Disc brakes

Abstract

Provided is a disc brake, in which a cutout portion (311) is provided at a location where an outer beam portion (32) and a friction pad (23), which is provided at a location facing the outer beam portion (32) in an axial direction of a disc (10), abut each other in a state in which an abutting portion (381) where the disc (10) abuts an end, in the axial direction of the disc (10), of a surface (321) on the disc (10) side of a friction material (212), and a contact portion where a groove portion and a lag portion contact each other are present when the friction pad (23) is tilted at a predetermined angle with respect to a radial direction of the disc (10).

Description

Technical Field

[0001] The present invention relates to a disc brake. This application claims priority based on Japanese Patent Application No. 2022-112914 filed in Japan on July 14, 2022, and incorporates its content herein.

Background Art

[0002] In order to stabilize the behavior of the friction pad during braking and suppress the occurrence of brake noise, a technique of providing a shim between the back plate of the friction pad and the member pressing the friction pad is disclosed (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] It is required to suppress a decrease in the assemblability of the friction pad to the carrier.

[0005] The present invention provides a disc brake capable of suppressing a decrease in the assemblability of the friction pad to the carrier.

Means for Solving the Problems

[0006] According to a first aspect of the present invention, a disc brake includes a friction pad and a carrier. The friction pad includes a plate which is moved toward the disc by the thrust of a piston, a friction material provided on the disc-side surface of the plate, a shim provided on the surface of the plate opposite to the friction material, a notch provided in the shim, and a lug protruding from at least one side in the longitudinal direction of the plate. The carrier includes a pair of bridge portions which straddle the disc and are spaced apart in the circumferential direction of the disc, groove portions provided in the bridge portions, and an outer beam portion which connects the pair of bridge portions and is provided at a position facing the friction pad in the axial direction of the disc. The friction pad, which is provided in the axial direction of the disk and facing the outer beam portion, is inclined at a predetermined angle with respect to the radial direction of the disk, and the notch is provided at the location where the outer beam portion and the friction pad come into contact, with the friction material having a contact portion where the axial end of the disk on the disk-side surface of the friction material abuts against the disk, and a contact portion where the groove portion and the lug portion come into contact. [Effects of the Invention]

[0007] According to the above-described embodiment, it is possible to suppress a decrease in the ease of assembling the friction pad to the carrier. [Brief explanation of the drawing]

[0008] [Figure 1] A front view showing a disc brake according to the first embodiment. [Figure 2] A cross-sectional view showing a disc brake according to the first embodiment. [Figure 3] A partially enlarged front view showing the disc brake of the first embodiment. [Figure 4] A partially enlarged front view showing the disc brake of the first embodiment. [Figure 5] A perspective view showing the first pad spring of a disc brake according to the first embodiment. [Figure 6]A front view showing the first pad spring of a disc brake according to the first embodiment. [Figure 7] A front view showing the outer friction pad of a disc brake according to the first embodiment. [Figure 8] A one-sided perspective view showing the process of assembling the outer friction pad to the carrier of the disc brake according to the first embodiment. [Figure 9] A one-sided perspective view showing the process of assembling the outer friction pad to the carrier of the disc brake according to the first embodiment. [Figure 10] A cross-sectional view showing the process of assembling the outer friction pad to the carrier of the disc brake according to the first embodiment. [Figure 11] A partially enlarged cross-sectional view showing the assembly process of the outer friction pad to the carrier of the disc brake in the first embodiment. [Figure 12] A schematic diagram illustrating the setting of the notch portion of the shim of the disc brake in the first embodiment. [Figure 13] A schematic diagram illustrating the setting of the notch portion of the shim of the disc brake in the first embodiment. [Figure 14] A schematic diagram illustrating the setting of the notch portion of the shim of the disc brake in the first embodiment. [Figure 15] A one-sided perspective view showing the process of assembling the outer friction pad to the carrier of the disc brake in the second embodiment. [Figure 16] A one-sided perspective view showing the process of assembling the outer friction pad to the carrier of the disc brake in the second embodiment. [Figure 17] A front view showing the first and second shims of the disc brake in the second embodiment. [Figure 18] A cross-sectional view from XVIII-XVIII in Figure 18, showing the first and second shims of the disc brake of the second embodiment. [Figure 19] A cross-sectional view showing the assembly process of the outer friction pad to the carrier of the disc brake in the second embodiment. [Modes for carrying out the invention]

[0009] [First Embodiment] The first embodiment will be described below with reference to FIGS. 1 to 14. The disc brake 1 in the embodiment shown in FIGS. 1 and 2 applies a braking force to a vehicle such as an automobile. Specifically, the disc brake 1 is for braking a four-wheel automobile. The disc brake 1 brakes the rotation of a disc-shaped disc 10 that rotates together with a wheel (not shown) of the vehicle.

