portion of the vehicle. The inner beam portion 21 and the pair of inner sidewall portions 22, 23 are disposed on the inner side of the carrier 5, which is the side that is attached to the non-rotating portion of the vehicle. The pair of outer sidewall portions 26, 27 and the outer beam portion 30 are disposed on the outer side of the carrier 5, opposite the inner side.

[0034] A recess 51 is formed in the inner portion of the outer side wall 26 in the disk rotation direction. The recess 51 is recessed from the inner surface 46 of the outer side wall 26 on the inner side in the disk rotation direction toward the outer side in the disk rotation direction. The recess 51 penetrates the outer side wall 26 in the disk axial direction.

[0035] A recess 52 is formed in the inner portion of the outer side wall 27 in the disk rotation direction. The recess 52 is recessed from the inner surface 48 of the outer side wall 27 on the inner side in the disk rotation direction toward the outer side in the disk rotation direction. The recess 52 penetrates the outer side wall 27 in the disk axial direction.

[0036] A recess 53 is formed in the inner portion of the inner side wall 23 in the disk rotation direction. The recess 53 is recessed from the inner surface 38 of the inner side wall 23 on the inner side in the disk rotation direction toward the outer side in the disk rotation direction. The recess 53 penetrates the inner side wall 23 in the disk axial direction.

[0037] A recess (not shown) is also formed on the inner side of the inner side wall 22 in the direction of disk rotation. This recess is recessed from an inner surface 36 on the inner side of the inner side wall 22 in the direction of disk rotation toward the outer side in the direction of disk rotation. This recess penetrates the inner side wall 22 in the direction of the disk axis.

[0038] These recesses 51 to 53 and the recess (not shown) of the inner side wall portion 22 have the same shape except that the orientations of the recesses on the first side in the disk rotation direction and the second side in the disk rotation direction are opposite.

[0039] The recess 51 of the outer side wall 26 and the recess (not shown) of the inner side wall 22, which are on the same first side in the disk rotation direction, are aligned in the disk radial direction and the disk rotation direction. The recess 51 of the outer side wall 26 and the recess (not shown) of the inner side wall 22 are spaced apart in the disk axial direction.

[0040] The recess 52 of the outer side wall 27 and the recess 53 of the inner side wall 23, which are on the same second side in the disk rotation direction, are aligned in the disk radial direction and the disk rotation direction. The recess 52 of the outer side wall 27 and the recess 53 of the inner side wall 23 are spaced apart in the disk axial direction.

[0041] The recesses 51-53 and the recess (not shown) of the inner side wall 22 have the same shape except that their orientations are opposite between the first side in the disk rotation direction and the second side in the disk rotation direction. Therefore, the following description will be given taking the recess 52 of the outer side wall 27 shown in Figure 2 as an example. The recess 52 has an outer wall surface 55, an inner wall surface 56, and a rear surface 57.

[0042] The outer wall surface portion 55 is located at the radially outer end of the recessed portion 52 and faces radially inward of the disk. The outer wall surface portion 55 is flat. The outer wall surface portion 55 extends perpendicular to a radial reference line.

[0043] The inner wall surface portion 56 is located at the end of the recess 52 that is on the inner side in the disk radial direction and faces outward in the disk radial direction. The inner wall surface portion 56 is flat. The inner wall surface portion 56 extends perpendicular to a radial reference line.

[0044] The rear surface portion 57 is located at the outer end of the recess 52 in the disc rotation direction and faces inward in the disc rotation direction. The rear surface portion 57 connects the outer edge of the outer wall surface portion 55 in the disc rotation direction to the outer edge of the inner wall surface portion 56 in the disc rotation direction. The rear surface portion 57 extends parallel to the radial reference line and the disc axis.

[0045] The recesses 51 to 53 and the recess (not shown) of the inner side wall 22 have outer wall surfaces 55 arranged in the same plane. The recesses 51 to 53 and the recess (not shown) of the inner side wall 22 have inner wall surfaces 56 arranged in the same plane. The recess 51 and the recess (not shown) of the inner side wall 22, both of which are on the first side in the disc rotation direction, have rear surfaces 57 arranged in the same plane. The rear surface 57 of the recess 52 on the second side in the disc rotation direction is arranged in the same plane as the rear surface 57 of the recess 53 of the inner side wall 23 on the second side in the disc rotation direction.

[0046] The outer friction pad 8 of the pair of friction pads 8, 9 is supported by the recess 51 of the outer side wall portion 26 and the recess 52 of the outer side wall portion 27. The inner friction pad 9 of the pair of friction pads 8, 9, shown in FIG. 1, is supported by the recess 53 of the inner side wall portion 23 and a recess (not shown) of the inner side wall portion 22.

[0047] The pair of friction pads 8, 9 are common parts with the same shape. For this reason, the outer friction pad 8 shown in Figs. 2 to 6 will be used as an example for explanation. As shown in Fig. 4, the outer friction pad 8 has a backing plate 61 and a lining 62. The backing plate 61 is made of metal. The lining 62 is a friction material that generates frictional resistance. As shown in Fig. 5, the lining 62 is attached to an attachment surface 65 on one side in the thickness direction of the backing plate 61. The backing plate 61 has a pressing surface 66 on the opposite side of the attachment surface 65 in the thickness direction, which extends parallel to the attachment surface 65. The attachment surface 65 and the pressing surface 66 face in opposite directions.

[0048] As shown in FIG. 4, the back plate 61 has a mirror-symmetrical shape. As shown in FIGS. 4 to 6, the back plate 61 has a main plate portion 71 to which the lining 62 is attached, and ears 72, 73 that protrude outward along the length of the main plate portion 71 from both longitudinal ends of the main plate portion 71. The pair of ears 72, 73 also have a mirror-symmetrical shape. Therefore, only one of the ears 72 will be described here. The ear 72 has a substantially rectangular shape. The ear 72 has a tip surface portion 81, an outward surface portion 82, and an inward surface portion 83. The tip surface portion 81, the outward surface portion 82, and the inward surface portion 83 are all flat and extend in the thickness direction of the back plate 61. The outward surface portion 82 and the inward surface portion 83 are parallel to each other and perpendicular to the tip surface portion 81.

[0049] The pair of ears 72, 73 have tip surface portions 81 that are parallel to each other and face in opposite directions. As shown in Fig. 6, the pair of ears 72, 73 have their outward facing surface portions 82 arranged on the same plane. The pair of ears 72, 73 have their inward facing surface portions 83 arranged on the same plane.

[0050] 4, a protrusion 91 is formed on the pressing surface 66 of the back plate 61 at the position of the ear 72, protruding from the pressing surface 66 in the opposite direction to the lining 62. A protrusion 92 is formed on the pressing surface 66 of the back plate 61 at the position of the ear 73, protruding from the pressing surface 66 in the opposite direction to the lining 62.

[0051] As shown in FIG. 2 , the outer friction pad 8 is supported by the recess 51 of the outer sidewall 26 and the recess 52 of the outer sidewall 27. At this time, the back plate 61 of the outer friction pad 8 is disposed on the outer side relative to the lining 62. At this time, the outer friction pad 8 is inserted into the recess 51 of the outer sidewall 26 with the ear 72 disposed at the end of the friction pad 8 on the first side in the disc rotation direction. At this time, the outer friction pad 8 is inserted into the recess 52 of the outer sidewall 27 with the ear 73 disposed at the end of the friction pad 8 on the second side in the disc rotation direction. In other words, the pair of ears 72, 73 of the outer friction pad 8 are nested in the recesses 51, 52 of the pair of outer sidewalls 26, 27.

[0052] 4 and 5 faces the rear surface 57 of the recess 51 shown in Fig. 2, the outward surface 82 shown in Fig. 4 and 5 faces the outer wall surface 55 of the recess 51 shown in Fig. 2, and the inward surface 83 shown in Fig. 4 and 6 faces the inner wall surface 56 of the recess 51. Similarly, the tip surface 81 of the ear 73 faces the rear surface 57 of the recess 52, the outward surface 82 faces the outer wall surface 55 of the recess 52, and the inward surface 83 faces the inner wall surface 56 of the recess 52.

[0053] In this way, the outer friction pad 8 supported by the carrier 5 extends in the disk rotation direction. In this state, the outer friction pad 8 is located on the outer side of the disk 2 and is movable in the disk axial direction relative to the carrier 5. In addition, in this state, the outer friction pad 8 faces the disk 2 with the lining 62 facing the disk 2.

[0054] The recess 51 of the outer side wall 26 restricts further radial inward movement of the ear 72 of the outer friction pad 8 when the inward surface 83 (shown in FIG. 6) of the ear 72 of the outer friction pad 8 abuts against the inner wall surface 56 (shown in FIG. 2). The recess 51 of the outer side wall 26 restricts further radial outward movement of the ear 72 of the outer friction pad 8 when the outward surface 82 (shown in FIGS. 4 to 6) of the ear 72 of the outer friction pad 8 abuts against the outer wall surface 55 (shown in FIG. 2). The recess 51 of the outer side wall 26 restricts further radial outward movement of the ear 72 of the outer friction pad 8 when the tip surface 81 (shown in FIGS. 4 and 5) of the ear 72 of the outer friction pad 8 abuts against the rear surface 57 (shown in FIG. 2).

[0055] The recess 52 of the outer side wall 27 restricts further radial inward movement of the ear 73 of the outer friction pad 8 when the inward surface 83 of the ear 73 abuts against the inner wall surface 56. The recess 52 of the outer side wall 27 restricts further radial outward movement of the ear 73 of the outer friction pad 8 when the outward surface 82 of the ear 73 of the outer friction pad 8 abuts against the outer wall surface 55. The recess 52 of the outer side wall 27 restricts further radial outward movement of the ear 73 of the outer friction pad 8 when the tip surface 81 of the ear 73 of the outer friction pad 8 abuts against the rear surface 57.

[0056] As described above, the recesses 51, 52 of the pair of outer side walls 26, 27 of the carrier 5 support the pair of ears 72, 73 of the outer friction pad 8 so that they can move in the disk axial direction while restricting movement in the disk radial direction and the disk rotational direction. In this state supported by the carrier 5, the back plate 61 of the outer friction pad 8 has its plate thickness direction aligned with the disk axial direction.

[0057] The inner-side friction pad 9 shown in FIG. 1 is supported by a recess 53 of the inner-side wall 23 and a recess (not shown) of the inner-side wall 22 shown in FIG. 2 in the same way as the outer-side friction pad 8 is supported by the recesses 51, 52 of the outer-side walls 26, 27. That is, the lug (not shown) of the inner-side friction pad 9 on the first side in the disc rotation direction is inserted into the recess (not shown) of the inner-side wall 22. At the same time, the lug (not shown) of the inner-side friction pad 9 on the second side in the disc rotation direction is inserted into the recess 53 of the inner-side wall 23. Therefore, a pair of lugs (not shown) of the inner-side friction pad 9 are nested in the recess (not shown) of the inner-side wall 22 and the recess 53 of the inner-side wall 23. At this time, the back plate (not shown) of the inner-side friction pad 9 is positioned on the inner side with respect to the lining 62.

[0058] In this way, the inner friction pad 9 supported by the carrier 5 extends in the disk rotation direction. In addition, in this state, the inner friction pad 9 is located on the inner side of the disk 2 and is movable in the disk axial direction relative to the carrier 5.

[0059] The recesses (not shown) of the pair of inner sidewalls 22 and the recesses 53 of the pair of inner sidewalls 23 of the carrier 5 support the pair of lugs (not shown) of the inner friction pad 9 so that they can move in the disk axial direction while restricting movement in the disk radial direction and the disk rotation direction. In this state supported by the carrier 5, the thickness direction of the back plate (not shown) of the inner friction pad 9 is aligned with the disk axial direction.

[0060] As described above, the pair of friction pads 8, 9 are both supported by the carrier 5. At this time, the pair of friction pads 8, 9 each face the disk 2 at the lining 62. That is, the outer-side friction pad 8 supported by the pair of outer sidewall portions 26, 27 faces the side surface of the lining 62 facing the outer side of the disk 2. Also, the inner-side friction pad 9 supported by the pair of inner sidewall portions 22, 23 faces the side surface of the lining 62 facing the inner side of the disk 2. Then, during braking, the pair of friction pads 8, 9 each come into contact with the side surface of the disk 2 that faces them at the lining 62.

[0061] 2 to 6, the return spring 11 is attached to an ear 72 on a first side in the disc rotation direction of the back plate 61 of the outer friction pad 8. The return spring 12 is attached to an ear 73 on a second side in the disc rotation direction of the back plate 61 of the outer friction pad 8. Both the return springs 11 and 12 are provided on the opposite side of the back plate 61 of the outer friction pad 8 from the lining 62 in the plate thickness direction of the back plate 61. Both the return springs 11 and 12 are attached to the back plate 61 in a state of surface contact with the pressing surface 66 of the back plate 61 of the outer friction pad 8.

[0062] 1 is attached to an ear on a first side in the disc rotation direction of a back plate (not shown) of the inner-side friction pad 9. Return spring 14 is attached to an ear on a second side in the disc rotation direction of a back plate (not shown) of the inner-side friction pad 9. Both return springs 13 and 14 are attached to the back plate (not shown) of the inner-side friction pad 9 in a state of surface contact with the pressing surface on the side opposite to the lining 62 of this back plate.

[0063] The return springs 11 to 14 are common parts with the same shape. For this reason, the return spring 11 attached to the first side in the disc rotation direction of the outer friction pad 8 will be described as an example. As shown in FIGS. 7 to 9, the return spring 11 has a mirror-symmetrical shape. The return spring 11 includes a fixed portion 100 shown in FIGS. 7 to 10, a first extending portion 101, a second extending portion 102, a contact portion 103 shown in FIG. 10, and a pair of cover portions 104, 105 shown in FIGS. 7 to 9. The return spring 11 is formed from a plate material having spring properties, specifically a steel plate. The return spring 11 is integrally formed by stamping and bending a flat steel plate of a uniform thickness using a press process. Therefore, the return spring 11 is formed seamlessly and integrally with the fixed portion 100, the first extending portion 101, the second extending portion 102, the contact portion 103, and the pair of cover portions 104, 105. In other words, the entire return spring 11 is formed seamlessly and integrally.

[0064] The fixing portion 100 is plate-shaped and has a flat plate shape with a constant thickness. The fixing portion 100 has a rectangular shape when viewed in the thickness direction. As shown in FIGS. 7 to 9, the fixing portion 100 has an edge portion 111, an edge portion 112, and an edge portion 113. The edge portions 111 to 113 are all surfaces that extend in the thickness direction of the fixing portion 100.

[0065] The edge portion 111 extends in one direction. The middle portion of the edge portion 111 in the extending direction is flat, and both end sides in the extending direction are curved surfaces with the center of curvature on the inside of the fixing portion 100.

[0066] The edge portion 112 extends linearly in one direction. The edge portion 112 is flat. The edge portion 112 extends perpendicularly to the flat portion of the edge portion 111 from one end of the edge portion 111 in the extension direction.

[0067] Edge portion 113 extends linearly in one direction. Edge portion 113 is flat. Edge portion 113 extends perpendicularly to the flat portion of edge portion 111 from the other end opposite edge portion 112 in the extension direction of edge portion 111. Edge portion 112 and edge portion 113 face in opposite directions and extend parallel to each other.

[0068] A fixing hole 115 is formed in the fixing portion 100 so as to penetrate in the thickness direction of the fixing portion 100. The fixing hole 115 is an elongated hole whose width in the direction in which the edge portion 111 extends is greater than the width in the direction in which the edge portions 112 and 113 extend.

[0069] The first extending portion 101 is plate-shaped and extends from the fixed portion 100 to one side in the thickness direction of the fixed portion 100. The first extending portion 101 has a substantially constant thickness and is curved in the thickness direction. The first extending portion 101 has a protruding plate portion 121 and an extending plate portion 122.

[0070] 7 and 8, the protruding plate portion 121 is a curved plate that is curved in an arc shape in the thickness direction. The protruding plate portion 121 protrudes from the end of the fixed portion 100 opposite the edge portion 111 to one side in the thickness direction of the fixed portion 100. The protruding plate portion 121 is curved so that the center of curvature is located on the edge portion 111 side relative to the protruding plate portion 121 in the extension direction of the edge portions 112 and 113.

[0071] The extending plate portion 122 extends from the end of the protruding plate portion 121 opposite the fixed portion 100 in the opposite direction to the fixed portion 100 in the plate thickness direction of the fixed portion 100. The extending plate portion 122 is curved in an arc shape so that the further it extends from the protruding plate portion 121, the further it moves away from the edge portion 111 in the extension direction of the edge portions 112, 113. The extending plate portion 122 is curved so that the center of its curvature is located on the opposite side of the extending plate portion 122 from the edge portion 111 in the extension direction of the edge portions 112, 113.

[0072] The first extending portion 101 has a protruding plate portion 121 that is arc-shaped, and an extending plate portion 122 that is also arc-shaped. In other words, the first extending portion 101 is curved as a whole.

[0073] 7, 8, or 9, the first extending portion 101 has an edge portion 124, an edge portion 125, an edge portion 126, an edge portion 127, an edge portion 128, and an edge portion 129. The edge portions 124 to 129 are all surfaces that extend in the thickness direction of the first extending portion 101.