[0010] Hereinafter, the rotation axis at the center of the rotation of the disc 10 is referred to as the disc rotation axis. Also, the direction in which the disc rotation axis extends is referred to as the disc axis direction. The radial direction of the disc 10 within the disc brake 1, that is, the direction orthogonal to the disc rotation axis, is referred to as the disc radial direction. The circumferential direction with respect to the disc rotation axis within the disc brake 1, that is, the rotation direction of the disc 10, is referred to as the disc circumferential direction or the disc rotation direction. The outlet side of the rotation direction R of the disc 10 within the disc brake 1 when the vehicle is moving forward is defined as the first side in the disc rotation direction, and the inlet side of the rotation direction of the disc 10 within the disc brake 1 when the vehicle is moving forward is defined as the second side in the disc rotation direction. The side on the disc rotation axis side in the disc radial direction is referred to as the inner side in the disc radial direction. The side opposite to the disc rotation axis in the disc radial direction is referred to as the outer side in the disc radial direction. The central side in the disc circumferential direction within the disc brake 1 is referred to as the inner side in the disc circumferential direction. The side opposite to the center in the disc circumferential direction within the disc brake 1 is referred to as the outer side in the disc circumferential direction. The outer side in the vehicle width direction of the vehicle provided with this disc brake 1 is referred to as the outer side. The inner side in the vehicle width direction of the vehicle provided with this disc brake 1 is referred to as the inner side.

[0011] The disc brake 1 has a carrier 11 and a caliper 12. The carrier 11 has a carrier body 20 and a pair of first pad springs 21 and second pad springs 22 shown in FIG. 1. Also, the disc brake 1 has an outer side friction pad 23 (friction pad) and an inner side friction pad 24 shown in FIG. 2.

[0012] A line that passes through the disc rotation axis and the center of the carrier body 20 and caliper 12 in the circumferential direction of the disc and runs along the disc radial direction is called the disc radial reference line. This disc radial reference line is perpendicular to the disc rotation axis. The plane containing this disc radial reference line and the disc rotation axis is called the disc radial reference plane.

[0013] The carrier 11 is attached to a non-rotating knuckle (not shown) that supports the vehicle's wheels. The carrier 11 is fixed to a knuckle (not shown) with the outer circumference of the disc 10 straddling it in the disc axial direction. The carrier 11 is a mounting member attached to the knuckle, which is a vehicle component separate from the disc brake 1, in the disc brake 1.

[0014] The carrier body 20 is made of metal. The carrier body 20 is integrally molded without seams. As shown in Figure 1, the carrier body 20 comprises a fixing portion 31, an outer beam portion 32, and a pair of first bridge portions 33 (bridge portion) and second bridge portions 34 (bridge portion). The carrier body 20 has a mirror-symmetric shape with respect to the disc radial reference plane. In other words, the disc radial reference line and the disc radial reference plane pass through the central position of the carrier body 20 in the disc circumferential direction.

[0015] As shown in Figure 2, the fixing portion 31 is provided on one side of the disk 10 in the disk axial direction. The fixing portion 31 is positioned opposite a knuckle (not shown). The fixing portion 31 is attached to the knuckle (not shown) in a manner that extends in the circumferential direction of the disk, as shown in Figure 1. In other words, the fixing portion 31 is provided between the disk 10 and the knuckle (not shown) in the disk axial direction. Here, the knuckle (not shown) to which the carrier body 20 is attached is located on the inner side of the disk axial direction relative to the disk 10. Therefore, the fixing portion 31 attached to this knuckle is also located on the inner side of the disk axial direction relative to the disk 10, as shown in Figure 2. The fixing portion 31 faces the disk 10 in the disk axial direction.

[0016] As shown in Figure 1, the fixing portion 31 has a mirror-symmetric shape with respect to the radial reference plane of the disk. The fixing portion 31 includes a first mounting portion 41, a second mounting portion 42, and an inner side connecting portion 43.

[0017] The first mounting portion 41 is located at the end of the fixing portion 31 on the first side in the disk rotation direction. The first mounting portion 41 has a first mounting hole portion 45. The first mounting hole portion 45 penetrates the first mounting portion 41 along the disk axis direction.

[0018] The second mounting portion 42 is located at the end of the fixing portion 31 on the second side in the disk rotation direction. The second mounting portion 42 has a second mounting hole portion 46. The second mounting hole portion 46 penetrates the first mounting portion 41 along the disk axial direction.

[0019] The inner connection portion 43 extends in the direction of disk rotation and connects the first mounting portion 41 and the second mounting portion 42.

[0020] The first bridge section 33 and the second bridge section 34 have a mirror-symmetric shape with respect to the radial reference plane of the disk. The first bridge section 33 includes a first inner extension 51, a first bridge body 52, and a first outer extension 53.

[0021] The first inner extension 51 extends radially outward from the first mounting portion 41 of the fixing portion 31. The first inner extension 51 is positioned on the inner side of the disk 10 in the disk axial direction. The first inner extension 51 faces the disk 10 in the disk axial direction.

[0022] The first bridge body portion 52 extends outward along the disk axis from the outer end of the first inner extension portion 51 in the disk radial direction, and also protrudes inward. The portion of the first bridge body portion 52 that extends outward straddles the radially outer side of the disk 10 in the disk axis direction. The first bridge body portion 52 has a first caliper support hole (not shown) that extends in the disk axis direction from the inner end face in the disk axis direction to an intermediate position in the first bridge body portion 52.

[0023] The first outer extension 53 extends inward in the disk radial direction from the outer end of the first bridge body 52. ​​The first outer extension 53 is positioned on the outer side of the disk 10 in the disk axial direction. The first outer extension 53 faces the disk 10 in the disk axial direction.

[0024] The first outer extension 53 has a first outer locking portion 55 formed on its inner side in the circumferential direction of the disk. The first outer locking portion 55 is recessed outward in the circumferential direction from the inner end face of the first outer extension 53 in the circumferential direction of the disk. The first outer locking portion 55 penetrates the first outer extension 53 in the axial direction of the disk.

[0025] As shown in Figure 3, the first outer locking portion 55 has a first outer bottom surface 56, a first outer inner wall surface 57, and a first outer outer outer wall surface 58.

[0026] The first outer bottom surface 56 is located at the outer end of the first outer locking portion 55 in the circumferential direction of the disk. In other words, the first outer bottom surface 56 is located at the inner end of the first outer locking portion 55 in the recess direction. The first outer bottom surface 56 is planar and extends parallel to the reference plane in the radial direction of the disk.

[0027] The first outer inner wall surface 57 extends inward in the circumferential direction of the disk from the radially inner edge of the first outer bottom surface 56. The first outer inner wall surface 57 is planar in shape and extends perpendicular to the radial reference line of the disk.

[0028] The first outer side outer wall surface 58 extends inward in the circumferential direction of the disk from the outer edge of the first outer side bottom surface 56 in the disk radial direction. The first outer side outer wall surface 58 is planar and extends perpendicular to the disk radial reference line. The first outer side inner wall surface 57 and the first outer side outer wall surface 58 are parallel and opposite each other.

[0029] Here, although not shown in the diagram, the first inner extension 51 also has a first inner locking portion that has the same shape as the first outer locking portion 55 of the first outer extension 53. This first inner locking portion is recessed outward in the circumferential direction of the disk from the inner end face of the first inner extension 51 in the circumferential direction of the disk. This first inner locking portion penetrates the first inner extension 51 in the axial direction of the disk. This first inner locking portion has a first inner bottom surface (not shown) which is in the same plane as the first outer bottom surface 56, a first inner wall surface (not shown) which is in the same plane as the first inner wall surface 57 which is in the same plane as the first outer wall surface 58 which is in the same plane as the first outer wall surface 58 which is in the same plane as the first inner wall surface 58.

[0030] The first bridge portion 33, which has a first inner extension portion 51, a first bridge body portion 52, and a first outer extension portion 53, straddles the disk 10 in the disk axis direction.

[0031] As shown in Figure 4, the second bridge portion 34 includes a second inner extension portion 61, a second bridge body portion 62, and a second outer extension portion 63.

[0032] The second inner extension 61 extends radially outward from the second mounting portion 42 of the fixing portion 31 in the disc radial direction. The second inner extension 61 is positioned on the inner side of the disc axial direction relative to the disc 10. The second inner extension 61 faces the disc 10 in the disc axial direction.

[0033] The second bridge body portion 62 extends outward along the disk axis from the outer end of the second inner extension portion 61 in the disk radial direction, and also protrudes inward. The portion of the second bridge body portion 62 that extends outward straddles the radially outer side of the disk 10 in the disk axis direction. The second bridge body portion 62 has a second caliper support hole (not shown) that extends in the disk axis direction from the inner end face in the disk axis direction to an intermediate position in the second bridge body portion 62.

[0034] The second outer extension 63 extends inward in the disc radial direction from the outer end of the second bridge body 62. The second outer extension 63 is positioned on the outer side of the disc 10 in the disc axial direction. The second outer extension 63 faces the disc 10 in the disc axial direction.

[0035] The second outer extension 63 has a second outer locking portion 65 formed on its inner side in the circumferential direction of the disk. The second outer locking portion 65 is recessed outward in the circumferential direction from the inner end face of the second outer extension 63 in the circumferential direction of the disk. The second outer locking portion 65 penetrates the second outer extension 63 in the axial direction of the disk.

[0036] The second outer side locking portion 65 has a second outer side bottom surface 66, a second outer side inner wall surface 67, and a second outer side outer wall surface 68.

[0037] The second outer bottom surface 66 is located at the outer end of the second outer locking portion 65 in the circumferential direction of the disk. In other words, the second outer bottom surface 66 is located at the inner end of the second outer locking portion 65 in the recess direction. The second outer bottom surface 66 is planar and extends parallel to the reference plane in the radial direction of the disk.

[0038] The inner wall surface 67 of the second outer side extends inward in the circumferential direction of the disk from the inner edge in the disk radial direction of the second outer side bottom surface 66. The inner wall surface 67 of the second outer side is planar and extends perpendicular to the reference line in the disk radial direction.

[0039] The second outer side outer wall surface 68 extends inward in the circumferential direction of the disk from the outer edge of the second outer side bottom surface 66 in the disk radial direction. The second outer side outer wall surface 68 is planar and extends perpendicular to the disk radial reference line. The second outer side inner wall surface 67 and the second outer side outer wall surface 68 are parallel and opposite each other.