[0074] 7, the edge portion 124 is formed on the end portion of the extending plate portion 122 on the protruding plate portion 121 side in the extension direction, and on the protruding plate portion 121. The edge portion 124 extends from the edge portion of the edge portion 112 on the opposite side to the edge portion 111. The edge portion 124 is flat and is disposed on the same plane as the edge portion 112.

[0075] 8, the edge portion 125 is formed on the end portion of the extending plate portion 122 on the protruding plate portion 121 side in the extension direction, and on the protruding plate portion 121. The edge portion 125 extends from the edge portion of the edge portion 113 on the opposite side to the edge portion 111. The edge portion 125 is flat and is disposed on the same plane as the edge portion 113. Therefore, the edge portion 125 faces away from the edge portion 124 and is parallel to the edge portion 124.

[0076] 9, edge portion 126 is formed in the middle portion in the extension direction of extending plate portion 122. Edge portion 126 extends from the edge portion of edge portion 124 on the opposite side to edge portion 112. Edge portion 126 is flat and inclined with respect to edge portion 124.

[0077] The edge portion 127 is formed in the middle portion in the extension direction of the extending plate portion 122. The edge portion 127 extends from the edge portion of the edge portion 125 on the opposite side to the edge portion 113. The edge portion 127 is flat and inclined with respect to the edge portion 125.

[0078] The edges 126 and 127 face away from each other and are inclined relative to the edges 124 and 125 so that the edges 126 and 127 approach each other as they move away from the edges 124 and 125 .

[0079] The edge portion 128 is formed at the end portion of the extending plate portion 122 opposite to the protruding plate portion 121 in the extending direction. The edge portion 128 extends from the edge portion of the edge portion 126 opposite to the edge portion 124. The edge portion 128 has a curved surface shape.

[0080] The edge portion 129 is formed at the end of the extending plate portion 122 opposite to the protruding plate portion 121 in the extension direction. The edge portion 129 extends from the edge portion of the edge portion 127 opposite to the edge portion 125. The edge portion 129 has a curved surface shape. The edge portion 129 faces away from the edge portion 128.

[0081] The second extending portion 102 is plate-shaped and extends from the end of the first extending portion 101 opposite the fixed portion 100 to just before the fixed portion 100 along the plate thickness direction of the fixed portion 100, as shown in Fig. 10. The second extending portion 102 has a substantially constant plate thickness and is partially curved in the plate thickness direction. The second extending portion 102 has a connecting plate portion 131 and an intermediate extending plate portion 132.

[0082] The connecting plate portion 131 is a curved plate that curves in an arc shape in its thickness direction. The connecting plate portion 131 extends from the end of the extending plate portion 122 opposite the protruding plate portion 121 in a direction away from the edge portion 111 in the extension direction of the edge portions 112, 113 and toward the fixed portion 100 in the thickness direction of the fixed portion 100, as shown in Fig. 7. The connecting plate portion 131 is curved so that the center of its curvature is located on the edge portion 111 side in the extension direction of the edge portions 112, 113 with respect to the connecting plate portion 131.

[0083] The intermediate extending plate portion 132 is flat and extends from the end of the connecting plate portion 131 opposite the extending plate portion 122 so as to approach the fixed portion 100 in the plate thickness direction of the fixed portion 100. The intermediate extending plate portion 132 approaches the edge portion 111 in the extension direction of the edge portions 112, 113 as it approaches the extending tip side.

[0084] The second extending portion 102 has an edge portion 134 and an edge portion 135. The edge portions 134, 135 are formed on the connecting plate portion 131 and the intermediate extending plate portion 132. The edge portions 134, 135 are both surfaces that extend in the plate thickness direction of the second extending portion 102.

[0085] 9, edge portion 134 extends from the edge of edge portion 128 on the opposite side to edge portion 126. Edge portion 134 is flat and extends parallel to edge portion 124. Edge portion 128 is slightly curved to smoothly connect edge portion 126 and edge portion 134.

[0086] Edge portion 135 extends from the edge of edge portion 129 opposite edge portion 127. Edge portion 135 is flat and extends parallel to edge portion 125. Edge portion 129 is slightly curved to smoothly connect edge portion 127 and edge portion 135. Edge portion 135 faces away from edge portion 134 and is parallel to edge portion 134. The distance between edge portions 134 and 135 is shorter than the distance between edge portions 124 and 125.

[0087] 10, the abutment portion 103 is plate-shaped and extends from the end of the intermediate extending plate portion 132 of the second extending portion 102 opposite the connecting plate portion 131 toward the first extending portion 101. The abutment portion 103 is arranged on the same side of the fixed portion 100 as the first extending portion 101 and the second extending portion 102 in the plate thickness direction of the fixed portion 100. The abutment portion 103 has a substantially constant plate thickness and is partially curved in the plate thickness direction. The abutment portion 103 has an abutment plate portion 141, an intermediate plate portion 142, and an inward extending plate portion 143.

[0088] The abutting plate portion 141 has a curved plate shape that is curved in its thickness direction. As shown in Fig. 7, the abutting plate portion 141 extends from the end of the intermediate extending plate portion 132 opposite the connecting plate portion 131 toward the fixed portion 100 in the extension direction of the edge portions 112, 113. As shown in Fig. 10, the abutting plate portion 141 is curved so that the center of its curvature is located on the opposite side of the abutting plate portion 141 from the fixed portion 100 in the thickness direction of the fixed portion 100.

[0089] The intermediate plate portion 142 is flat and extends from the end of the abutting plate portion 141 opposite the intermediate extending plate portion 132. The intermediate plate portion 142 extends from the abutting plate portion 141 toward the edge portion 111 as shown in Fig. 10 in the extending direction of the edge portions 112, 113 shown in Fig. 7. The intermediate plate portion 142 becomes more distant from the fixed portion 100 in the plate thickness direction of the fixed portion 100 as it approaches the extending tip side. The angle between the intermediate plate portion 142 and the intermediate extending plate portion 132 is an acute angle of less than 90 degrees.

[0090] The inward extending plate portion 143 has a curved plate shape that curves in its thickness direction. The inward extending plate portion 143 extends from an end of the intermediate plate portion 142 opposite the abutting plate portion 141 to the opposite side of the fixed portion 100 in the thickness direction of the fixed portion 100. The inward extending plate portion 143 is curved so that the center of curvature is located on the opposite side of the inward extending plate portion 143 to the edge portion 111 in the extension direction of the edge portions 112, 113 shown in FIG.

[0091] The abutment portion 103 has an edge portion 145 and an edge portion 146 shown in Fig. 7. The edge portions 145, 146 are formed on the abutment plate portion 141 and the inward extending plate portion 143 shown in Fig. 10, the end portion of the intermediate plate portion 142 on the abutment plate portion 141 side, and the end portion of the intermediate plate portion 142 on the inward extending plate portion 143 side. The edge portions 145, 146 shown in Fig. 7 are both surfaces that extend in the plate thickness direction of the abutment portion 103.

[0092] Edge portion 145 extends from the edge of edge portion 134 opposite edge portion 128 shown in Fig. 8. Edge portion 145 shown in Fig. 7 is planar and is disposed in the same plane as edge portion 134.

[0093] Edge portion 146 extends from the edge of edge portion 135 opposite edge portion 129. Edge portion 146 is planar and is disposed in the same plane as edge portion 135. Thus, edge portion 146 faces away from edge portion 145 and extends parallel to edge portion 145.

[0094] The lines along the plate thickness direction of the fixed portion 100, the first extending portion 101, the second extending portion 102, and the abutting portion 103 all pass through a single plane. The edge portions 112, 113, 124, 125, 134, 135, 145, and 146 are parallel to this plane.

[0095] The return spring 11 is provided such that the cover portions 104 and 105 shown in Figures 7 to 9 extend from at least one of the first extending portion 101, the second extending portion 102, and the contact portion 103 shown in Figure 10. Specifically, the cover portions 104 and 105 shown in Figures 7 to 9 extend from the intermediate plate portion 142 of the contact portion 103 shown in Figure 10.

[0096] 7 to 9, the cover portion 104 extends from an edge portion 145 of the abutting portion 103 shown in FIG. 7, and the cover portion 105 extends from an edge portion 146 of the abutting portion 103. The pair of cover portions 104, 105 have mirror-symmetrical shapes. Both of the cover portions 104, 105 have a substantially constant thickness and are partially curved in the thickness direction. Both of the cover portions 104, 105 have a base end plate portion 151, a cover plate portion 152, and a tip end plate portion 153 shown in FIG. 9.

[0097] The base end plate portion 151 of the cover portion 104 protrudes from the edge portion 145 of the abutting portion 103 shown in Fig. 7. The base end plate portion 151 of the cover portion 105 shown in Fig. 9 protrudes from the edge portion 146 of the abutting portion 103 shown in Fig. 7. The base end plate portions 151 of the cover portions 104 and 105 shown in Fig. 9 are both provided at the position of the intermediate plate portion 142 of the abutting portion 103, and both protrude from the intermediate plate portion 142, as shown in Fig. 10 for the base end plate portion 151 of the cover portion 105.

[0098] The base end plate portion 151 of the cover portion 104 shown in Fig. 9 protrudes perpendicularly to the edge portion 145 shown in Fig. 7, which is a surface, and curves toward the second extending portion 102 in the thickness direction of the intermediate plate portion 142 shown in Fig. 10. The base end plate portion 151 of the cover portion 105 protrudes perpendicularly to the edge portion 146 shown in Fig. 7, which is a surface, and curves toward the second extending portion 102 in the thickness direction of the intermediate plate portion 142 shown in Fig. 10.

[0099] As shown in FIGS. 7 and 8, the cover plate portions 152 of the cover portions 104 and 105 are both flat. The cover plate portion 152 of the cover portion 104 shown in FIG. 7 extends from the end of the base end plate portion 151 of the cover portion 104 opposite the abutting portion 103 in a direction away from the intermediate plate portion 142 along the plate thickness direction of the intermediate plate portion 142 shown in FIG. 10. The cover plate portion 152 of the cover portion 105 extends from the end of the base end plate portion 151 of the cover portion 105 opposite the abutting portion 103 in a direction away from the intermediate plate portion 142 along the plate thickness direction of the intermediate plate portion 142. The cover plate portions 152 of the cover portions 104 and 105 shown in FIG. 7 extend parallel to the edge portions 134, 135, 145, and 146, which are surfaces. Therefore, the cover plate portions 152 of the cover portions 104 and 105 extend parallel to each other.

[0100] As shown in Fig. 10, the cover plate portions 152 of the cover portions 104, 105 each extend further away from the fixed portion 100 than the first extending portion 101 and the second extending portion 102 in the thickness direction of the fixed portion 100. As shown in Fig. 10, the cover plate portions 152 of the cover portions 104, 105 each overlap the entire second extending portion 102, the portion of the extending plate portion 122 on the connecting plate portion 131 side, and the tip end of the inward extending plate portion 143 of the abutting portion 103 on the side opposite to the intermediate plate portion 142, in the direction in which the edge portions 134, 135, which are all surfaces, extend.

[0101] 7 to 9 covers at least a portion of edge portions 124, 126, 128, 134, and 145 shown in Fig. 7 or 9. Specifically, cover plate portion 152 of cover portion 104 faces and covers a portion of edge portion 124 on the edge portion 126 side shown in Fig. 9, the entire edge portion 126, the entire edge portion 128, the entire edge portion 134, and the tip end of edge portion 145 shown in Fig. 7 on the opposite side to edge portion 134.

[0102] 7 to 10 covers at least a portion of edge portions 125, 127, 129, 135, and 146 shown in Fig. 7 or 9. Specifically, cover plate portion 152 of cover portion 105 faces and covers a portion of edge portion 125 on the edge portion 127 side, all of edge portion 127, all of edge portion 129, all of edge portion 135, and the tip end of edge portion 146 on the opposite side to edge portion 135, in a direction perpendicular to edge portion 135.

[0103] 7 and 8, the tip plate portion 153 of the cover portion 104 extends from the edge portion of the cover plate portion 152 of the cover portion 104 opposite to the base end plate portion 151. The tip plate portion 153 of the cover portion 104 protrudes from the cover plate portion 152 of the cover portion 104 while curving in the thickness direction of the cover plate portion 152 so as to approach the cover portion 105.

[0104] The tip plate portion 153 of the cover portion 105 extends from the edge portion of the cover plate portion 152 of the cover portion 105 opposite to the base end plate portion 151. The tip plate portion 153 of the cover portion 105 protrudes from the cover plate portion 152 of the cover portion 105 while curving in the thickness direction of the cover plate portion 152 so as to approach the cover portion 104.

[0105] 4 to 6, the return spring 11 is attached to the ear portion 72 of the outer friction pad 8. At this time, the protrusion portion 91 provided on the ear portion 72 shown in FIGS. 4 to 6 is fitted into the fixing hole 115 shown in FIGS. 7 to 10, and the return spring 11 is brought into contact with the pressing surface 66 at the fixed portion 100. Moreover, the return spring 11 is arranged so that the first extending portion 101 and the second extending portion 102 shown in FIG. 4, the contact portion 103 shown in FIG. 5, and the cover portions 104 and 105 shown in FIG. 4 are located on the opposite side of the fixed portion 100 from the main plate portion 71.

[0106] In this state, the portion of the return spring 11 that protrudes beyond the fixing portion 100 of the protruding portion 91 is crimped and crushed, thereby fixing the fixing portion 100 to the ear portion 72. Here, the protruding portion 91 has the same shape as the fixing hole 115, which is an elongated hole, shown in FIGS. 7 to 9, and prevents the return spring 11 from rotating relative to the friction pad 8.

[0107] In this way, the fixed portion 100 of the return spring 11 is fixed to the friction pad 8. In this state, the first extending portion 101 and the second extending portion 102 shown in Fig. 4, the contact portion 103 shown in Fig. 5, and the cover portions 104 and 105 shown in Fig. 4 of the return spring 11 protrude beyond the ear portion 72 on the side opposite to the main plate portion 71. In this state, of the second extending portion 102, the contact portion 103, and the cover portions 104 and 105 of the return spring 11, the contact plate portion 141 of the contact portion 103 shown in Fig. 5 is positioned closest to the back plate 61 in the thickness direction of the back plate 61 of the friction pad 8.

[0108] 4 to 6, the return spring 12 is fixed to the ear portion 73 of the outer friction pad 8 in a manner that prevents it from rotating, similar to the return spring 11. At this time, the return spring 12 abuts against the pressing surface 66 at the fixed portion 100, and is arranged so that the first extending portion 101 and the second extending portion 102 shown in FIG. 6, the abutting portion 103 shown in FIG. 5, and the cover portions 104 and 105 shown in FIG. 4 are located on the opposite side of the fixed portion 100 from the main plate portion 71.

[0109] The return spring 12 has its fixing portion 100 fixed to the friction pad 8. In this state, the first extending portion 101 and the second extending portion 102 shown in FIG. 6, the contact portion 103 shown in FIG. 5, and the cover portions 104 and 105 shown in FIG. 4 of the return spring 12 protrude beyond the ear portion 73 on the side opposite to the main plate portion 71. In this state, of the second extending portion 102, the contact portion 103, and the cover portions 104 and 105 of the return spring 12, the contact plate portion 141 of the contact portion 103 shown in FIG. 5 is positioned closest to the back plate 61 in the thickness direction of the back plate 61 of the friction pad 8.

[0110] As shown in Fig. 2, the outer friction pad 8, with the return springs 11 and 12 attached, is supported in the recesses 51 and 52 of the pair of outer side walls 26 and 27 of the carrier 5 in the above-described manner. As a result, both of the pair of return springs 11 and 12 are disposed on the outer side of the outer friction pad 8. Furthermore, one of the return springs 11 and 12, the return spring 11, is disposed on the first side in the disk rotation direction. Furthermore, the other of the return springs 11 and 12, the return spring 12, is disposed on the second side in the disk rotation direction.

[0111] 7 or 9 face in the disc radial direction. In the return spring 11, the cover portion 104 covers part of the edge portion 124, the entire edge portion 126, the entire edge portion 128, the entire edge portion 134, and the tip portion of the edge portion 145 on the disc radial outer side. In the return spring 11, the cover portion 105 covers part of the edge portion 125, the entire edge portion 127, the entire edge portion 129, the entire edge portion 135, and the tip portion of the edge portion 146 on the disc radial inner side.

[0112] 2, the return spring 11 has a first extending portion 101 extending from the fixed portion 100 in a direction away from the friction pad 8 in the thickness direction of the friction pad 8. At this time, the first extending portion 101 of the return spring 11 extends from the fixed portion 100 in a direction away from the first side in the disk rotation direction. The second extending portion 102 of the return spring 11 extends from an end of the first extending portion 101 opposite the fixed portion 100 toward the inner side in the thickness direction of the friction pad 8. That is, the second extending portion 102 of the return spring 11 extends from the first extending portion 101 in a pressing direction (described later) of the friction pad 8 by the caliper 6 shown in FIG.