[0040] The first outer bottom surface 56 shown in Figure 3 and the second outer bottom surface 66 shown in Figure 4 are arranged parallel to each other with their positions aligned in the disk axial direction and disk radial direction. The first outer inner wall surface 57 shown in Figure 3 and the second outer inner wall surface 67 shown in Figure 4 are arranged on the same plane with their positions aligned in the disk axial direction and disk radial direction. The first outer outer wall surface 58 shown in Figure 3 and the second outer outer wall surface 68 shown in Figure 4 are arranged on the same plane with their positions aligned in the disk axial direction and disk radial direction.

[0041] Here, although not shown in the diagram, the second inner extension 61 also has a second inner locking portion, which has the same shape as the second outer locking portion 65 of the second outer extension 63. This second inner locking portion is recessed outward in the circumferential direction of the disk from the inner end face of the second inner extension 61 in the circumferential direction of the disk. This second inner locking portion penetrates the second inner extension 61 in the axial direction of the disk. This second inner locking portion has a second inner bottom surface (not shown) which is in the same plane as the second outer bottom surface 66, a second inner wall surface (not shown) which is in the same plane as the second outer inner wall surface 67, and a second outer wall surface (not shown) which is in the same plane as the second outer outer wall surface 68.

[0042] The second bridge portion 34, which has a second inner extension portion 61, a second bridge body portion 62, and a second outer extension portion 63, straddles the disk 10 in the disk axis direction. The pair of first bridge sections 33 and second bridge sections 34 both straddle the disk 10 and are spaced apart from each other in the circumferential direction of the disk 10, as shown in Figure 1.

[0043] The outer beam portion 32 connects the inner end in the disk radial direction of the first outer extension portion 53 of the first bridge portion 33 and the inner end in the disk radial direction of the second outer extension portion 63 of the second bridge portion 34. In other words, the outer beam portion 32 connects the pair of first bridge portions 33 and second bridge portions 34. As shown in Figure 2, the outer beam portion 32 is provided on the outer side of the disk 10 in the disk axial direction. The outer beam portion 32 faces the disk 10 in the disk axial direction. As shown in Figure 1, the outer beam portion 32 extends in the disk circumferential direction. The outer beam portion 32 has a mirror-symmetric shape with respect to the disk radial reference plane.

[0044] The outer beam section 32 comprises a first base extension 81 (straight section), a second base extension 82 (straight section), and an outer-side connecting section 83 (convex section, arc-shaped section).

[0045] The first base extension 81 is located at the end of the outer beam 32 on the first side in the disk rotation direction. The first base extension 81 extends inward in the disk circumferential direction from the end of the first outer extension 53 of the first bridge 33 that is on the disk radial side. The first base extension 81 has a linear shape perpendicular to the disk radial reference plane.

[0046] The first base extension 81 has a first outer surface portion 91 on the outer side in the radial direction of the disk. The first outer surface portion 91 is planar and extends perpendicular to the reference line in the radial direction of the disk. The first base extension 81 has a first inner surface portion 92 on the inner side in the radial direction of the disk. The first inner surface portion 92 is planar in shape and extends perpendicular to the reference line in the radial direction of the disk.

[0047] The second base extension 82 is located at the end of the outer beam 32 on the second side in the disk rotation direction. The second base extension 82 extends inward in the disk circumferential direction from the end of the second outer extension 63 of the second bridge 34 that is on the disk radial side. The second base extension 82 has a linear shape perpendicular to the disk radial reference plane. The first base extension 81 and the second base extension 82 are arranged on the same straight line.

[0048] The second base extension 82 has a second outer surface 95 on its radially outward side in the disk direction. The second outer surface 95 is planar and extends perpendicularly to the disk radial reference line. The second outer surface 95 is positioned on the same plane as the first outer surface 91, with their positions aligned in the disk axial direction and the disk radial direction.

[0049] The second base extension 82 has a second inner surface portion 96 on its inner side in the disk radial direction. The second inner surface portion 96 is planar in shape and extends perpendicular to the disk radial reference line. The second inner surface portion 96 is arranged on the same plane as the first inner surface portion 92, with their positions aligned in the disk axial direction and the disk radial direction.

[0050] The outer-side connecting portion 83 is located at the center of the outer beam portion 32 in the direction of disk rotation. The outer-side connecting portion 83 connects the inner end of the first base extension portion 81 in the disk circumferential direction to the inner end of the second base extension portion 82 in the disk circumferential direction. The outer-side connecting portion 83 is an arc shape centered on the disk rotation axis. The outer-side connecting portion 83 is a convex arc shape that extends outward in the disk radial direction. The outer-side connecting portion 83 is a convex portion that extends outward in the disk radial direction. The inner side of the outer-side connecting portion 83 in the disk circumferential direction is located further outward in the direction of the disk radial reference line. The central position of the outer-side connecting portion 83 in the disk circumferential direction is located furthest outward in the disk radial direction in the direction of the disk radial reference line.

[0051] The outer-side connecting portion 83 has one circumferential end that extends to the inner end of the first inner surface portion 92 of the first base extension portion 81 in the circumferential direction of the disk, and the other circumferential end that extends to the inner end of the second inner surface portion 96 of the second base extension portion 82 in the circumferential direction of the disk. The outer-side connecting portion 83 has a first end face portion 101 on one circumferential end and inner side in the disk radial direction that is planar and is coplanar and continuous with the first inner surface portion 92 of the first base extension portion 81. The outer-side connecting portion 83 has a second end face portion 102 on the other circumferential end and inner side in the disk radial direction that is planar and is coplanar and continuous with the second inner surface portion 96 of the second base extension portion 82. The first end face portion 101 and the second end face portion 102 are arranged on the same plane with their positions aligned in the disk axial direction and the disk radial direction.

[0052] The outer connection portion 83 has an outer connection surface portion 105 on the outer side in the radial direction of the disk. The outer connection surface portion 105 connects the inner edge portion of the first outer surface portion 91 in the circumferential direction of the disk and the inner edge portion of the second outer surface portion 95 in the circumferential direction of the disk. The outer connection surface portion 105 is shaped like a part of a cylindrical surface centered on the disk rotation axis. The outer connection surface portion 105 has an arc shape that bulges outward in the radial direction of the disk. The outer connection surface portion 105 is located further outward in the direction of the disk radial reference line as it moves inward in the circumferential direction of the disk. The central position of the outer connection surface portion 105 in the circumferential direction of the disk is located furthest outward in the disk radial direction in the direction of the disk radial reference line.

[0053] The outer connecting portion 83 has an inner connecting surface portion 106 on the inner side in the disc radial direction. The inner connecting surface portion 106 connects the inner edge portion of the first end surface portion 101 in the disc circumferential direction and the inner edge portion of the second end surface portion 102 in the disc circumferential direction. The inner connecting surface portion 106 is shaped like a part of a cylindrical surface centered on the disc rotation axis. The inner connecting surface portion 106 is concave in an arc shape on the inner side in the disc radial direction. The inner connecting surface portion 106 is located further outward in the disc radial direction, in the direction of the disc radial reference line, as it moves further inward in the disc circumferential direction. The central position of the inner connecting surface portion 106 in the disc circumferential direction is located furthest outward in the disc radial direction, in the direction of the disc radial reference line.

[0054] The outer connection portion 83 has an outer peripheral side portion 111 and an inner peripheral side portion 112, both of which are arc-shaped when viewed in the disk axis direction, on the disk 10 side in the disk axis direction, i.e., on the inner side. The outer peripheral surface portion 111 is shaped like a part of a conical surface centered on the disk rotation axis. In other words, the outer peripheral surface portion 111 is tapered around the disk rotation axis. The outer peripheral surface portion 111 extends inward in the disk radial direction from the inner edge of the outer connecting surface portion 105 in the disk axial direction. The outer peripheral surface portion 111 is inclined so that the inner part in the disk radial direction is located closer to the inner side in the disk axial direction. One circumferential edge of the outer peripheral surface portion 111 extends to the first end surface portion 101 shown in Figure 1 and connects to the first end surface portion 101, while the other circumferential edge extends to the second end surface portion 102 and connects to the second end surface portion 102.

[0055] The inner circumferential surface portion 112 shown in Figure 2 is planar in shape perpendicular to the disk rotation axis. The inner circumferential surface portion 112 extends inward in the disk radial direction from the inner edge of the outer circumferential surface portion 111 in the disk radial direction. One circumferential edge of the inner circumferential surface portion 112 extends to the first end face portion 101 shown in Figure 1 and connects to the first end face portion 101. The other circumferential edge of the inner circumferential surface portion 112 extends to the second end face portion 102 and connects to the second end face portion 102.

[0056] As shown in Figure 2, an edge portion 115 is formed at the boundary between the outer peripheral side portion 111 and the outer connecting surface portion 105, as highlighted by a thick dashed line in Figures 2 to 4. The edge portion 115 has an arc shape centered on the disk rotation axis. As shown in Figure 1, one circumferential edge of the edge portion 115 extends to the first end surface portion 101 and connects to it, and the other circumferential edge extends to the second end surface portion 102 and connects to it. The intersection of the outer peripheral side portion 111 and the outer connecting surface portion 105 shown in Figure 2 forms a continuous line created by the trajectory of the outer beam portion 32, as shown in Figure 1.

[0057] In the outer connecting portion 83, the portion that does not overlap with the first base extension portion 81 and the second base extension portion 82 in the circumferential direction has a constant cross-sectional shape in the circumferential direction of this portion, that is, in the direction perpendicular to the extension direction of this portion.

[0058] The inner end face of the first base extension 81 in the disk axial direction is positioned on the outer side in the disk axial direction compared to the outer peripheral side surface 111 shown in Figure 2. The inner end face of the second base extension 82 in the disk axial direction shown in Figure 1 is also positioned on the outer side in the disk axial direction compared to the outer peripheral side surface 111 shown in Figure 2.

[0059] As described above, the outer beam portion 32 has an outer-side connecting portion 83 which is a convex portion in the disk radial direction, as shown in Figure 1. The outer beam portion 32 has an outer-side connecting portion 83 which is an arc-shaped portion that is convex outward in the disk radial direction. The outer beam portion 32 has a first base end extension portion 81 and a second base end extension portion 82, both of which are straight portions.