[0113] 2, the first extending portion 101, the second extending portion 102, the contact portion 103, and the cover portions 104 and 105 of the return spring 11, which are all located on the first side in the disc rotation direction relative to the fixed portion 100, overlap with the outer side wall portion 26 in the disc rotation direction and the disc radial direction. At least a portion of the first extending portion 101, the second extending portion 102, the contact portion 103, and the cover portions 104 and 105 of the return spring 11 overlap with the outer-side protruding portion 28 in the disc rotation direction, the disc radial direction, and the disc axial direction. At least a portion of the outer-side protruding portion 28 is offset outward in the disc rotation direction relative to the return spring 11, and at least a portion of the outer-side protruding portion 28 is offset inward in the disc radial direction relative to the return spring 11. The contact portion 103 of the return spring 11 extends from the second extending portion 102 and comes into contact with the surface portion 45 of the outer side wall portion 26 of the carrier 5 at the contact plate portion 141 as shown in Fig. 3. At this time, the contact portion 103 of the return spring 11 extends from the second extending portion 102 shown in Fig. 2 to the second side in the disk rotation direction.

[0114] The first extending portion 101 of the return spring 12 extends from the fixed portion 100 in a direction away from the friction pad 8 in the thickness direction of the friction pad 8. At this time, the first extending portion 101 of the return spring 12 extends from the fixed portion 100 in a direction away from the second side in the disk rotation direction. The second extending portion 102 of the return spring 12 shown in FIG. 6 extends from the end of the first extending portion 101 opposite to the fixed portion 100 shown in FIG. 2 toward the inner side in the thickness direction of the friction pad 8. That is, the second extending portion 102 of the return spring 12 shown in FIG. 6 extends from the first extending portion 101 in a pressing direction (described later) of the friction pad 8 by the caliper 6.

[0115] 2, 3, or 6, the first extending portion 101, the second extending portion 102, the contact portion 103, and the cover portions 104, 105 of the return spring 12, which are all located on the second side in the disc rotation direction relative to the fixed portion 100, overlap with the outer side wall portion 27 in the disc rotation direction and the disc radial direction. At least a portion of the first extending portion 101, the second extending portion 102, the contact portion 103, and the cover portions 104, 105 of the return spring 12 overlap with the outer-side protruding portion 29 in the disc rotation direction, the disc radial direction, and the disc axial direction. At least a portion of the outer-side protruding portion 29 is offset outward in the disc rotation direction relative to the return spring 12, and at least a portion of the outer-side protruding portion 29 is offset inward in the disc radial direction relative to the return spring 12. The contact portion 103 of the return spring 12 extends from the second extending portion 102 and comes into contact with the surface portion 47 of the outer side wall portion 27 of the carrier 5 at the contact plate portion 141 as shown in Fig. 3. At this time, the contact portion 103 of the return spring 12 extends from the second extending portion 102 shown in Fig. 6 to the first side in the disk rotation direction.

[0116] A return spring 13 is attached to the first side in the disk rotation direction of the inner friction pad 9 shown in Fig. 1, and a return spring 14 is attached to the second side in the disk rotation direction of the inner friction pad 9 in the same manner as the return springs 11 and 12 are attached to the friction pad 8 described above. The return spring 13 abuts against a surface 35 shown in Fig. 3 of the inner side wall 22 of the carrier 5. The return spring 14 shown in Fig. 1 abuts against a surface 37 shown in Fig. 3 of the inner side wall 23 of the carrier 5.

[0117] 1, the caliper 6 has a shape that is almost mirror-symmetrical. The caliper 6 includes a caliper body 161, the slide pins 41 and 42, mounting bolts 162 and 163, and a piston (not shown).

[0118] The caliper body 161 is seamlessly molded as a single piece by casting. The caliper body 161 has a cylinder portion 171, a bridge portion 172, a pressing claw 173, and a pair of pin mounting portions 174, 175. A slide pin 41 is attached to one pin mounting portion 174 of the pair of pin mounting portions 174, 175 of the caliper body 161 by a mounting bolt 162. A slide pin 42 is attached to the other pin mounting portion 175 of the pair of pin mounting portions 174, 175 of the caliper body 161 by a mounting bolt 163. The caliper body 161 is supported by the carrier 5 via the slide pins 41, 42. At this time, the slide pin 41 slidably fits into a pin insertion hole (not shown) of the pin insertion portion 24 of the carrier 5, and the slide pin 42 slidably fits into a pin insertion hole (not shown) of the pin insertion portion 25. As a result, the caliper 6 including the caliper body 161 is provided on the carrier 5 so as to be movable in the disk axial direction. The pair of boots 7 cover the portions of the corresponding slide pins 41, 42 that protrude from the carrier 5, respectively.

[0119] When the caliper body 161 is supported by the carrier 5, the cylinder portion 171 is disposed on the inner side of the disk 2 in the disk axial direction.

[0120] In this supported state, the caliper body 161 has the bridge portion 172 extending from the outer edge of the cylinder portion 171 in the radial direction of the disk to the outer side along the disk axis so as to straddle the outer periphery of the disk 2 .

[0121] In this supported state, the caliper body 161 has the pressing claws 173 extending radially inward from the edge of the bridge portion 172 opposite the cylinder portion 171. The pressing claws 173 are disposed on the outer side of the disk 2 in the disk axial direction.

[0122] In this supported state, the caliper body 161 has the pin attachment portion 174 extending from the cylinder portion 171 to a first side in the disk rotation direction, and the pin attachment portion 175 extending from the cylinder portion 171 to a second side in the disk rotation direction.

[0123] In the caliper body 161, a pair of pistons (not shown) are housed in a cylinder portion 171 so as to be movable in the disc axial direction. The pair of pistons (not shown) have the same shape and are aligned in the disc radial direction and arranged side by side in the disc rotation direction. The pair of pistons (not shown) are arranged so as to be able to protrude from the cylinder portion 171 toward the pressing claw 173.

[0124] The inner friction pad 9 supported by the carrier 5 is disposed between the disc 2 and a pair of pistons (not shown) of the caliper 6 also supported by the carrier 5. The outer friction pad 8 supported by the carrier 5 is disposed between the pressing claws 173 of the caliper 6 also supported by the carrier 5 and the disc 2. At this time, the linings 62 of both the friction pads 8 and 9 face the disc 2 side.

[0125] Brake fluid is introduced into the cylinder portion 171 of the caliper 6 via brake piping (not shown). Then, brake fluid pressure acts on a pair of pistons (not shown) in the cylinder portion 171. As a result, the pair of pistons (not shown) advance toward the disc 2 and press the inner-side friction pad 9 disposed between these pistons and the disc 2 toward the disc 2. Then, the pair of ears (not shown) of the inner-side friction pad 9 are guided by the inner-side recess 53 and the recess (not shown) and move toward the disc 2, i.e., the outer side, relative to the carrier 5, and the lining 62 comes into contact with the inner-side side surface of the disc 2.

[0126] The reaction force of the pressure from the pair of pistons (not shown) causes the caliper body 161 to slide the slide pins 41, 42 relative to the carrier 5, moving in the disc axial direction. As a result, the pressing claw 173 of the caliper body 161 presses the outer friction pad 8, which is disposed between the pressing claw 173 and the disc 2, toward the disc 2. Then, the pair of ears 72, 73 of the outer friction pad 8 shown in FIG. 2 are guided by the pair of outer recesses 51, 52 and move toward the disc 2, i.e., the inner side, relative to the carrier 5, bringing the lining 62 into contact with the outer side surface of the disc 2.

[0127] 1, which is movably mounted on the carrier 5, clamps the pair of friction pads 8, 9 from both sides in the disk axial direction between the pistons (not shown) and the pressing claws 173 by the operation of the pistons, and presses the friction pads 8, 9 against both sides of the disk 2. As a result, the caliper 6 applies frictional resistance to the disk 2, generating a braking force. The caliper 6 is a so-called fist-type caliper that moves axially relative to the carrier 5.

[0128] 3, the abutment plate portion 141 of the abutment portion 103 of the return spring 11 abuts against the surface portion 45 of the outer side wall portion 26, restricting movement toward the inner side. Therefore, when the outer friction pad 8 moves toward the inner side relative to the carrier 5 as described above, the return spring 11, which had been in a standby state until then, elastically deforms mainly the connecting plate portions 131 of the first extension portion 101 and the second extension portion 102 shown in FIG. 10, and enters an elastically deformed state. As a result, the return spring 11 separates, in the disk axial direction, the fixed portion 100 fixed to the friction pad 8 shown in FIG. 3 from the abutment portion 103, whose movement relative to the carrier 5 is restricted.

[0129] Furthermore, the abutment plate portion 141 of the abutment portion 103 of the return spring 12 abuts against the surface portion 47 of the outer side wall portion 27, restricting movement toward the disk 2. Therefore, when the outer friction pad 8 moves toward the disk 2 relative to the carrier 5 as described above, the return spring 12, which was in a standby state, elastically deforms and enters an elastically deformed state, similar to the return spring 11. As a result, the return spring 12 separates its fixed portion 100, which is fixed to the friction pad 8, from its abutment portion 103, whose movement relative to the carrier 5 is restricted, in the disk axial direction.

[0130] When the caliper 6 is released from pressing the outer friction pad 8, the return spring 11, which was in an elastically deformed state, restores the elastic deformation of the connecting plate portion 131 of the first extension portion 101 and the second extension portion 102 shown in FIG. 10, which had been elastically deformed up until then, and returns to a standby state. Then, the return spring 11 moves its fixed portion 100, which is fixed to the friction pad 8 shown in FIG. 3, and its abutting portion 103, which abuts against the carrier 5, closer in the disk axial direction. As a result, the outer friction pad 8 moves toward the outer side relative to the carrier 5 in the disk axial direction, separating its lining 62 from the disk 2.

[0131] Furthermore, when the pressure applied to the outer friction pad 8 by the caliper 6 is released, the return spring 12, which was in an elastically deformed state, also returns to a standby state from the elastically deformed state, similar to the return spring 11. Then, the return spring 12 moves its fixed portion 100, which is fixed to the friction pad 8, and its abutting portion 103, which abuts against the carrier 5, closer in the disk axial direction. This also causes the outer friction pad 8 to move toward the outer side relative to the carrier 5 in the disk axial direction, separating its lining 62 from the disk 2.

[0132] 1 attached to the inner friction pad 9 also operate in the same manner as the return springs 11 and 12 when the pressure applied to the inner friction pad 9 by the caliper 6 is released. Then, the return springs 13 and 14 move the inner friction pad 9 to the opposite side from the disc 2 in the disc axial direction relative to the carrier 5, i.e., to the inner side, and separate the lining 62 from the disc 2.

[0133] The above-mentioned Patent Document 1 describes a disc brake that uses a return spring that is integrally formed by punching a springy steel plate and then bending it using a press or other means. When a user maintains the disc brake, such as replacing parts or washing the car, if the edge of the return spring is exposed, there is a risk that the user's fingers may get caught on this edge, reducing the ease of maintenance. In recent years, many different shapes of return springs have been developed to reduce the size of disc brakes, but this miniaturization of disc brakes in particular has made it even easier for users to get caught on the exposed edge of the return spring, further reducing the ease of maintenance.

[0134] In contrast, the return springs 11 and 12 of the first embodiment have a fixed portion 100 fixed to the friction pad 8, a first extending portion 101 formed in a plate shape and extending from the fixed portion 100 in a direction away from the friction pad 8, a second extending portion 102 formed in a plate shape and extending from the first extending portion 101 in the pressing direction of the friction pad 8, and an abutting portion 103 formed in a plate shape and extending from the second extending portion 102 to abut against the carrier 5. Moreover, the return springs 13 and 14 have the same configuration as the return springs 11 and 12 except that they are fixed to the friction pad 9.

[0135] Return springs 11 to 14 have a similar configuration. To explain this using return spring 11 as an example, return spring 11 has edge portions 124 to 129, 134, 135, 145, and 146, which are surfaces extending in the plate thickness direction between first extending portion 101, second extending portion 102, and abutting portion 103. Return spring 11 has cover portion 104 that covers at least a portion of edge portions 124, 126, 128, 134, and 145, and cover portion 105 that covers at least a portion of edge portions 125, 127, 129, 135, and 146. Therefore, cover portion 104 can prevent edge portions 124, 126, 128, 134, and 145 from being exposed, and can prevent fingers from getting caught on edge portions 124, 126, 128, 134, and 145. Furthermore, the cover portion 105 can prevent the edge portions 125, 127, 129, 135, and 146 from being exposed, and can prevent fingers from getting caught on the edge portions 125, 127, 129, 135, and 146. Therefore, the disc brake 1 provided with the return springs 11 to 14 can be easily maintained.

[0136] In the return springs 11 to 14 having a similar configuration, the first extending portion 101 is formed in an arc shape. This makes it possible to suppress local stress occurring in the return springs 11 to 14. As a result, the reliability of the return springs 11 to 14 can be improved.

[0137] Return springs 11 to 14 have a similar configuration. Taking return spring 11 as an example, its cover portions 104 and 105 extend from at least one of the first extending portion 101, the second extending portion 102, and the abutting portion 103. In return spring 11, the cover portions 104 and 105 extend from the intermediate plate portion 142 of the abutting portion 103. Therefore, the cover portions 104 and 105 can be molded integrally with the fixed portion 100, the first extending portion 101, the second extending portion 102, and the abutting portion 103. Therefore, return springs 11 to 14 can be manufactured easily and inexpensively, and an increase in the number of assembly steps can be suppressed.

[0138] Return springs 11 to 14 have a similar configuration, and taking return spring 11 as an example, cover portions 104 and 105 extend from flat intermediate plate portion 142, which has less effect on the generated spring load, rather than from a curved portion that affects the generated spring load. Therefore, return springs 11 to 14 can suppress the effect of forming cover portions 104 and 105 on the generated spring load, i.e., on spring performance.

[0139] In the return springs 11 to 14 of the first embodiment, only one of the cover portions 104, 105 may be provided. For example, only one of the cover portions 104, 105 that is disposed on the outer side in the disk radial direction may be provided. Also, for example, only one of the cover portions 104, 105 that is disposed on the inner side in the disk radial direction may be provided.

[0140] [Second embodiment] Next, the second embodiment will be described, focusing on the differences from the first embodiment, mainly with reference to Figures 11 to 14. Note that parts common to the first embodiment will be designated by the same names and symbols.

[0141] In the second embodiment, a return spring 11A is partially modified from the return spring 11 of the first embodiment. Return springs 12 to 14 are also modified in the same manner.

[0142] As shown in Figures 11 to 13, the return spring 11A has a mirror-symmetric shape and has a first extension portion 101A that is modified from the first extension portion 101, and a second extension portion 102A that is modified from the second extension portion 102.

[0143] The first extending portion 101A is also plate-shaped and extends from the fixed portion 100 to one side in the thickness direction of the fixed portion 100. The first extending portion 101A has a substantially constant thickness and is partially curved in the thickness direction. The first extending portion 101A has a protruding plate portion 121 similar to that of the first embodiment, a base-end extending plate portion 201A, an intermediate plate portion 202A (first curved portion), and a tip-end extending plate portion 203A (connecting portion).

[0144] The base-end extending plate portion 201A is flat and extends from an end of the protruding plate portion 121 opposite the fixed portion 100 to the opposite side of the fixed portion 100 in the plate thickness direction of the fixed portion 100. As shown in Fig. 14, the base-end extending plate portion 201A forms an acute angle of less than 90 degrees with the fixed portion 100. Therefore, the base-end extending plate portion 201A approaches the edge portion 111 in the extension direction of the edge portions 112, 113 shown in Figs. 11 and 12 as it approaches the extending tip side.

[0145] The intermediate plate portion 202A is a curved plate that curves in an arc shape in its thickness direction. The intermediate plate portion 202A protrudes from the end of the base-end extending plate portion 201A opposite the protruding plate portion 121 to the opposite side from the edge portion 111 in the extension direction of the edge portions 112, 113. The intermediate plate portion 202A is curved so that the center of its curvature is located on the fixed portion 100 side in the thickness direction of the fixed portion 100 relative to the intermediate plate portion 202A.

[0146] The distal end extending plate portion 203A is flat and extends from the end of the intermediate plate portion 202A opposite the base end extending plate portion 201A in the opposite direction to the edge portion 111 in the extending direction of the edge portions 112, 113. As shown in Fig. 14, the distal end extending plate portion 203A is aligned with the fixed portion 100 and is parallel to the fixed portion 100. The angle formed by the distal end extending plate portion 203A and the base end extending plate portion 201A is an acute angle of less than 90 degrees.

[0147] 11, 12, or 13, first extending portion 101A has edge portion 124A, edge portion 125A, edge portion 126A, edge portion 127A, edge portion 128A, and edge portion 129A. Edge portions 124A to 129A are all surfaces that extend in the thickness direction of first extending portion 101A.

[0148] 11, edge portion 124A is formed on protruding plate portion 121, base-end extending plate portion 201A, and intermediate plate portion 202A. Edge portion 124A extends from the edge portion on the opposite side of edge portion 111 in the extension direction of edge portion 112. Edge portion 124A is planar and is disposed on the same plane as edge portion 112.

[0149] 12, edge portion 125A is formed on protruding plate portion 121, base-end extending plate portion 201A, and intermediate plate portion 202A. Edge portion 125A extends from the edge portion opposite edge portion 111 in the extension direction of edge portion 113. Edge portion 125A is flat and is disposed on the same plane as edge portion 113. Therefore, edge portion 125A faces away from edge portion 124A and is parallel to edge portion 124A.

[0150] 13, edge portion 126A is formed on tip-side extending plate portion 203A. Edge portion 126A extends from the edge of edge portion 124A on the side opposite edge portion 112. Edge portion 126A is flat and inclined relative to edge portion 124A.