[0060] Here, the entire outer beam portion 32 may be made into an outer-side connection portion 83. In that case, the entire outer beam portion 32 will have a constant cross-sectional shape perpendicular to the extending direction of the outer beam portion 32. That is, it is sufficient that at least a part of the outer beam portion 32 has an outer-side connection portion 83. Also, it is sufficient that at least a part of the outer beam portion 32 has a constant cross-sectional shape perpendicular to the extending direction of the outer beam portion 32.

[0061] Alternatively, the entire outer beam portion 32 may be made into a first base extension portion 81 and a second base extension portion 82, and these may be made continuous. In other words, it is sufficient that at least a part of the outer beam portion 32 has a first base extension portion 81 and a second base extension portion 82.

[0062] The pair of first pad springs 21 and second pad springs 22 are common parts of the same shape. Therefore, the first pad spring 21 will be used as an example for explanation.

[0063] As shown in Figures 5 and 6, the first pad spring 21 has a mirror-symmetric shape. The first pad spring 21 is formed by press molding from a single sheet of material of a certain thickness. The first pad spring 21 has a pair of pad support parts 141 and a connecting part 142 that connects the pair of pad support parts 141 and the pad support parts 141.

[0064] Furthermore, in one first pad spring 21, the pair of pad support portions 141 and the pad support portion 141 have a mirror-symmetrical shape. For this reason, one of the pad support portions 141 will be described.

[0065] The pad support portion 141 includes an outer end plate portion 151, an outer support plate portion 152, an outer guide plate portion 153, a tip plate portion 154, an intermediate plate portion 155, a guide plate portion 156, a base plate portion 157, and a biasing plate portion 158.

[0066] The outer end plate portion 151 is located on the pad support portion 141, closest to the connection portion 142. The outer end plate portion 151 has a flat plate shape. The outer support plate portion 152 has a flat plate shape. The outer support plate portion 152 extends perpendicularly to the outer end plate portion 151 from the edge opposite to the connection portion 142 of the outer end plate portion 151.

[0067] The outer guide plate portion 153 has a flat plate shape. The outer guide plate portion 153 of one pad support portion 141 extends from the edge of the outer support plate portion 152 of that pad support portion 141 that is opposite to the other pad support portion 141, and toward the opposite side of the other pad support portion 141. The outer guide plate portion 153 is inclined with respect to the outer support plate portion 152 such that the extension end is located toward the connection portion 142 in the thickness direction of the outer support plate portion 152. The boundary line between the outer guide plate portion 153 and the outer support plate portion 152 has a straight shape perpendicular to the outer end plate portion 151.

[0068] The tip plate portion 154 is flat. The tip plate portion 154 extends from the edge of the outer guide plate portion 153 opposite to the outer support plate portion 152 toward the connection portion 142 in the thickness direction of the outer support plate portion 152. The boundary line between the tip plate portion 154 and the outer guide plate portion 153 has a straight shape perpendicular to the outer end plate portion 151.

[0069] The intermediate plate portion 155 has a flat plate shape. The intermediate plate portion 155 extends from the edge of the outer support plate portion 152 opposite to the outer end plate portion 151, perpendicular to the outer support plate portion 152 and away from the outer end plate portion 151. The intermediate plate portion 155 spreads out parallel to the outer end plate portion 151.

[0070] The guide plate portion 156 has a flat plate shape. The guide plate portion 156 of one pad support portion 141 extends from the edge of the intermediate plate portion 155 of that one pad support portion 141 that is opposite to the other pad support portion 141, and toward the opposite side of the other pad support portion 141. The guide plate portion 156 is inclined with respect to the intermediate plate portion 155 such that, as it extends towards the tip, it is located on the opposite side of the outer support plate portion 152 in the thickness direction of the intermediate plate portion 155.

[0071] The base plate portion 157 has a flat plate shape. The base plate portion 157 extends perpendicularly to the intermediate plate portion 155 from the end of the intermediate plate portion 155 opposite to the outer support plate portion 152, and on the same side as the outer support plate portion 152. The base plate portion 157 spreads out parallel to the outer support plate portion 152.

[0072] The outer support plate portion 152, the outer guide plate portion 153, the intermediate plate portion 155, the guide plate portion 156, and the base plate portion 157 together form a fitting recessed portion 161 that is recessed from the outer end plate portion 151.

[0073] The biasing plate portion 158 of one pad support portion 141 extends from the edge of the base plate portion 157 of this one pad support portion 141 that is opposite to the other pad support portion 141, and is folded back towards the outer support plate portion 152, and is positioned on the outer support plate portion 152 side of the base plate portion 157.

[0074] The biasing plate portion 158 has a folded portion 171 and an inner support plate portion 172. One of the pad support portions 141 has a folded portion 171 that extends from the end of the base plate portion 157 opposite to the other pad support portion 141, folding back in an arc shape towards the outer support plate portion 152.

[0075] The inner support plate portion 172 of one pad support portion 141 extends linearly from the extended end of the folded portion 171 of one pad support portion 141 toward the other pad support portion 141. The inner support plate portion 172 is inclined so that it moves away from the base plate portion 157 in the thickness direction, with increasing inclination towards the tip end extending from the folded portion 171.