[0151] Edge portion 127A is formed on tip-side extending plate portion 203A. Edge portion 127A extends from the edge of edge portion 125A on the side opposite edge portion 113. Edge portion 127A is flat and inclined relative to edge portion 125A.

[0152] Edges 126A and 127A face in opposite directions and are inclined relative to edges 124A and 125A so that the further away from edges 124A and 125A they are, the closer they become to each other.

[0153] Edge portion 128A is formed on tip-side extending plate portion 203A. Edge portion 128A extends from the edge of edge portion 126A on the opposite side to edge portion 124A. Edge portion 128A has a curved surface shape.

[0154] Edge portion 129A is formed on tip-side extending plate portion 203A. Edge portion 129A extends from the edge of edge portion 127A on the opposite side to edge portion 125A. Edge portion 129A has a curved surface shape. Edge portion 129A faces away from edge portion 128A.

[0155] The second extending portion 102A is plate-shaped and extends from the end of the tip-side extending plate portion 203A opposite to the intermediate plate portion 202A in the plate thickness direction of the fixed portion 100 to just before the fixed portion 100, as shown in Fig. 14. The second extending portion 102A has a substantially constant plate thickness and is partially curved in the plate thickness direction. The second extending portion 102A has a connecting plate portion 131A (second curved portion) and an intermediate extending plate portion 132A.

[0156] The connecting plate portion 131A protrudes from the end of the tip-side extending plate portion 203A opposite to the intermediate plate portion 202A toward the fixed portion 100 in the plate thickness direction of the fixed portion 100. The connecting plate portion 131A is a curved plate that curves in an arc shape in the plate thickness direction. The connecting plate portion 131A is curved so that the center of curvature is located on the edge portion 111 side in the extension direction of the edge portions 112, 113 shown in Figures 11 and 12 with respect to the connecting plate portion 131A. The radius of curvature of the connecting plate portion 131A is smaller than that of the connecting plate portion 131 of the return spring 11. The length of the connecting plate portion 131A in the circumferential direction is shorter than that of the connecting plate portion 131 of the return spring 11.

[0157] As shown in FIG. 11, the intermediate extending plate portion 132A has a flat plate shape and extends from the end of the connecting plate portion 131A opposite the tip-side extending plate portion 203A. As shown in FIG. 14, the intermediate extending plate portion 132A extends from the connecting plate portion 131A so as to approach the fixed portion 100 in the plate thickness direction of the fixed portion 100. The intermediate extending plate portion 132A approaches the edge portion 111 in the extension direction of the edge portions 112, 113 shown in FIGS. 11 and 12 as it approaches the tip end side. As shown in FIG. 14, the intermediate extending plate portion 132A forms an acute angle of less than 90 degrees with the tip-side extending plate portion 203A. The intermediate extending plate portion 132A is longer in the extension direction than the intermediate extending plate portion 132 of the return spring 11.

[0158] 11, the second extending portion 102A has an edge portion 134A and an edge portion 135A. The edge portions 134A and 135A are formed on the connecting plate portion 131A and the intermediate extending plate portion 132A. Both the edge portions 134A and 135A are surfaces that extend in the plate thickness direction of the second extending portion 102A.

[0159] 13, edge portion 134A extends from the edge of edge portion 128A on the side opposite edge portion 126A. Edge portion 134A is flat and extends parallel to edge portion 124A. Edge portion 128A is slightly curved to smoothly connect edge portion 126A and edge portion 134A.

[0160] Edge portion 135A extends from the edge of edge portion 129A on the opposite side to edge portion 127A. Edge portion 135A is flat and extends parallel to edge portion 125A. Edge portion 129A is slightly curved to smoothly connect edge portion 127A and edge portion 135A. Edge portion 135A faces away from edge portion 134A and is parallel to edge portion 134A. The distance between edge portions 134A and 135A is smaller than the distance between edge portions 124A and 125A.

[0161] As shown in Fig. 14, the abutting portion 103 has the same shape as in the first embodiment. The abutting portion 103 extends from the end of the intermediate extending plate portion 132A opposite the connecting plate portion 131A in a direction approaching the edge portion 111 in the extending direction of the edge portions 112, 113 shown in Figs. 11 and 12. As shown in Fig. 14, the abutting portion 103 is disposed on the same side of the fixed portion 100 as the first extending portion 101A and the second extending portion 102A in the plate thickness direction of the fixed portion 100.

[0162] The abutting portion 103 has an abutting plate portion 141 that protrudes from the end of the intermediate extending plate portion 132A opposite the connecting plate portion 131A in a direction approaching the edge portion 111 in the extension direction of the edge portions 112, 113 shown in Figures 11 and 12. The abutting plate portion 141 is curved so that the center of curvature is located on the opposite side of the abutting plate portion 141 from the fixed portion 100 in the plate thickness direction of the fixed portion 100.

[0163] The intermediate plate portion 142 extends from the end of the abutting plate portion 141 opposite the intermediate extending plate portion 132A, approaching the edge portion 111 in the extending direction of the edge portions 112, 113 shown in Figures 11 and 12, and extending in a direction away from the fixed portion 100 in the plate thickness direction of the fixed portion 100 shown in Figure 14. The angle between the intermediate plate portion 142 and the intermediate extending plate portion 132A is an acute angle of less than 90 degrees.

[0164] The inwardly extending plate portion 143 extends from an end portion of the intermediate plate portion 142 opposite the abutting plate portion 141 to the opposite side of the fixed portion 100 in the plate thickness direction of the fixed portion 100. The inwardly extending plate portion 143 is curved so that the center of its curvature is located on the opposite side of the inwardly extending plate portion 143 to the edge portion 111 in the extension direction of the edge portions 112, 113 shown in Figures 11 and 12.

[0165] In the abutting portion 103, an edge portion 145 shown in FIG. 11 extends from the edge portion of the edge portion 134A opposite to the edge portion 128A shown in FIG. 13. The edge portion 145 shown in FIG. 11 is disposed on the same plane as the edge portion 134A. In the abutting portion 103, an edge portion 146 extends from the edge portion of the edge portion 135A opposite to the edge portion 129A. The edge portion 146 is disposed on the same plane as the edge portion 135A.

[0166] The lines extending along the thickness direction of the fixed portion 100, the first extending portion 101A, the second extending portion 102A, and the abutting portion 103 all pass through a single plane. The edge portions 112, 113, 124A, 125A, 134A, 135A, 145, and 146 are parallel to this plane.

[0167] 11 to 13 are provided so as to extend from at least one of the first extending portion 101A, the second extending portion 102A, and the abutting portion 103. Specifically, like the return spring 11, the return spring 11A has the cover portions 104 and 105 provided so as to extend from the intermediate plate portion 142 of the abutting portion 103.

[0168] As shown in Fig. 14, the cover plate portions 152 of the cover portions 104 and 105 extend to the opposite side of the first extending portion 101A and the second extending portion 102A from the fixed portion 100 in the plate thickness direction of the fixed portion 100. As shown in Fig. 14, the cover plate portions 152 of the cover portions 104 and 105 overlap the entire second extending portion 102A, the portion of the tip-side extending plate portion 203A of the first extending portion 101A on the second extending portion 102A side, and the tip portion of the inward extending plate portion 143 of the abutting portion 103 opposite the intermediate plate portion 142, all of which are surfaces of the second extending portion 102A, in the extending direction of the edge portions 134A and 135A shown in Fig. 11.

[0169] 11 to 13 covers at least a portion of edge portions 124A, 126A, 128A, 134A, and 145 shown in Fig. 11, 12, or 13. Specifically, cover plate portion 152 of cover portion 104 faces and covers a portion of edge portion 126A on the edge portion 128A side, all of edge portion 128A, all of edge portion 134A, and the tip end of edge portion 145 on the opposite side to edge portion 134A, in a direction perpendicular to edge portion 134A.

[0170] 11 to 14 covers at least a portion of edge portions 125A, 127A, 129A, 135A, and 146 shown in Fig. 11, 12, or 13. Specifically, cover plate portion 152 of cover portion 105 faces and covers a portion of edge portion 127A on the edge portion 129A side, all of edge portion 129A, all of edge portion 135A, and the tip end of edge portion 146 on the opposite side to edge portion 135A, in a direction perpendicular to edge portion 135A.

[0171] The return spring 11A is also attached to the ear portions 72 of the outer friction pad 8 shown in FIGS. 4 to 6 at the fixed portion 100 in the same manner as the return spring 11. With the return spring 11A attached, the friction pad 8 is supported by the recesses 51, 52 of the pair of outer side walls 26, 27 of the carrier 5, as in the first embodiment. Then, the base end extending plate portion 201A of the first extending portion 101A of the return spring 11A extends from the fixed portion 100 in a direction away from the friction pad 8 in the plate thickness direction of the friction pad 8. At this time, the tip end extending plate portion 203A of the first extending portion 101A of the return spring 11A extends from the fixed portion 100 in a direction away from the first side in the disc rotation direction. The second extending portion 102A of the return spring 11A extends from the tip-side extending plate portion 203A of the first extending portion 101A toward the inner side in the plate thickness direction of the friction pad 8. That is, the second extending portion 102A of the return spring 11A extends from the tip-side extending plate portion 203A of the first extending portion 101A in the pressing direction of the friction pad 8 by the caliper 6.

[0172] The second extending portion 102A, the contact portion 103, and the cover portions 104 and 105 of the return spring 11A, which are all located on the first side in the disk rotation direction relative to the fixed portion 100, are positioned to overlap with the outer side wall portion 26 in the disk rotation direction and the disk radial direction. The contact portion 103 of the return spring 11A extends from the second extending portion 102A and contacts the surface portion 45 of the outer side wall portion 26 of the carrier 5 at the contact plate portion 141. At this time, the contact portion 103 of the return spring 11A extends from the intermediate extending plate portion 132A of the second extending portion 102A in a direction away from the second side in the disk rotation direction.

[0173] In the return spring 11A, the edge portions 124A to 129A, 134A, 135A, 145, and 146 form surfaces facing the disc radial direction. In the return spring 11A, the cover portion 104 covers part of the edge portion 126A, all of the edge portions 128A and 134A, and the tip portion of the edge portion 145 on the disc radial outer side. In addition, the cover portion 105 covers part of the edge portion 127A, all of the edge portions 129A and 135A, and the tip portion of the edge portion 146 on the disc radial inner side.

[0174] The contact plate portion 141 of the contact portion 103 of the return spring 11A contacts the surface portion 45 of the outer side wall portion 26, restricting movement toward the disk 2. Therefore, when the outer friction pad 8 moves toward the disk 2 relative to the carrier 5 due to pressure from the caliper 6, the return spring 11A, which was in a standby state, elastically deforms mainly its first extension portion 101A and enters an elastically deformed state. As a result, the return spring 11A separates its fixed portion 100, which is fixed to the friction pad 8, from its contact portion 103, whose movement relative to the carrier 5 is restricted, in the disk axial direction.

[0175] Furthermore, when the pressure of the caliper 6 on the outer friction pad 8 is released, the return spring 11A, which was in an elastically deformed state, releases the elastic deformation of its first extension portion 101A, which had been elastically deformed up until then, and returns to its standby state. Then, the return spring 11A brings its fixed portion 100, which is fixed to the friction pad 8, and its abutting portion 103, which abuts against the carrier 5, closer to each other in the disk axial direction. As a result, the outer friction pad 8 moves to the opposite side of the carrier 5 from the disk 2 in the disk axial direction, and separates its lining 62 from the disk 2.

[0176] The return springs 12 to 14 are also modified to be common parts with the same shape as the return spring 11A, and are attached to the friction pads 8 and 9 in the same manner as in the first embodiment. The modified return springs 12 to 14 also operate in the same manner as the return spring 11A.

[0177] The return spring 11A of the second embodiment also includes edge portions 124A to 129A, 134A, 135A, 145, and 146, which are surfaces extending in the plate thickness direction between the first extending portion 101A, the second extending portion 102A, and the abutting portion 103. The return spring 11A also includes a cover portion 104 that covers at least a portion of the edge portions 124A, 126A, 128A, 134A, and 145, and a cover portion 105 that covers at least a portion of the edge portions 125A, 127A, 129A, 135A, and 146. Therefore, the cover portion 104 can prevent the edge portions 124A, 126A, 128A, 134A, and 145 from being exposed, and can prevent fingers from getting caught on the edge portions 124A, 126A, 128A, 134A, and 145. Furthermore, the cover portion 105 can prevent the edge portions 125A, 127A, 129A, 135A, and 146 from being exposed, and can prevent fingers from getting caught on the edge portions 125A, 127A, 129A, 135A, and 146. Therefore, the disc brake 1 provided with the return spring 11A and the like can be easily maintained.

[0178] Similarly, the return spring 11A has cover portions 104 and 105 extending from at least one of the first extending portion 101A, the second extending portion 102A, and the abutting portion 103. Specifically, the cover portions 104 and 105 of the return spring 11A extend from the intermediate plate portion 142 of the abutting portion 103. Therefore, the cover portions 104 and 105 can be molded integrally with the fixed portion 100, the first extending portion 101A, the second extending portion 102A, and the abutting portion 103. Therefore, the return spring 11A can be manufactured easily and inexpensively, and an increase in the number of assembly steps can be suppressed.

[0179] Similarly, the cover portions 104 and 105 of the return spring 11A are not curved portions that affect the generated spring load, but extend from the flat intermediate plate portion 142, which has little effect on the generated spring load. Therefore, the effect of the cover portions 104 and 105 on the generated spring load, i.e., on the spring performance, of the return spring 11A can also be suppressed.

[0180] Furthermore, the return spring 11A is provided with a distal end extending plate portion 203A that connects the protruding plate portion 121, the base end extending plate portion 201A, and the intermediate plate portion 202A of the first extending portion 101A to the second extending portion 102A in a direction different from that of the protruding plate portion 121, the base end extending plate portion 201A, the intermediate plate portion 202A, and the second extending portion 102A. This makes it easy to integrally mold the fixing portion 100, the protruding plate portion 121, the base end extending plate portion 201A, the intermediate plate portion 202A, the distal end extending plate portion 203A, the second extending portion 102A, and the abutting portion 103. This allows the return spring 11A to be manufactured easily and inexpensively.

[0181] Furthermore, the return spring 14A includes at least one of, specifically both, an intermediate plate portion 202A, which is a first curved portion provided on the first extending portion 101A and connected to the distal extending plate portion 203A, and a connecting plate portion 131A, which is a second curved portion provided on the second extending portion 102F and connected to the distal extending plate portion 203A. Therefore, the fixed portion 100, the protruding plate portion 121, the base end extending plate portion 201A, the intermediate plate portion 202A, the distal extending plate portion 203A, the second extending portion 102A, and the abutting portion 103 can be easily molded integrally. Therefore, the return spring 11A can be manufactured easily and inexpensively.

[0182] Furthermore, the return spring 11A is provided at a position where the cover portions 104, 105 overlap at least one of the intermediate plate portion 202A (the first curved portion) and the connecting plate portion 131A (the second curved portion), specifically the connecting plate portion 131A, in the plate thickness direction. Therefore, the cover portions 104, 105 can prevent at least one of the intermediate plate portion 202A and the connecting plate portion 131A, specifically the connecting plate portion 131A, from being exposed, and can prevent fingers from getting caught on the intermediate plate portion 202A and the connecting plate portion 131A. Therefore, the disc brake 1 provided with the return spring 11A and the like can be easily maintained.

[0183] Furthermore, in the return spring 11A, the cover portions 104 and 105 are provided at a predetermined distance from the intermediate plate portion 202A, which is the first curved portion, or the connecting plate portion 131A, which is the second curved portion, specifically, from both the intermediate plate portion 202A and the connecting plate portion 131A. This makes it easy to mold the cover portions 104 and 105 integrally with the fixed portion 100, the protruding plate portion 121, the base-end extending plate portion 201A, the intermediate plate portion 202A, the tip-end extending plate portion 203A, the second extending portion 102A, and the abutting portion 103. This allows the return spring 14A to be manufactured easily and inexpensively.

[0184] In the return spring 11A etc. of the second embodiment, similarly to the first embodiment, only one of the cover portions 104, 105 may be provided.

[0185] [Third embodiment] Next, the third embodiment will be described, focusing on the differences from the first embodiment, mainly with reference to Figures 15 to 18. Note that parts common to the first embodiment will be designated by the same names and symbols.

[0186] In the third embodiment, a return spring 11B is partially modified from the return spring 11 of the first embodiment. Return springs 12 to 14 are also modified in the same manner.

[0187] As shown in Figures 15 to 17, the return spring 11B has a mirror-symmetric shape and has a first extension portion 101B that is modified from the first extension portion 101, a second extension portion 102B that is modified from the second extension portion 102, and an abutment portion 103B that is partially modified from the abutment portion 103.

[0188] The first extending portion 101B is also plate-shaped and extends from the fixed portion 100 to one side in the thickness direction of the fixed portion 100. The first extending portion 101B has a substantially constant thickness and is partially curved in the thickness direction. The first extending portion 101B has a protruding plate portion 121B and an extending plate portion 122B.

[0189] 15 and 16, the protruding plate portion 121B is a curved plate that is curved in an arc shape in its thickness direction. The protruding plate portion 121B has the same radius of curvature as the protruding plate portion 121 of the return spring 11, and is longer in the circumferential direction than the protruding plate portion 121. The protruding plate portion 121B protrudes from the end of the fixed portion 100 opposite the edge portion 111 to one side in the thickness direction of the fixed portion 100. The protruding plate portion 121B is curved so that the center of curvature is located on the edge portion 111 side relative to the protruding plate portion 121B in the extension direction of the edge portions 112 and 113.