[0076] The connecting portion 142 connects one pad support portion 141 described above to the other pad support portion 141 which is mirror-symmetrical to it. The connecting portion 142 includes a connecting plate portion 175 and a positioning portion 176.

[0077] The connecting plate portion 175 connects the pair of pad support portions 141 and the outer end plate portions 151 of each pad support portion 141 to the opposite sides of the outer support plate portion 152. The positioning portion 176 is provided between the pair of pad support portions 141. The positioning portion 176 extends from the edge of the connecting plate portion 175 on the outer end plate portion 151 side toward the same side as the outer support plate portion 152.

[0078] As shown in Figure 3, the first pad spring 21 is attached to the first bridge portion 33 on the first side of the carrier body 20 in the disc rotation direction. At this time, with the connecting portion 142 of the first pad spring 21 positioned outward in the disc radial direction from the pair of pad support portions 141 and the pad support portions 141, the concave fitting recess 161 of one pad support portion 141 is fitted into the first outer locking portion 55 of the first outer extension portion 53, and the concave fitting recess 161 of the other pad support portion 141 is fitted into the first inner locking portion (not shown) of the first inner extension portion 51. At the same time, the positioning portion 176 of the first pad spring 21 is fitted between the first inner extension portion 51 and the first outer extension portion 53. In this way, the first pad spring 21 is positioned and attached to the carrier body 20.

[0079] In this state, the base plate portion 157 of the outer fitting recess 161 of the first pad spring 21, which fits into the first outer locking portion 55, is positioned on the inside in the disc radial direction of the fitting recess 161 and contacts the first outer inner wall surface 57 of the first outer locking portion 55. Also in this state, the outer support plate portion 152 of the outer fitting recess 161 of the first pad spring 21 is positioned on the outside in the disc radial direction of the fitting recess 161 and contacts the first outer outer outer wall surface 58 of the first outer locking portion 55 by surface contact. Also in this state, the intermediate plate portion 155 of the outer fitting recess 161 of the first pad spring 21 is positioned on the outside in the disc circumferential direction of the fitting recess 161 and contacts the first outer bottom surface 56 on the inner side of the first outer locking portion 55 by surface contact.

[0080] Furthermore, in this state, the base plate portion 157 of the inner fitting recess 161 of the first pad spring 21, which fits into the first inner locking portion (not shown), is positioned on the inside of the fitting recess 161 in the disc radial direction and contacts the first inner wall surface (not shown). Furthermore, in this state, the outer support plate portion 152 of the inner fitting recess 161 of the first pad spring 21 is positioned on the outside of the fitting recess 161 in the disc radial direction and contacts the first inner outer wall surface (not shown) by surface contact. Furthermore, in this state, the intermediate plate portion 155 of the inner fitting recess 161 of the first pad spring 21 is positioned on the outside of the fitting recess 161 in the disc circumferential direction and contacts the first inner bottom surface (not shown) by surface contact.

[0081] With the first pad spring 21 attached to the first inner extension 51 and the first outer extension 53 in this manner, the pair of fitting recesses 161 that fit into the first inner locking portion and the first outer locking portion 55 (not shown) are recessed outward in the circumferential direction of the disc.

[0082] In the first pad spring 21, the space between the outer support plate portion 152 and the outer guide plate portion 153 and the biasing plate portion 158 inside the outer fitting recessed portion 161 at this time forms the outer side first groove portion 181 (groove portion).

[0083] Furthermore, in the first pad spring 21, the space between the outer support plate portion 152 and the outer guide plate portion 153 and the biasing plate portion 158 inside the inner fitting recessed portion 161 of the first pad spring 21 becomes an inner first groove portion (not shown).

[0084] As shown in Figure 4, the second pad spring 22 is attached to the second inner extension 61 and the second outer extension 63, both located on the second side in the disc rotation direction of the carrier body 20. At this time, with the connecting portion 142 of the second pad spring 22 positioned radially outward from the pair of pad support portions 141, the concave fitting recess 161 of one pad support portion 141 is fitted into the second outer locking portion 65 of the second outer extension 63, and the concave fitting recess 161 of the other pad support portion 141 is fitted into the second inner locking portion (not shown) of the second inner extension 61. Simultaneously, the positioning portion 176 of the second pad spring 22 is fitted between the second inner extension 61 and the second outer extension 63. In this way, the second pad spring 22 is positioned and attached to the carrier body 20.

[0085] In this state, the base plate portion 157 of the outer fitting recess 161 of the second pad spring 22, which fits into the second outer locking portion 65, is positioned on the inside in the disc radial direction of the fitting recess 161 and abuts against the inner wall surface 67 of the second outer locking portion 65. Also in this state, the outer support plate portion 152 of the outer fitting recess 161 of the second pad spring 22 is positioned on the outside in the disc radial direction of the fitting recess 161 and abuts against the outer wall surface 68 of the second outer locking portion 65 by surface contact. Also in this state, the intermediate plate portion 155 of the outer fitting recess 161 of the second pad spring 22 is positioned on the outside in the disc circumferential direction of the fitting recess 161 and abuts against the inner second outer bottom surface 66 of the second outer locking portion 65.