[0190] The extending plate portion 122B is flat and extends from an end of the protruding plate portion 121B opposite the fixed portion 100 to the opposite side of the fixed portion 100 in the plate thickness direction of the fixed portion 100. As shown in Fig. 18, the extending plate portion 122B forms an obtuse angle with the fixed portion 100 that is greater than 90 degrees. The extending plate portion 122B becomes more distant from the edge portion 111 in the extension direction of the edge portions 112, 113 shown in Figs. 15 and 16 as it approaches the extending tip side.

[0191] 16, the first extending portion 101B has an edge portion 124B and an edge portion 125B. The edge portions 124B and 125B are both surfaces that extend in the thickness direction of the first extending portion 101B.

[0192] Edge portion 124B is formed by protruding plate portion 121B and extending plate portion 122B. Edge portion 124B extends from the edge portion opposite edge portion 111 in the extension direction of edge portion 112. Edge portion 124B is flat and is disposed on the same plane as edge portion 112. Edge portion 125B is formed on protruding plate portion 121B and extending plate portion 122B. Edge portion 125B extends from the edge portion opposite edge portion 111 in the extension direction of edge portion 113. Edge portion 125B is flat and is disposed on the same plane as edge portion 113. Therefore, edge portion 125B faces away from edge portion 124B and is parallel to edge portion 124B.

[0193] 18, the second extending portion 102B extends from the end of the extending plate portion 122B opposite to the protruding plate portion 121B in the thickness direction of the fixed portion 100 to just before the fixed portion 100. The second extending portion 102B has a substantially constant thickness and is partially curved in the thickness direction. The second extending portion 102B has a connecting plate portion 131B and an intermediate extending plate portion 132B.

[0194] The connecting plate portion 131B is a curved plate that curves in an arc shape in its thickness direction. The connecting plate portion 131B extends from an end of the extending plate portion 122B opposite the protruding plate portion 121B to the opposite side of the edge portion 111 in the extending direction of the edge portions 112, 113 shown in Figures 15 and 16. The connecting plate portion 131B is curved so that the center of its curvature is located on the fixed portion 100 side in the thickness direction of the fixed portion 100 relative to the connecting plate portion 131B.

[0195] The intermediate extending plate portion 132B is flat and extends from the end of the connecting plate portion 131B opposite the extending plate portion 122B. The intermediate extending plate portion 132B extends from the connecting plate portion 131B so as to approach the fixed portion 100 in the plate thickness direction of the fixed portion 100. The intermediate extending plate portion 132B becomes more distant from the edge portion 111 in the extension direction of the edge portions 112, 113 as it approaches the extending tip side. As shown in FIG. 18 , the angle between the intermediate extending plate portion 132B and the extending plate portion 122B is an acute angle of less than 90 degrees.

[0196] 17, the second extending portion 102B has an edge portion 211B, an edge portion 212B, an edge portion 213B, an edge portion 214B, an edge portion 215B, and an edge portion 216B. The edge portions 211B to 216B are all surfaces that extend in the thickness direction of the second extending portion 102B.

[0197] As shown in FIG. 16, the edge portions 211B and 212B are formed on the connecting plate portion 131B.

[0198] Edge portion 211B extends from the edge of edge portion 124B on the opposite side to edge portion 112. Edge portion 211B is flat and is disposed on the same plane as edge portion 124B.

[0199] Edge portion 212B extends from the edge of edge portion 125B on the opposite side to edge portion 113. Edge portion 212B is planar and is disposed on the same plane as edge portion 125B. Therefore, edge portion 212B faces away from edge portion 211B and is parallel to edge portion 211B.

[0200] As shown in FIG. 17, the edge portions 213B and 214B are formed on the portion of the intermediate extending plate portion 132B on the connecting plate portion 131B side.

[0201] Edge portion 213B extends from the edge of edge portion 211B on the side opposite edge portion 124B. Edge portion 213B is flat and inclined relative to edge portion 211B.

[0202] Edge portion 214B extends from the edge portion of edge portion 212B on the opposite side to edge portion 125B. Edge portion 214B is flat and inclined relative to edge portion 212B.

[0203] The edge portions 213B and 214B face in opposite directions and are inclined relative to the edge portions 211B and 212B so that the further away from the edge portions 211B and 212B they are, the closer they become to each other.

[0204] The edge portions 215B and 216B are formed on the opposite side of the intermediate extending plate portion 132B from the connecting plate portion 131B.

[0205] Edge portion 215B extends from the edge of edge portion 213B on the opposite side to edge portion 211B. Edge portion 215B is flat and extends parallel to edge portion 211B.

[0206] Edge portion 216B extends from the edge of edge portion 214B opposite edge portion 212B. Edge portion 216B is planar and extends parallel to edge portion 212B. Therefore, edge portion 216B faces away from edge portion 215B and is parallel to edge portion 215B. The distance between edge portions 215B and 216B is shorter than the distance between edge portions 211B and 212B.

[0207] The abutment portion 103B is also plate-shaped, and as shown in FIG. 18, has an abutment plate portion 141B that is partially different from the abutment plate portion 141 of the return spring 11. The abutment plate portion 141B is curved in its thickness direction. The abutment plate portion 141B has the same radius of curvature as the abutment plate portion 141 of the return spring 11 and is longer in the circumferential direction than the abutment plate portion 141. The abutment plate portion 141B extends from the end of the intermediate extending plate portion 132B opposite the connecting plate portion 131B toward the fixed portion 100 in the thickness direction of the fixed portion 100. The abutment plate portion 141B is curved so that the center of curvature is located on the edge portion 111 side in the extension direction of the edge portions 112 and 113 shown in FIGS. 15 and 16 relative to the abutment plate portion 141B.

[0208] 18, the abutting portion 103B has an intermediate plate portion 142 extending from the end of the abutting plate portion 141B opposite the intermediate extending plate portion 132B. The angle formed by the intermediate plate portion 142 of the abutting portion 103B and the intermediate extending plate portion 132B is an acute angle of less than 90 degrees, which is smaller than the angle formed by the intermediate plate portion 142 and the intermediate extending plate portion 132 of the return spring 11. The angle formed by the intermediate plate portion 142 of the return spring 11B and the fixed portion 100 is equal to the angle formed by the intermediate plate portion 142 and the fixed portion 100 of the return spring 11.

[0209] As shown in Fig. 15, the contact portion 103B has an edge portion 145B and an edge portion 146B. The edge portions 145B and 146B are formed on the contact plate portion 141B, the intermediate plate portion 142, and the inward extending plate portion 143 shown in Fig. 18. Both the edge portions 145B and 146B are surfaces that extend in the plate thickness direction of the contact portion 103B.

[0210] Edge portion 145B shown in Fig. 15 extends from the edge portion opposite edge portion 213B of edge portion 215B shown in Fig. 17. Edge portion 145B shown in Fig. 15 is planar and is disposed in the same plane as edge portion 215B shown in Fig. 17.

[0211] Edge portion 146B shown in Fig. 15 extends from the edge portion opposite edge portion 214B of edge portion 216B shown in Fig. 17. Edge portion 146B shown in Fig. 15 is planar and is disposed on the same plane as edge portion 216B shown in Fig. 17. Therefore, edge portion 146B shown in Fig. 15 faces away from edge portion 145B and is parallel to edge portion 145B.

[0212] The lines extending along the thickness direction of the fixed portion 100, the first extending portion 101B, the second extending portion 102B, and the abutting portion 103B all pass through a single plane, and the edge portions 112, 113, 124B, 125B, 211B, 212B, 215B, 216B, 145B, and 146B are parallel to this plane.

[0213] The return spring 11B has cover portions 104 and 105 extending from at least one of the first extending portion 101B, the second extending portion 102B, and the contact portion 103B. Specifically, the return spring 11B has cover portions 104 and 105 extending from the intermediate plate portion 142 of the contact portion 103B, similar to the return spring 11.

[0214] As shown in Fig. 18, the cover plate portions 152 of the cover portions 104, 105 each extend to the opposite side of the first extending portion 101B and the second extending portion 102B from the fixed portion 100 in the plate thickness direction of the fixed portion 100. As shown in Fig. 18, the cover plate portions 152 of the cover portions 104, 105 overlap the positions in the extending direction of the edge portions 215B, 216B shown in Fig. 17, which are all surfaces of the second extending portion 102B, with a part of the connecting plate portion 131B on the intermediate extending plate portion 132B side, the intermediate extending plate portion 132B, a part of the abutting plate portion 141B on the intermediate extending plate portion 132B side, and the tip end of the inward extending plate portion 143 on the opposite side from the intermediate plate portion 142.

[0215] Cover plate portion 152 of cover portion 104 covers at least a portion of edge portions 124B, 211B, 213B, 215B, and 145B. Specifically, cover plate portion 152 of cover portion 104 faces and covers a portion of edge portion 211B on the edge portion 213B side, all of edge portion 213B, all of edge portion 215B, a portion of edge portion 145B on the edge portion 215B side, and the tip portion of edge portion 145B on the opposite side from edge portion 215B, in a direction perpendicular to edge portion 215B.

[0216] Cover plate portion 152 of cover portion 105 covers at least a portion of edge portions 125B, 212B, 214B, 216B, and 146B. Specifically, cover plate portion 152 of cover portion 105 faces and covers a portion of edge portion 212B on the edge portion 214B side, the entire edge portion 214B, the entire edge portion 216B, a portion of edge portion 146B on the edge portion 216B side, and the tip portion of edge portion 146B on the opposite side from edge portion 216B, in a direction perpendicular to edge portion 216B.

[0217] The return spring 11B is also attached to the ear portion 72 of the outer friction pad 8 shown in FIGS. 4 to 6 at the fixed portion 100 in the same manner as the return spring 11. With the return spring 11B attached, the friction pad 8 is supported by the recesses 51, 52 of the pair of outer side walls 26, 27 of the carrier 5, as in the first embodiment. Then, the first extension portion 101B of the return spring 11B extends from the fixed portion 100 in a direction away from the friction pad 8 in the thickness direction of the friction pad 8. At this time, the first extension portion 101B of the return spring 11B extends from the fixed portion 100 in a direction away from the first side in the disk rotation direction. The second extension portion 102B of the return spring 11B extends from the first extension portion 101B toward the inner side in the thickness direction of the friction pad 8. That is, the return spring 11B has a second extending portion 102B extending from the first extending portion 101B in the direction in which the caliper 6 presses the friction pad 8.

[0218] The second extending portion 102B, the contact portion 103B, and the cover portions 104 and 105 of the return spring 11B, which are all located on the first side in the disk rotation direction relative to the fixed portion 100, are positioned to overlap with the outer side wall portion 26 in the disk rotation direction and the disk radial direction. The contact portion 103B of the return spring 11B extends from the second extending portion 102B and contacts the surface portion 45 of the outer side wall portion 26 of the carrier 5 at the contact plate portion 141B. At this time, the contact portion 103B of the return spring 11B extends from the intermediate extending plate portion 132B of the second extending portion 102B to the second side in the disk rotation direction.

[0219] In the return spring 11B, the edge portions 124B, 125B, 211B to 216B, 145B, and 146B form surfaces facing the disc radial direction. In the return spring 11B, the cover portion 104 covers a part of the edge portion 211B, the entire edge portion 213B, the entire edge portion 215B, and the base end and tip end of the edge portion 145B on the disc radial outer side. In addition, the cover portion 105 covers a part of the edge portion 212B, the entire edge portion 214B, the entire edge portion 216B, and the base end and tip end of the edge portion 146B on the disc radial inner side.

[0220] The contact plate portion 141B of the contact portion 103B of the return spring 11B contacts the surface portion 45 of the outer side wall portion 26, restricting movement of the return spring 11B toward the disk 2. Therefore, when the outer friction pad 8 moves toward the disk 2 relative to the carrier 5 due to the pressure of the caliper 6, the return spring 11B, which was in a standby state, elastically deforms mainly its first extension portion 101B and its second extension portion 102B, and enters an elastically deformed state. As a result, the return spring 11B separates its fixed portion 100, which is fixed to the friction pad 8, from its contact portion 103B, whose movement relative to the carrier 5 is restricted, in the disk axial direction.

[0221] Furthermore, when the pressure from the caliper 6 is released, the return spring 11B, which was in an elastically deformed state, releases the elastic deformation of its first extension portion 101B and its second extension portion 102B, which had been elastically deformed up until then, and returns to its standby state. Then, the return spring 11B brings its fixed portion 100, which is fixed to the friction pad 8, and its abutting portion 103B, which abuts against the carrier 5, closer in the disk axial direction. As a result, the outer friction pad 8 moves toward the opposite side of the carrier 5 from the disk 2 in the disk axial direction, and separates its lining 62 from the disk 2.

[0222] The return springs 12 to 14 are also modified to be common parts with the same shape as the return spring 11B, and are attached to the friction pads 8 and 9 in the same manner as in the first embodiment. The modified return springs 12 to 14 also operate in the same manner as the return spring 11B.

[0223] The return spring 11B of the third embodiment also includes edge portions 124B, 125B, 211B to 216B, 145B, and 146B, which are surfaces extending in the plate thickness direction between the first extending portion 101B, the second extending portion 102B, and the abutting portion 103B. The return spring 11B also includes a cover portion 104 that covers at least a portion of the edge portions 124B, 211B, 213B, 215B, and 145B, and a cover portion 105 that covers at least a portion of the edge portions 125B, 212B, 214B, 216B, and 146B. Therefore, the cover portion 104 can prevent the edge portions 124B, 211B, 213B, 215B, and 145B from being exposed, thereby preventing fingers from getting caught on the edge portions 124B, 211B, 213B, 215B, and 145B. Furthermore, the cover portion 105 can prevent the edge portions 125B, 212B, 214B, 216B, and 146B from being exposed, and can prevent fingers from getting caught on the edge portions 125B, 212B, 214B, 216B, and 146B. Therefore, the disc brake 1 provided with the return spring 11B and the like can be easily maintained.

[0224] Similarly, the return spring 11B has cover portions 104 and 105 extending from at least one of the first extending portion 101B, the second extending portion 102B, and the abutting portion 103B. Specifically, the cover portions 104 and 105 of the return spring 11B extend from the intermediate plate portion 142 of the abutting portion 103B. Therefore, the cover portions 104 and 105 can be molded integrally with the fixed portion 100, the first extending portion 101B, the second extending portion 102B, and the abutting portion 103B. Therefore, the return spring 11B can be manufactured easily and inexpensively, and an increase in the number of assembly steps can be suppressed.

[0225] Similarly, the cover portions 104 and 105 of the return spring 11B are not provided on the curved portion that affects the generated spring load, but are provided by extending from the flat intermediate plate portion 142 that has little effect on the generated spring load. Therefore, the effect of the cover portions 104 and 105 on the generated spring load, i.e., on the spring performance, of the return spring 11B can also be suppressed.

[0226] In the return spring 11B etc. of the third embodiment, similarly to the first embodiment, only one of the cover portions 104, 105 may be provided.

[0227] [Fourth embodiment] Next, the fourth embodiment will be described, focusing on the differences from the second embodiment, mainly with reference to Figures 19 to 21. Note that parts common to the second embodiment will be designated by the same names and symbols.

[0228] In the fourth embodiment, a return spring 11C is partially modified from the return spring 11A of the second embodiment. The return spring 13 is similarly modified, and the return springs 12 and 14 are also modified in almost the same manner.

[0229] As shown in FIG. 19, the return spring 11C has a return spring main body 221C that does not have the cover portions 104 and 105 of the return spring 11A of the second embodiment. That is, the return spring main body 221C has the fixed portion 100, the first extending portion 101A, the second extending portion 102A, and the abutting portion 103, all of which are the same as those of the return spring 11A. On the other hand, the return spring main body 221C does not have the cover portions 104 and 105. Because the cover portion 104 is not provided, the edge portion 145 of the abutting portion 103 extends over the entire extension direction of the abutting portion 103. In this case, too, the edge portion 145 is disposed on the same plane as the edge portion 134A. Because the cover portion 105 is not provided, the edge portion 146 of the abutting portion 103 extends over the entire extension direction of the abutting portion 103. Again, edge portion 146 is disposed flush with edge portion 135A.

[0230] As shown in FIGS. 19 and 20, the return spring 11C has a cover portion 222C that covers at least a portion of the edge portions 124A, 126A, 128A, 134A, and 145 of the return spring main body 221C. Specifically, the cover portion 222C is provided on the distal extension plate portion 203A of the first extension portion 101A, and as shown in FIG. 20, covers the entire edge portion 126A and the entire edge portion 128A. Therefore, the cover portion 222C extends in the longitudinal direction of the edge portions 126A and 128A. The cover portion 222C is made of an elastic material such as rubber. The cover portion 222C is bonded and fixed to the return spring main body 221C. Specifically, the cover portion 222C is bonded to the return spring main body 221C by vulcanization adhesion.

[0231] 21, the cover portion 222C has an edge covering portion 231C, a protruding portion 232C, and a protruding portion 233C. In the cover portion 222C, the edge covering portion 231C, the protruding portion 232C, and the protruding portion 233C are seamlessly integrated together. In other words, the entire cover portion 222C is seamlessly molded as a single piece.

[0232] The edge covering portion 231C has a semicircular cross section perpendicular to the longitudinal direction. The contact surface of the edge covering portion 231C with the edge portions 126A and 128A shown in FIG. 20 is bonded to the edge portions 126A and 128A, thereby covering the edge portions 126A and 128A. As shown in FIG. 21, the length of the edge covering portion 231C in the thickness direction of the tip side extending plate portion 203A is longer than the thickness of the tip side extending plate portion 203A. The edge covering portion 231C protrudes on both sides beyond the tip side extending plate portion 203A in the thickness direction of the tip side extending plate portion 203A.

[0233] The protruding portion 232C is provided on the opposite side of the tip-side extending plate portion 203A in the thickness direction of the tip-side extending plate portion 203A from the abutting portion 103. The protruding portion 232C protrudes from the edge covering portion 231C toward the edge portion 127A.

[0234] The protruding portion 233C is provided closer to the contact portion 103 than the tip side extending plate portion 203A in the plate thickness direction of the tip side extending plate portion 203A. The protruding portion 233C protrudes from the edge covering portion 231C toward the edge portion 127A. The contact surfaces of the protruding portions 232C and 233C with the tip side extending plate portion 203A are also bonded to the tip side extending plate portion 203A.

[0235] The return spring 11C is also attached at its return spring body 221C to the ear portion 72 of the outer friction pad 8 shown in FIGS. 4 to 6 in the same manner as the return spring 11A.

[0236] With the return spring 11C attached, the friction pad 8 is supported by the recesses 51, 52 of the pair of outer side wall portions 26, 27 of the carrier 5, similar to the second embodiment. Then, the return spring 11C has the return spring main body 221C with the first extending portion 101A, the second extending portion 102A, and the contact portion 103 arranged in the same manner as the return spring 11A. Then, the return spring 11C brings the contact portion 103 into contact with the surface portion 45 of the outer side wall portion 26 of the carrier 5, similar to the return spring 11A.

[0237] In the return spring 11C, the edge portions 124A to 129A, 134A, 135A, 145, and 146 are surfaces facing the disc radial direction. In the return spring 11C, the cover portion 222C covers the entire edge portion 126A and the entire edge portion 128A of the return spring main body 221C on the outer side in the disc radial direction.

[0238] The return spring 11C has a return spring body 221C that operates in the same manner as the return spring 11A.

[0239] The return spring 12 is modified to be a component having a mirror-symmetrical shape to the return spring 11C, and is attached to the friction pad 8 in the same manner as in the second embodiment. The return spring 12 modified in this way is configured so that the cover portion having a mirror-symmetrical shape to the cover portion 222C covers the edge portions 127A, 129A of the return spring main body 221C. The return spring 12 modified in this way is configured so that the cover portion having a mirror-symmetrical shape to the cover portion 222C covers the return spring main body 221C on the outer side in the disc radial direction.

[0240] The return spring 13 is modified to be a common part having the same shape as the return spring 11C, and is attached to the friction pad 9 in the same manner as in the second embodiment. In the return spring 13 modified in this way, the cover portion 222C covers the return spring main body 221C on the outer side in the disc radial direction.

[0241] The return spring 14 is modified to be a component having a mirror-symmetrical shape to the return spring 11C, and is attached to the friction pad 9 in the same manner as in the second embodiment. The return spring 14 modified in this manner is configured so that the cover portion having a mirror-symmetrical shape to the cover portion 222C covers the edge portions 127A, 129A of the return spring main body 221C. The return spring 14 modified in this manner is configured so that the cover portion having a mirror-symmetrical shape to the cover portion 222C covers the return spring main body 221C on the outer side in the disc radial direction.

[0242] The return spring 11C of the fourth embodiment also includes edge portions 124A to 129A, 134A, 135A, 145, and 146, which are surfaces extending in the plate thickness direction of the first extending portion 101A, the second extending portion 102A, and the abutting portion 103. The return spring 11C also includes a cover portion 222C that covers at least a portion of the edge portions 124A to 129A, 134A, 135A, 145, and 146. Specifically, the return spring 11C includes a cover portion 222C that covers the edge portions 126A and 128A, which are at least a portion of the edge portions 124A, 126A, 128A, 134A, and 145. Therefore, the cover portion 222C can prevent the edges 124A, 126A, 128A, 134A, and 145 from being exposed, and the edges 124A, 126A, 128A, 134A, and 145 can be prevented from getting caught by fingers.

[0243] Furthermore, in the return spring 11C, the cover portion 222C is made of an elastic material, so that the cover portion 222C can be easily provided on an appropriate portion of the edge portions 124A to 129A, 134A, 135A, 145, and 146.

[0244] Here, the return spring 11C of the fourth embodiment has been described as being provided with a cover portion 222C that covers at least a portion of the edge portions 124A, 126A, 128A, 134A, and 145, but this is not limiting. For example, in addition to or instead of the cover portion 222C, a cover portion similar to the cover portion 222C may be provided so as to cover at least a portion of the edge portions 125A, 127A, 129A, 135A, and 146. In this case, similar changes are made to the return springs 12 to 14.

[0245] Furthermore, the return spring 11C of the fourth embodiment has a return spring main body 221C that does not have the cover portions 104 and 105 of the return spring 11A of the second embodiment, and the return spring main body 221C has cover portions 222C made of an elastic member provided on at least some of the edge portions 124A to 129A, 134A, 135A, 145, and 146 of the return spring main body 221C. However, this is not limited to this. For example, it is also possible to use a return spring main body that does not have the cover portions 104 and 105 of the return spring 11 of the first embodiment, and to provide cover portions similar to the cover portion 222C so as to cover at least some of the edge portions 124 to 127, 134, 135, 145, and 146 of the return spring main body. In addition, for example, it is possible to remove the cover portions 104 and 105 of the return spring 11B of the third embodiment and use the resultant return spring body as the return spring body, and provide a cover portion similar to cover portion 222C so as to cover at least a portion of the edge portions 124B, 125B, 211B to 216B, 145B, and 146B of this return spring body.

[0246] [Fifth embodiment] Next, the fifth embodiment will be described, focusing on the differences from the fourth embodiment, mainly with reference to Figures 22 to 24. Note that parts common to the fourth embodiment will be designated by the same names and symbols.

[0247] In the fifth embodiment, a return spring 11D is partially modified from the return spring 11C of the fourth embodiment, and the return springs 12 to 14 are also modified in the same manner.

[0248] As shown in FIG. 22, the return spring 11D has a cover portion 222D different from the cover portion 222C instead of the cover portion 222C.

[0249] The cover portion 222D is made of an elastic material such as rubber. The cover portion 222D is a separate member from the return spring main body 221C. The cover portion 222D is detachable from the return spring main body 221C. The cover portion 222D is fitted into and fixed to the return spring main body 221C. The cover portion 222D may be fixed to the return spring main body 221C with an adhesive to make it difficult to attach or detach.

[0250] The cover portion 222D covers at least a part of the edge portions 124A to 129A, 134A, 135A, 145, and 146 of the return spring main body 221C. Specifically, the cover portion 222D is provided on the tip-side extending plate portion 203A of the first extending portion 101A, and covers the entire edge portion 126A, the entire edge portion 127A, a part of the edge portion 128A on the edge portion 126A side, and a part of the edge portion 129A on the edge portion 127A side, as shown in FIG.

[0251] 24, the cover portion 222D has an intermediate covering portion 241D, an edge covering portion 242D, an edge covering portion 243D, a locking portion 244D, and a locking portion 245D. In the cover portion 222D, the intermediate covering portion 241D, the edge covering portion 242D, the edge covering portion 243D, the locking portion 244D, and the locking portion 245D are seamlessly integrated. In other words, the entire cover portion 222D is seamlessly molded as a single piece.

[0252] The intermediate covering portion 241D covers the side of the tip-side extending plate portion 203A opposite to the abutting portion 103 in the plate thickness direction.

[0253] The edge covering portion 242D extends from the edge portion on the edge portion 126A side of the intermediate covering portion 241D so as to cover the edge portions 126A and 128A shown in FIG. 23 and is in contact with the edge portions 126A and 128A.

[0254] As shown in FIG. 24, the edge covering portion 243D extends from the edge portion on the edge portion 127A side of the intermediate covering portion 241D to cover the edge portions 127A and 129A as shown in FIG. 23, and is in contact with the edge portions 127A and 129A.

[0255] 24, the locking portion 244D protrudes from the edge of the edge covering portion 242D opposite to the intermediate covering portion 241D toward the edge portion 127A. The locking portion 244D contacts the abutment portion 103 side in the thickness direction of the tip-side extending plate portion 203A. As a result, the intermediate covering portion 241D and the locking portion 244D sandwich the edge of the tip-side extending plate portion 203A on the side of the edge portions 126A and 128A shown in FIG. 23.

[0256] 24, the locking portion 245D protrudes from the edge of the edge covering portion 243D opposite to the intermediate covering portion 241D toward the edge portion 126A. The locking portion 245D contacts the abutment portion 103 side in the plate thickness direction of the tip-side extending plate portion 203A. As a result, the intermediate covering portion 241D and the locking portion 245D sandwich the edge of the tip-side extending plate portion 203A on the side of the edge portions 127A and 129A shown in FIG.

[0257] The return spring body 221C of the return spring 11D is also attached to the ear portion 72 of the outer friction pad 8 shown in FIGS. 4 to 6 in the same manner as the return spring body 221C of the return spring 11C.

[0258] With the return spring 11D attached, the friction pad 8 is supported by the recesses 51, 52 of the pair of outer sidewalls 26, 27 of the carrier 5, as in the third embodiment. Then, the return spring 11D has the return spring main body 221C with the first extending portion 101A, the second extending portion 102A, and the abutting portion 103 arranged in the same manner as the return spring main body 221C of the return spring 11C, i.e., in the same manner as the return spring 11A. Then, the return spring 11D also abuts the abutting plate portion 141 of the abutting portion 103 against the surface portion 45 of the outer sidewall 26 of the carrier 5.

[0259] In this state, the return spring 11D is configured such that the cover portion 222D covers the entire edge portion 126A and a portion of the edge portion 128A on the edge portion 126A side on the radially outer side of the disk. Also, in this state, the return spring 11D is configured such that the cover portion 222D covers the entire edge portion 127A and a portion of the edge portion 129A on the edge portion 127A side on the radially inner side of the disk.

[0260] The return spring 11D also has a return spring main body 221C that operates in the same manner as the return spring 11A.

[0261] The return springs 12 to 14 are also modified to be common parts having the same shape as the return spring 11D, and are attached to the friction pads 8 and 9 in the same manner as in the fourth embodiment.

[0262] The return spring 11D of the fifth embodiment also includes a cover portion 222D that covers at least a portion of the edge portions 124A to 129A, 134A, 135A, 145, and 146, specifically, the edge portions 126A to 129A. Therefore, the cover portion 222D can prevent the edge portions 124A to 129A, 134A, 135A, 145, and 146 from being exposed, and can prevent fingers from getting caught on the edge portions 124A to 129A, 134A, 135A, 145, and 146.

[0263] Furthermore, in the return spring 11D, the cover portion 222D is made of an elastic material, so that the cover portion 222C can be easily provided on an appropriate portion of the edge portions 124A to 129A, 134A, 135A, 145, and 146.

[0264] Furthermore, in the return spring 11D, the cover portion 222D is made of a separate material from the return spring main body 221C having the first extension portion 101A, the second extension portion 102A, and the abutment portion 103, so that if the cover portion 222C, for example, deteriorates, it is easy to replace only the cover portion 222C.

[0265] Here, the return spring 11D of the fifth embodiment can also be modified in the same way as the return spring 11C of the fourth embodiment. That is, it is possible to use a return spring main body that does not have the cover portions 104 and 105 of the return spring 11 of the first embodiment, and to provide a cover portion similar to the cover portion 222D so as to cover at least a portion of the edge portions 124 to 127, 134, 135, 145, and 146 of this return spring main body. Furthermore, for example, it is also possible to use a return spring main body that does not have the cover portions 104 and 105 of the return spring 11B of the third embodiment, and to provide a cover portion similar to the cover portion 222D so as to cover at least a portion of the edge portions 124B, 125B, 211B to 216B, 145B, and 146B of this return spring main body.

[0266] [Sixth embodiment] Next, the sixth embodiment will be described, focusing on the differences from the fourth embodiment, mainly with reference to Figures 25 to 27. Note that parts common to the fourth embodiment will be designated by the same names and symbols.

[0267] In the sixth embodiment, a return spring 11E is partially modified from the return spring 11C of the fourth embodiment. The return spring 13 is similarly modified, and the return springs 12 and 14 are also modified in almost the same manner.

[0268] 25 to 27, the return spring 11E has a cover portion 222E different from the cover portion 222C instead of the cover portion 222C. As shown in Fig. 25, the cover portion 222E covers at least a portion of the edge portions 124A to 129A, 134A, 135A, 145, and 146 of the return spring main body 221C. Specifically, the cover portion 222E is provided on the first extending portion 101A and the second extending portion 102A, and covers a portion of the edge portion 124A on the edge portion 126A side, the entire edge portion 126A, the entire edge portion 128A, and the entire edge portion 134A.

[0269] The cover portion 222E extends along the extension direction of the edge portions 124A, 126A, 128A, and 134A. The cover portion 222E is made of a resin member. The cover portion 222E is fixed to the return spring main body 221C, for example, by being applied and cured. As shown in FIG. 27, the cross section of the cover portion 222E perpendicular to the longitudinal direction is semicircular. As shown in FIG. 25, the contact surfaces of the cover portion 222E with the edge portions 124A, 126A, 128A, and 134A are fixed to the edge portions 124A, 126A, 128A, and 134A. The cover portion 222E is provided on the edge portions 124A, 126A, 128A, and 134A and covers the edge portions 124A, 126A, 128A, and 134A.

[0270] The return spring body 221C of the return spring 11E is also attached to the ear portion 72 of the outer friction pad 8 shown in FIGS. 4 to 6 in the same manner as the return spring body 221C of the return spring 11C.

[0271] With the return spring 11E attached, the friction pad 8 is supported by the recesses 51, 52 of the pair of outer sidewalls 26, 27 of the carrier 5, as in the fourth embodiment. Then, the return spring main body 221C of the return spring 11E has the first extending portion 101A, the second extending portion 102A, and the abutting portion 103 arranged in the same manner as the return spring main body 221C of the return spring 11C, i.e., in the same manner as the return spring 11A. Then, the return spring 11E also abuts the abutting plate portion 141 of the abutting portion 103 against the surface portion 45 of the outer sidewall 26 of the carrier 5.

[0272] The return spring 11E also has a return spring main body 221C that operates in the same manner as the return spring 11A.

[0273] The return spring 12 is modified to be a component having a mirror-symmetrical shape to the return spring 11E, and is attached to the friction pad 8 in the same manner as in the fourth embodiment. The return spring 12 modified in this manner is configured so that the cover portion having a mirror-symmetrical shape to the cover portion 222E covers the edge portions 124A, 127A, 129A, and 135A of the return spring main body 221C. The return spring 12 modified in this manner is configured so that the cover portion having a mirror-symmetrical shape to the cover portion 222E covers the return spring main body 221C on the outer side in the disc radial direction.

[0274] The return spring 13 is modified to be a common part having the same shape as the return spring 11E, and is attached to the friction pad 9 in the same manner as in the fourth embodiment. In the return spring 13 modified in this way, a cover portion similar to the cover portion 222E covers the return spring main body 221C on the outer side in the disc radial direction.

[0275] The return spring 14 is modified to be a component having a mirror-symmetrical shape to the return spring 11E, and is attached to the friction pad 9 in the same manner as in the fourth embodiment. The return spring 14 modified in this manner is configured so that the cover portion having a mirror-symmetrical shape to the cover portion 222E covers the edge portions 124A, 127A, 129A, and 135A of the return spring main body 221C. The return spring 14 modified in this manner is configured so that the cover portion having a mirror-symmetrical shape to the cover portion 222E covers the return spring main body 221C on the outer side in the disc radial direction.

[0276] The return spring 11E of the sixth embodiment also includes a cover portion 222E that covers at least a portion of the edge portions 124A to 129A, 134A, 135A, 145, and 146 of the return spring main body 221C. Specifically, the return spring 11E includes a cover portion 222E that covers the edge portions 124A, 126A, 128A, and 134A, which are at least a portion of the edge portions 124A, 126A, 128A, 134A, and 145. Therefore, the cover portion 222E can prevent the edge portions 124A, 126A, 128A, 134A, and 145 from being exposed, and can prevent fingers from getting caught on the edge portions 124A, 126A, 128A, 134A, and 145.

[0277] Furthermore, in the return spring 11E, the cover portion 222E is made of resin, so that the cover portion 222E can be easily provided on an appropriate portion of the edge portions 124A to 129A, 134A, 135A, 145, and 146.

[0278] Here, the return spring 11E of the sixth embodiment has been described as being provided with a cover portion 222E that covers at least a portion of the edge portions 124A, 126A, 128A, 134A, and 145, but this is not limiting. For example, in addition to or instead of the cover portion 222E, a cover portion similar to the cover portion 222E may be provided so as to cover at least a portion of the edge portions 125A, 127A, 129A, 135A, and 146. In this case, the same modifications are made to the return springs 12 to 14.

[0279] The return spring 11E of the sixth embodiment can also be modified in the same manner as the return spring 11C of the fourth embodiment. That is, it is possible to use a return spring main body that does not have the cover portions 104 and 105 of the return spring 11 of the first embodiment, and to provide a cover portion similar to the cover portion 222E so as to cover at least a portion of the edge portions 124 to 127, 134, 135, 145, and 146 of this return spring main body. Also, for example, it is possible to use a return spring main body that does not have the cover portions 104 and 105 of the return spring 11B of the third embodiment, and to provide a cover portion similar to the cover portion 222E so as to cover at least a portion of the edge portions 124B, 125B, 211B to 216B, 145B, and 146B of this return spring main body.

[0280] [Seventh embodiment] Next, the seventh embodiment will be described, focusing on the differences from the first embodiment, mainly with reference to Figures 28 to 35. Note that parts common to the first embodiment will be designated by the same names and symbols.

[0281] In the seventh embodiment, as shown in Figures 28 to 30, a return spring 13F, which is a partial modification of the return spring 13 of the first embodiment, is provided instead of the return spring 13, and a return spring 14F, which is a partial modification of the return spring 14, is provided instead of the return spring 14. In the seventh embodiment, as shown in Figure 30, a return spring 11F, which is a partial modification of the return spring 11, is provided instead of the return spring 11, and a return spring 12F, which is a partial modification of the return spring 12, is provided instead of the return spring 12. The return springs 11F to 14F are also common parts having the same shape. For this reason, the following description will be given taking as an example the return spring 13F attached to the first side in the disc rotation direction of the inner friction pad 9.

[0282] 31 to 35, the return spring 13F has a mirror-symmetric shape. As shown in FIGS. 31 to 34, the return spring 13F has a first extending portion 101F that is a modification of the first extending portion 101, a second extending portion 102F that is a modification of the second extending portion 102, and a connecting portion 203F that connects the first extending portion 101F and the second extending portion 102F. The return spring 13F has a cover portion 104F shown in FIGS. 31, 32, and 34 that is provided in place of the cover portion 104, and a cover portion 105F shown in FIGS. 31 to 33 that is provided in place of the cover portion 105.

[0283] The first extending portion 101F is plate-shaped and extends from the fixed portion 100 to one side in the thickness direction of the fixed portion 100. The first extending portion 101F has a substantially constant thickness and is partially curved in the thickness direction. The first extending portion 101F has a protruding plate portion 121 similar to that of the first embodiment, a base-end extending plate portion 201F, and a first curved portion 202F.

[0284] The base-end extending plate portion 201F is flat and extends from the end of the protruding plate portion 121 opposite the fixed portion 100 to the opposite side of the fixed portion 100 in the plate thickness direction of the fixed portion 100. As shown in Figures 33 and 34, the base-end extending plate portion 201F forms an acute angle with the fixed portion 100 that is less than 90 degrees.

[0285] The first curved portion 202F is a curved plate that curves in an arc shape in its thickness direction. The first curved portion 202F protrudes from the end of the base-end extending plate portion 201F opposite the protruding plate portion 121 to the opposite side from the edge portion 111 in the extension direction of the edge portions 112, 113. The first curved portion 202F is curved so that the center of curvature is located on the fixed portion 100 side in the thickness direction of the fixed portion 100 relative to the first curved portion 202F.

[0286] 31 and 32, the first extending portion 101F has an edge portion 124F and an edge portion 125F. The edge portions 124F and 125F are both surfaces that extend in the thickness direction of the first extending portion 101F.

[0287] 32, edge portion 124F is formed on protruding plate portion 121, base-end extending plate portion 201F, and first curved portion 202F. Edge portion 124F extends from the edge portion on the opposite side of edge portion 111 in the extension direction of edge portion 112. Edge portion 124F is flat and is disposed on the same plane as edge portion 112.

[0288] 31, edge portion 125F is formed on protruding plate portion 121, base-end extending plate portion 201F, and first curved portion 202F. Edge portion 125F extends from the edge portion opposite edge portion 111 in the extension direction of edge portion 113. Edge portion 125F is flat and is disposed on the same plane as edge portion 113. Therefore, edge portion 125F faces away from edge portion 124F and is parallel to edge portion 124F.

[0289] As shown in FIGS. 32 and 35, a through-hole 247F is formed in the first curved portion 202F at the center position between the edge portions 124F and 125F, penetrating the first curved portion 202F in the thickness direction.

[0290] 33 and 34, the connecting portion 203F is flat and extends from an end of the first bending portion 202F opposite the base-end extending plate portion 201F in the opposite direction to the edge portion 111 in the extending direction of the edge portions 112, 113. The connecting portion 203F is aligned with the fixing portion 100. The angle formed by the connecting portion 203F and the base-end extending plate portion 201F is an acute angle of less than 90 degrees.

[0291] The second extending portion 102F is plate-shaped and extends from the end of the connecting portion 203F opposite to the first curved portion 202F in the thickness direction of the fixed portion 100 to just before the fixed portion 100. The second extending portion 102F has a substantially constant thickness and is partially curved in the thickness direction. The second extending portion 102F has a second curved portion 131F and an intermediate extending plate portion 132F.

[0292] The second curved portion 131F protrudes from the end of the connecting portion 203F opposite to the first curved portion 202F toward the fixed portion 100 in the plate thickness direction of the fixed portion 100. The second curved portion 131F is curved in an arc shape in the plate thickness direction. The second curved portion 131F is curved so that the center of curvature is located on the edge portion 111 side in the extension direction of the edge portions 112 and 113 with respect to the second curved portion 131F.

[0293] The intermediate extending plate portion 132F is flat and extends from the end of the second curved portion 131F opposite the connecting portion 203F. The intermediate extending plate portion 132F extends from the second curved portion 131F so as to approach the fixed portion 100 in the plate thickness direction of the fixed portion 100. The intermediate extending plate portion 132F approaches the edge portion 111 in the extension direction of the edge portions 112, 113 as it extends toward the tip end. The angle formed by the intermediate extending plate portion 132F and the connecting portion 203F is an acute angle of less than 90 degrees.

[0294] As described above, in the return spring 13F, the connecting portion 203F connects the first extending portion 101F and the second extending portion 102F in a direction different from the first extending portion 101F and the second extending portion 102F. The return spring 13F also includes a first curved portion 202F provided on the first extending portion 101F and connected to the connecting portion 203F, and a second curved portion 131F provided on the second extending portion 102F and connected to the connecting portion 203F. The return spring 13F may include only one of the first curved portion 202F and the second curved portion 131F. As shown in FIGS. 31 and 32, the return spring 13F has cover portions 104F and 105F extending from the connecting portion 203F.

[0295] The second extending portion 102F has an edge portion 134F shown in Fig. 32 and an edge portion 135F shown in Fig. 31. The edge portions 134F, 135F are both formed on the second curved portion 131F and the intermediate extending plate portion 132F. The edge portions 134F, 135F are both surfaces that extend in the plate thickness direction of the second extending portion 102F. As shown in Fig. 35, the distance between the edge portions 134F, 135F of the second extending portion 102F is shorter than the distance between the edge portions 124F, 125F of the first extending portion 101F.

[0296] 33 and 34, the abutment portion 103 has the same shape as in the first embodiment. The abutment portion 103 extends from the end of the intermediate extending plate portion 132F opposite the second curved portion 131F to just before the first extending portion 101F in a direction approaching the edge portion 111 in the extending direction of the edge portions 112 and 113. The abutment portion 103 is disposed on the same side of the fixed portion 100 as the first extending portion 101F and the second extending portion 102F in the plate thickness direction of the fixed portion 100.

[0297] The abutment portion 103 has an abutment plate portion 141 that protrudes from the end of the intermediate extending plate portion 132F opposite the second curved portion 131F in a direction approaching the edge portion 111 in the extension direction of the edge portions 112, 113. The abutment plate portion 141 is curved so that the center of its curvature is located on the opposite side of the abutment plate portion 141 from the fixed portion 100 in the plate thickness direction of the fixed portion 100.

[0298] The intermediate plate portion 142 extends from the end of the abutting plate portion 141 opposite the intermediate extending plate portion 132F, approaching the edge portion 111 in the extension direction of the edge portions 112, 113, and away from the fixed portion 100 in the plate thickness direction of the fixed portion 100. The angle between the intermediate plate portion 142 and the intermediate extending plate portion 132F is an acute angle of less than 90 degrees.

[0299] The inwardly extending plate portion 143 extends from the end of the intermediate plate portion 142 opposite the abutting plate portion 141 to the opposite side of the fixed portion 100 in the plate thickness direction of the fixed portion 100. The inwardly extending plate portion 143 is curved so that the center of its curvature is located on the opposite side of the inwardly extending plate portion 143 to the edge portion 111 in the extension direction of the edge portions 112, 113.

[0300] The abutting portion 103 has an edge portion 145 shown in FIG. 32 extending from the edge portion of the edge portion 134F opposite to the cover portion 104F. The edge portion 145 is disposed on the same plane as the edge portion 134F. The abutting portion 103 has an edge portion 146 shown in FIG. 31 extending from the edge portion of the edge portion 135F opposite to the cover portion 105F. The edge portion 146 is disposed on the same plane as the edge portion 135F.

[0301] The lines extending along the thickness direction of the fixing portion 100, the first extending portion 101F, the connecting portion 203F, the second extending portion 102F, and the abutting portion 103 all pass through a single plane. The edge portions 112, 113, 124F, 125F, 134F, 135F, 145, and 146 are parallel to this plane.

[0302] As shown in Fig. 32, the cover portion 104F extends from between the edge portion 124F and the edge portion 134F. As shown in Fig. 31, the cover portion 105F extends from between the edge portion 125F and the edge portion 135F. The pair of cover portions 104F, 105F have mirror-symmetric shapes. Both of the cover portions 104F, 105F have a substantially constant plate thickness and are partially curved in the plate thickness direction. Both of the cover portions 104F, 105F have a base end plate portion 151F and a cover plate portion 152F.

[0303] 32, the base end plate portion 151F of the cover portion 104F protrudes from between the edge portion 124F and the edge portion 134F. The base end plate portion 151F of the cover portion 104F protrudes perpendicularly to the surfaces of the edge portions 124F and 134F, and curves toward the abutment portion 103 in the plate thickness direction of the connection portion 203F.

[0304] The cover plate 152F of the cover portion 104F is flat and extends from the end of the base end plate 151F of the cover portion 104F opposite the connecting portion 203F in the thickness direction of the connecting portion 203F toward the abutting portion 103. The cover plate 152F of the cover portion 104F extends parallel to and spaced a predetermined distance from the edge portions 124F and 134F, which are surfaces.

[0305] The cover portion 104F covers at least a portion of the edge portions 124F, 134F, and 145. The cover portion 104F is provided at a position overlapping at least a portion of the first curved portion 202F and the second curved portion 131F in the plate thickness direction.

[0306] Specifically, as shown in FIG. 34, the cover portion 104F is provided at a position overlapping the second curved portion 131F in the thickness direction of the second curved portion 131F, and at a predetermined distance from the second curved portion 131F in the direction perpendicular to the edge portion 134F (surface) as shown in FIG. 32. In other words, the cover portion 104F overlaps the second curved portion 131F of the second extending portion 102F in the direction in which the edge portion 134F (surface) extends. In yet another way, the cover portion 104F faces the edge constituent portion 251F formed on the second curved portion 131F of the edge portion 134F in the direction perpendicular to the edge portion 134F (surface), and covers the edge constituent portion 251F at a position separated by a predetermined distance from the edge constituent portion 251F. The cover portion 104F overlaps the entire edge constituent portion 251F in the thickness direction of the second curved portion 131F.

[0307] Here, the cover portion 104F may be provided at a position overlapping the first bending portion 202F in the thickness direction of the first bending portion 202F, and at a predetermined distance from the edge constituent portion 248F in a direction perpendicular to the edge constituent portion 248F provided in the first bending portion 202F of the edge portion 124F so as to cover the edge constituent portion 248F. Furthermore, the cover portion 104F may be provided at a position overlapping the first bending portion 202F in the thickness direction of the first bending portion 202F and at a position overlapping the second bending portion 131F in the thickness direction of the second bending portion 131F, with respect to both the first bending portion 202F and the second bending portion 131F, so as to cover the edge constituent portions 248F, 251F at a predetermined distance from the edge constituent portions 248F, 251F in a direction perpendicular to the edge constituent portions 248F, 251F.

[0308] 31, the base end plate portion 151F of the cover portion 105F protrudes from between the edge portion 125F and the edge portion 135F. The base end plate portion 151F of the cover portion 105F protrudes perpendicularly to the surfaces of the edge portions 125F and 135F, and curves toward the abutment portion 103 in the plate thickness direction of the connection portion 203F.

[0309] The cover plate portion 152F of the cover portion 105F is flat. The cover plate portion 152F of the cover portion 105F extends from the end of the base end plate portion 151F of the cover portion 105F opposite the connecting portion 203F in the thickness direction of the connecting portion 203F toward the abutting portion 103. The cover plate portion 152F of the cover portion 105F extends parallel to and spaced a predetermined distance from the edge portions 125F and 135F, which are surfaces. Therefore, the cover plate portions 152F of the cover portions 104F and 105F extend parallel to each other.

[0310] The cover portion 105F covers at least a portion of the edge portions 125F, 135F, and 146. The cover portion 105F is provided at a position overlapping at least a portion of the first curved portion 202F and the second curved portion 131F in the plate thickness direction.

[0311] Specifically, as shown in FIG. 33, the cover portion 105F is provided at a position overlapping the second curved portion 131F in the thickness direction of the second curved portion 131F, and at a predetermined distance from the second curved portion 131F in the direction perpendicular to the edge portion 135F (face) as shown in FIG. 31. In other words, the cover portion 105F overlaps the second curved portion 131F of the second extending portion 102F in the direction in which the edge portion 135F (face) extends. In further words, the cover portion 105F faces the edge constituent portion 252F formed on the second curved portion 131F of the edge portion 135F in the direction perpendicular to the edge portion 135F (face), and covers the edge constituent portion 252F at a position separated by a predetermined distance from the edge constituent portion 252F. The cover portion 105F overlaps the entire edge constituent portion 252F in the thickness direction of the second curved portion 131F.

[0312] Here, the cover portion 105F may be provided at a position overlapping the first bending portion 202F in the thickness direction of the first bending portion 202F, and at a predetermined distance from the edge constituent portion 249F in a direction perpendicular to the edge constituent portion 249F provided in the first bending portion 202F of the edge portion 125F so as to cover the edge constituent portion 249F. Furthermore, the cover portion 105F may be provided at a position overlapping the first bending portion 202F in the thickness direction of the first bending portion 202F and at a position overlapping the second bending portion 131F in the thickness direction of the second bending portion 131F, with respect to both the first bending portion 202F and the second bending portion 131F, so as to cover the edge constituent portions 249F, 252F at a predetermined distance from the edge constituent portions 249F, 252F in a direction perpendicular to the edge constituent portions 249F, 252F.

[0313] 28 and 29, the return spring 13F is attached to the ear portion 73 of the inner-side friction pad 9 in the same manner as the return spring 13. At this time, the return spring 13F is arranged so that the first extending portion 101F, the connecting portion 203F, the second extending portion 102F, and the cover portions 104F and 105F shown in FIG. 28, and the abutting portion 103 shown in FIG. 30 are located on the opposite side of the fixing portion 100 from the main plate portion 71.

[0314] When the return spring 13F is fixed to the friction pad 9, the connecting portion 203F, the second extending portion 102F, and the cover portions 104F and 105F shown in Fig. 28, and the abutting portion 103 shown in Fig. 30, protrude beyond the ear portion 73 to the side opposite the main plate portion 71. In this state, of the connecting portion 203F, the second extending portion 102F, and the cover portions 104F and 105F shown in Fig. 28, and the abutting portion 103 shown in Fig. 30, the abutting plate portion 141 of the abutting portion 103 is positioned closest to the back plate 61 in the thickness direction of the back plate 61 of the friction pad 9.

[0315] The return spring 14F is fixed to the lug 72 of the inner friction pad 9 in a state where it is arranged in mirror symmetry with the return spring 13F and is prevented from rotating. At this time, the return spring 14F is arranged so that the first extending portion 101F, the connecting portion 203F, the second extending portion 102F, the abutting portion 103, and the cover portions 104F and 105F shown in FIG. 28 are located on the opposite side of the fixing portion 100 from the main plate portion 71.

[0316] When the return spring 14F is fixed to the friction pad 9, the connecting portion 203F, the second extending portion 102F, the abutting portion 103, and the cover portions 104F and 105F protrude beyond the ear portions 72 to the side opposite the main plate portion 71. In this state, of the connecting portion 203F, the second extending portion 102F, the abutting portion 103, and the cover portions 104F and 105F of the return spring 14F, the abutting plate portion 141 of the abutting portion 103 shown in FIG. 30 is positioned closest to the back plate 61 in the thickness direction of the back plate 61 of the friction pad 9.

[0317] 30, the return spring 11F is fixed to the ear portion 72 of the outer friction pad 8 in a manner that prevents it from rotating, similar to the return spring 14F. At this time, the return spring 11F is arranged so that the first extending portion 101F, the connecting portion 203F, the second extending portion 102F, the abutting portion 103, and the cover portions 104F and 105F are located on the opposite side of the fixing portion 100 from the main plate portion 71.

[0318] When the return spring 11F is fixed to the friction pad 8, the connecting portion 203F, the second extending portion 102F, the contact portion 103, and the cover portions 104F and 105F protrude beyond the ear portion 72 to the side opposite the main plate portion 71. In this state, of the connecting portion 203F, the second extending portion 102F, the contact portion 103, and the cover portions 104F and 105F of the return spring 11F, the contact plate portion 141 of the contact portion 103 is positioned closest to the back plate 61 of the friction pad 8 in the thickness direction of the back plate 61.

[0319] The return spring 12F is fixed to the ear 73 of the outer friction pad 8 in a manner that prevents it from rotating, similar to the return spring 13F. At this time, the return spring 12F is arranged so that the first extending portion 101F, the connecting portion 203F, the second extending portion 102F, the abutting portion 103, and the cover portions 104F and 105F are located on the opposite side of the fixing portion 100 from the main plate portion 71.

[0320] When the return spring 12F is fixed to the friction pad 8, the connecting portion 203F, the second extending portion 102F, the abutting portion 103, and the cover portions 104F and 105F protrude from the ear portion 73 to the opposite side of the main plate portion 71. In this state, of the connecting portion 203F, the second extending portion 102F, the abutting portion 103, and the cover portions 104F and 105F of the return spring 12F, the abutting plate portion 141 of the abutting portion 103 is positioned closest to the back plate 61 of the friction pad 8 in the thickness direction of the back plate 61.

[0321] 28, with the return springs 13F and 14F attached, the inner-side friction pad 9 is supported by the recess 53 of the inner side wall portion 23 of the carrier 5 and the recess 54 of the inner side wall portion 22, which is mirror-symmetrical to the recess 53. As a result, both of the pair of return springs 13F and 14F are disposed on the inner side of the inner-side friction pad 9. Furthermore, the return spring 13F, which is one of the return springs 13F and 14F, is disposed on the first side in the disk rotation direction. Furthermore, the other return spring 14F, which is the other of the return springs 13F and 14F, is disposed on the second side in the disk rotation direction.

[0322] 31 or 32 face in the disc radial direction. In the return spring 13F, the cover portion 104F covers the entire edge constituent portion 251F of the edge portion 134F on the outer side in the disc rotation direction, on the inner side in the disc radial direction. In the return spring 13F, the cover portion 105F covers the entire edge constituent portion 252F of the edge portion 135F on the outer side in the disc rotation direction, on the outer side in the disc radial direction.

[0323] 28, the return spring 13F has a first extending portion 101F extending from the fixed portion 100 in a direction away from the friction pad 9 in the thickness direction of the friction pad 9. The return spring 13F also has a connecting portion 203F extending from an inner edge of the first extending portion 101F to a first side in the disc rotation direction. The return spring 13F also has a second extending portion 102F extending from an edge of the connecting portion 203F on the first side in the disc rotation direction to an outer side in the thickness direction of the friction pad 9. That is, the return spring 13F has a second extending portion 102F extending from the connecting portion 203F in a direction in which the friction pad 9 is pressed by the caliper 6 shown in FIG. 1.

[0324] The connecting portion 203F, the second extending portion 102F, the contact portion 103, and the cover portions 104F and 105F of the return spring 13F are positioned to overlap with the inner side wall portion 22 in the disk rotation direction and the disk radial direction. As shown in Fig. 30, the contact portion 103 of the return spring 13F extends from the second extending portion 102F and contacts the surface portion 35 of the inner side wall portion 22 of the carrier 5 at the contact plate portion 141. At this time, the contact portion 103 of the return spring 13F extends from the second extending portion 102F to the second side in the disk rotation direction.

[0325] 28, the return spring 14F has a first extending portion 101F extending from the fixed portion 100 in a direction away from the friction pad 9 in the thickness direction of the friction pad 9. The return spring 14F also has a connecting portion 203F extending from an inner edge of the first extending portion 101F to a second side in the disc rotation direction. The return spring 14F also has a second extending portion 102F extending from an edge of the connecting portion 203F on the second side in the disc rotation direction to an outer side in the thickness direction of the friction pad 9. That is, the return spring 14F has a second extending portion 102F extending from the connecting portion 203F in the direction in which the friction pad 9 is pressed by the caliper 6 shown in FIG. 1.

[0326] The connecting portion 203F, the second extending portion 102F, the contact portion 103, and the cover portions 104F and 105F of the return spring 14F are positioned to overlap with the inner side wall portion 23 in the disk rotation direction and the disk radial direction. The contact portion 103 of the return spring 14F extends from the second extending portion 102F and contacts the surface portion 37 of the inner side wall portion 23 of the carrier 5 at the contact plate portion 141, as shown in Fig. 30. At this time, the contact portion 103 of the return spring 14F extends from the second extending portion 102F to the first side in the disk rotation direction.

[0327] 30, a return spring 11F is attached to the first side in the disk rotation direction and a return spring 12F is attached to the second side in the disk rotation direction in the same manner as the return springs 13F and 14F are attached to the friction pad 9 described above. The return spring 11F abuts against the surface 45 of the outer side wall 26 of the carrier 5. The return spring 12F abuts against the surface 47 of the outer side wall 27 of the carrier 5.

[0328] The contact plate portion 141 of the contact portion 103 of the return spring 13F contacts the surface portion 35 of the inner side wall portion 22, restricting movement toward the disk 2. Therefore, when the inner-side friction pad 9 moves toward the disk 2 relative to the carrier 5 due to pressure from the caliper 6, the return spring 13F, which was in a standby state, elastically deforms mainly the first curved portion 202F of the first extending portion 101F and the second curved portion 131F of the second extending portion 102F, and enters an elastically deformed state. As a result, the return spring 13F separates its fixed portion 100, which is fixed to the friction pad 9, from its contact portion 103, whose movement relative to the carrier 5 is restricted, in the disk axial direction.

[0329] Furthermore, when the caliper 6 releases the pressure on the inner friction pad 9, the return spring 13F, which was in an elastically deformed state, releases the elastic deformation of the first curved portion 202F of the first extension portion 101F and the second curved portion 131F of the second extension portion 102F, which had been elastically deformed up until then, and returns to a standby state. Then, the return spring 13F brings its fixed portion 100, which is fixed to the friction pad 9, and its abutting portion 103, which abuts against the carrier 5, closer in the disc axial direction. As a result, the inner friction pad 9 moves toward the opposite side of the disc 2 with respect to the carrier 5 in the disc axial direction, and separates its lining 62 from the disc 2.

[0330] The return springs 11F, 12F, and 14F are also common parts with the same shape as the return spring 13F, and operate in the same manner as the return springs 11, 12, and 14.

[0331] Return springs 11F-14F have a similar configuration. For example, return spring 13F has edge portions 124F, 125F, 134F, 135F, 145, and 146, which are surfaces extending in the thickness direction of first extending portion 101F, connecting portion 203F, second extending portion 102F, and abutting portion 103. Return spring 13F also has cover portion 104F that covers at least a portion of edge portions 124F, 134F, and 145, specifically edge portion 134F, and cover portion 105F that covers at least a portion of edge portions 125F, 135F, and 146, specifically edge portion 135F. Therefore, return spring 13F can prevent edge portions 124F, 134F, and 145 from being exposed by cover portion 104F, and can prevent fingers from getting caught on edge portions 124F, 134F, and 145. Furthermore, the cover portion 105F of the return spring 13F can prevent the edge portions 125F, 135F, and 146 from being exposed, thereby preventing fingers from getting caught on the edge portions 125F, 135F, and 146. Therefore, the disc brake 1 provided with the return springs 11F to 14F can be made easier to maintain.

[0332] Return springs 11F-14F have a similar configuration. For example, return spring 13F has cover portion 104F covering edge portion 134F on the outer side in the disc rotation direction, and cover portion 105F covering edge portion 135F on the outer side in the disc rotation direction. Therefore, return spring 13F can effectively prevent fingers from getting caught on edge portions 124F, 125F. Therefore, disc brake 1 provided with return springs 11F-14F can effectively improve its maintainability.

[0333] Return springs 11F to 14F have a similar configuration. For example, return spring 13F has cover portions 104F and 105F extending from at least one of first extending portion 101F, connecting portion 203F, second extending portion 102F, and abutting portion 103. Specifically, return spring 13F has cover portions 104F and 105F extending from connecting portion 203F. Therefore, return spring 13F can have cover portions 104F and 105F integrally molded with fixed portion 100, first extending portion 101F, connecting portion 203F, second extending portion 102F, and abutting portion 103. Therefore, return springs 11F to 14F can be manufactured easily and inexpensively, and an increase in assembly time can be suppressed.

[0334] Return springs 11F to 14F have a similar configuration, but in the case of return spring 13F, cover portions 104F and 105F extend from flat connecting portion 203F, which has less effect on the spring load, rather than from a curved portion that affects the spring load. Therefore, return springs 11F to 14F can suppress the effect of cover portions 104F and 105F on the spring load, i.e., on spring performance.

[0335] Return springs 11F to 14F have a similar configuration, and will be described using return spring 13F as an example. Cover portions 104F and 105F extend from connecting portion 203F, which is closer to the middle, rather than from contact portion 103 on the tip side. Therefore, return springs 11F to 14F improve material yield and enable cost reduction.

[0336] Furthermore, for return springs 11F to 14F having a similar configuration, taking return spring 13F as an example, cover portions 104F and 105F are provided extending from connecting portion 203F. Therefore, in return spring 13F, cover portions 104F and 105F can be easily molded integrally with fixed portion 100, first extending portion 101F, connecting portion 203F, second extending portion 102F, and abutting portion 103. Therefore, return springs 11F to 14F can be manufactured easily and inexpensively.

[0337] Furthermore, among the return springs 11F to 14F having a similar configuration, for example, return spring 13F is provided with a connecting portion 203F that connects the first extending portion 101F and the second extending portion 102F in a direction different from the first extending portion 101F and the second extending portion 102F. Therefore, the return spring 13F can easily be formed by integrally molding the fixed portion 100, the first extending portion 101F, the connecting portion 203F, the second extending portion 102F, and the abutting portion 103. Therefore, the return springs 11F to 14F can be manufactured easily and inexpensively.

[0338] Furthermore, the return springs 11F to 14F, each having a similar configuration, are provided with at least one, specifically both, of a first curved portion 202F provided on the first extending portion 101F and connected to the connecting portion 203F, and a second curved portion 131F provided on the second extending portion 102F and connected to the connecting portion 203F. Therefore, the return spring 13F can easily be formed by integrally molding the fixed portion 100, the first extending portion 101F, the connecting portion 203F, the second extending portion 102F, and the abutting portion 103. Therefore, the return springs 11F to 14F can be manufactured easily and inexpensively.

[0339] Furthermore, among the return springs 11F to 14F having a similar configuration, for example, the return spring 13F has cover portions 104F and 105F provided at a position overlapping at least one of the first curved portion 202F and the second curved portion 131F, specifically the second curved portion 131F, in the plate thickness direction. Therefore, the cover portions 104F and 105F of the return spring 13F can prevent at least one of the first curved portion 202F and the second curved portion 131F, specifically the second curved portion 131F on the outer side in the disc rotation direction, from being exposed, and can prevent fingers from getting caught on the first curved portion 202F and the second curved portion 131F. Therefore, the disc brake 1 provided with the return springs 11F to 14F can be improved in maintainability.

[0340] Furthermore, among the return springs 11F to 14F having a similar configuration, for example, the return spring 13F has a cover portion 104F spaced a predetermined distance from the first curved portion 202F or the second curved portion 131F, specifically from both the first curved portion 202F and the second curved portion 131F. Furthermore, the return spring 13F has a cover portion 105F spaced a predetermined distance from the first curved portion 202F or the second curved portion 131F, specifically from both the first curved portion 202F and the second curved portion 131F. Therefore, the return spring 13F can easily have the cover portions 104F and 105F integrally molded with the fixed portion 100, the first extending portion 101F, the connecting portion 203F, the second extending portion 102F, and the abutting portion 103. Therefore, the return springs 11F to 14F can be manufactured easily and inexpensively.

[0341] In the return springs 11F to 14F of the seventh embodiment, similarly to the first embodiment, only one of the cover portions 104F and 105F may be provided.

[0342] According to a first aspect of the embodiment described above, the return spring comprises: a fixing portion fixed to the friction pad; a first extending portion formed in a plate shape and extending from the fixing portion in a direction away from the friction pad; a second extending portion formed in a plate shape and extending from the first extending portion in a pressing direction of the friction pad; a plate-shaped contact portion extending from the second extension portion and contacting a carrier attached to a non-rotating portion of a vehicle; an edge portion that is a surface extending in a plate thickness direction between the first extension portion, the second extension portion, and the abutting portion; a cover portion that covers at least a portion of the edge portion; Equipped with. This makes it possible to improve the maintainability of the disc brake provided with the return spring.

[0343] The second aspect is the first aspect, A connection portion is provided that connects the first extending portion and the second extending portion in a direction different from the first extending portion and the second extending portion.

[0344] The third aspect is the second aspect, At least one of a first curved portion provided on the first extending portion and connected to the connecting portion and a second curved portion provided on the second extending portion and connected to the connecting portion is provided.

[0345] The fourth aspect is the first aspect, The cover portion is provided so as to extend from at least one of the first extending portion, the second extending portion, and the abutting portion.

[0346] The fifth aspect is the third aspect, The cover portion is provided so as to extend from the intermediate plate portion, and is provided at a position where it overlaps with at least one of the first curved portion and the second curved portion in the plate thickness direction.

[0347] The sixth aspect is the fifth aspect, The cover portion and the first curved portion or the second curved portion are provided at a predetermined distance from each other.

[0348] The seventh aspect is the first aspect, The cover is made of resin.

[0349] The eighth aspect is the first aspect, The cover portion is made of an elastic material.

[0350] A ninth aspect is the first aspect, The cover portion is formed as a separate member from a return spring body having the first extending portion, the second extending portion, and the abutting portion.

[0351] According to a tenth aspect, a disc brake includes: Friction pads are provided, The return spring includes a fixed portion fixed to the friction pad, a first extending portion formed in a plate shape and extending from the fixed portion in a direction away from the friction pad, a second extending portion formed in a plate shape and extending from the first extending portion in the pressing direction of the friction pad, a contact portion formed in a plate shape and extending from the second extending portion and contacting a carrier attached to a non-rotating part of the vehicle, an edge portion which is a surface extending in the plate thickness direction between the first extending portion, the second extending portion, and the contact portion, and a cover portion which covers at least a portion of the edge portion. This makes it possible to improve the maintainability of the disc brake. [Industrial Applicability]

[0352] The return spring and disc brake described above can improve maintainability. [Explanation of symbols]

[0353] 1...Disc brake, 5...Carrier, 8, 9...Friction pad, 11, 11A to 11F...Return spring, 100...Fixed portion, 101, 101A, 101B, 101F...First extension portion, 102, 102F, 102B, 102F...Second extension portion, 103, 103B...Abutment portion, 104, 105, 222C, 222D, 222E, 104F, 105F...Cover portion, 124 to 127, 12 4B, 125B, 124F, 125F, 134, 134F, 135, 135F, 145, 145B, 146, 146B, 211B to 216B...edge portion, 131A...connecting plate portion (second curved portion), 131F...second curved portion, 202A...intermediate plate portion (first curved portion), 202F...first curved portion, 203A...tip side extending plate portion (connection portion), 203F...connection portion, 221C...return spring body.

Claims

1. a fixing portion fixed to the friction pad; a first extending portion formed in a plate shape and extending from the fixing portion in a direction away from the friction pad; a second extending portion formed in a plate shape and extending in a pressing direction of the friction pad; a plate-shaped contact portion extending from the second extension portion and contacting a carrier attached to a non-rotating portion of a vehicle; an edge portion that is a surface extending in a plate thickness direction between the first extending portion, the second extending portion, and the abutting portion; a cover portion that covers at least a portion of the edge portion; Equipped with the cover portion is provided extending from at least one of the first extending portion, the second extending portion, and the abutting portion, The first extension portion, the second extension portion, and the abutment portion are return springs in which a line extending along the plate thickness direction passes through a single plane.

2. The return spring according to claim 1 , further comprising a connecting portion that connects the first extending portion and the second extending portion in a direction different from that of the first extending portion and the second extending portion.

3. A return spring as described in claim 2, wherein at least one of a first curved portion provided on the first extension portion and connected to the connection portion and a second curved portion provided on the second extension portion and connected to the connection portion is provided.

4. The return spring according to claim 3 , wherein the cover portion extends from the connection portion and is positioned so as to overlap at least one of the first curved portion and the second curved portion in a plate thickness direction.

5. The return spring according to claim 4 , wherein the cover portion and the first curved portion or the second curved portion are spaced apart by a predetermined distance.

6. Friction pads are provided, a first extending portion formed in a plate shape and extending from the fixed portion in a direction away from the friction pad; a second extending portion formed in a plate shape and extending in a pressing direction of the friction pad; a contact portion formed in a plate shape and extending from the second extending portion and contacting a carrier attached to a non-rotating part of a vehicle; an edge portion which is a surface extending in the plate thickness direction between the first extending portion, the second extending portion, and the contact portion; and a cover portion which covers at least a part of the edge portion, wherein the cover portion extends from at least one of the first extending portion, the second extending portion, and the contact portion, and the first extending portion, the second extending portion, and the contact portion are provided with a return spring whose line along the plate thickness direction passes through a single plane.

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