[0086] Furthermore, in this state, the base plate portion 157 of the inner fitting recess 161 of the second pad spring 22, which fits into the second inner locking portion (not shown), is positioned on the inside of the fitting recess 161 in the disc radial direction and contacts the inner wall surface of the second inner side (not shown). Furthermore, in this state, the outer support plate portion 152 of the inner fitting recess 161 of the second pad spring 22 is positioned on the outside of the fitting recess 161 in the disc radial direction and contacts the outer wall surface of the second inner side (not shown) by surface contact. Furthermore, in this state, the intermediate plate portion 155 of the inner fitting recess 161 of the second pad spring 22 is positioned on the outside of the fitting recess 161 in the disc circumferential direction and contacts the bottom surface of the second inner side (not shown).

[0087] With the second pad spring 22 attached to the second inner extension 61 and the second outer extension 63 in this manner, the pair of fitting recessed portions 161 that fit into the second inner locking portion and the second outer locking portion 65 (not shown) are recessed outward in the circumferential direction of the disc.

[0088] In the second pad spring 22, the space between the outer support plate portion 152 and the outer guide plate portion 153 and the biasing plate portion 158 inside the outer fitting recessed portion 161 at this time forms the outer side second groove portion 182 (groove portion).

[0089] Furthermore, in the second pad spring 22, the space between the outer support plate portion 152 and the outer guide plate portion 153 and the biasing plate portion 158 inside the inner fitting recessed portion 161 of the second pad spring 22 becomes an inner second groove portion (not shown).

[0090] As described above, a pair of first pad springs 21 and second pad springs 22 are attached to the carrier body 20 to form the carrier 11.

[0091] The outer first groove 181 and the inner first groove (not shown) are provided on the first bridge portion 33, which is one of a pair of first bridge portions 33 and second bridge portions 34. The outer second groove 182 and the inner second groove (not shown) are provided in the second bridge portion 34, which is the other of the pair of first bridge portions 33 and second bridge portions 34.

[0092] As shown in Figure 1, the outer friction pad 23 is supported in the outer first groove 181 and outer second groove 182 of the carrier 11, which are recessed in opposite directions, so as to be movable in the disk axial direction. Furthermore, the inner friction pad 24 shown in Figure 2 is supported in the inner first groove (not shown) and inner second groove (not shown), which are recessed in opposite directions on the carrier 11, so as to be movable in the disk axial direction.

[0093] As shown in Figure 1, the outer friction pad 23 includes a friction pad body 201, a shim 202, and a spring 203. The friction pad body 201 has a shape that is approximately mirror-symmetrical. As shown in Figure 7, the friction pad body 201 includes a plate 211 and a friction material 212.

[0094] The plate 211 has a flat substrate portion 221, a pair of first ear portions 222 (ear portion) and second ear portion 223 (ear portion), a first projection 224 shown in Figure 3, and a second projection 225 shown in Figure 8.

[0095] The pair of first and second ear portions 222 and 223 shown in Figure 7 have the same flat plate shape that is continuous with the base portion 221. The pair of first and second ear portions 222 and 223 protrude from both ends of the base portion 221 in the longitudinal direction of the plate 211, and protrude in opposite directions along this longitudinal direction. The base portion 221 has a mirror-symmetric shape. The first ear portion 222 and the second ear portion 223 have a mirror-symmetric shape. The first projection 224 shown in Figure 3 protrudes from the first ear portion 222 in the thickness direction of the first ear portion 222. The second projection 225 shown in Figure 8 protrudes from the second ear portion 223 in the thickness direction of the second ear portion 223. The first projection 224 shown in Figure 3 and the second projection 225 shown in Figure 8 protrude from the first ear portion 222 shown in Figure 3 and the second ear portion 223 shown in Figure 8 on the same side in the thickness direction of these portions.

[0096] Here, in the outer friction pad 23 and plate 211, the direction connecting the first ear portion 222 and the second ear portion 223 is the longitudinal direction. Also, in the outer friction pad 23 and plate 211, the thickness direction of the base portion 221, the first ear portion 222, and the second ear portion 223 is the thickness direction. Furthermore, in the outer friction pad 23 and plate 211, the direction perpendicular to the longitudinal direction and perpendicular to the thickness direction is the height direction.

[0097] As shown in Figure 7, the friction material 212 is attached to the adhesive surface 231 of the plate 211 on the side opposite to the first projection 224 shown in Figure 3 and the second projection 225 shown in Figure 8, in the thickness direction of the outer friction pad 23. The adhesive surface 231 has a planar shape that extends perpendicular to the thickness direction of the substrate portion 221. The adhesive surface 231 has a planar shape that is continuous with the substrate portion 221 and the pair of first and second ear portions 222 and 223.

[0098] The plate 211 has a main surface portion 232, shown in Figure 1, on the side opposite to the friction material 212 in the thickness direction of the outer friction pad 23. The main surface portion 232 has a planar shape that extends perpendicular to the thickness direction of the outer friction pad 23. The main surface portion 232 is formed in a planar shape that is continuous with the substrate portion 221 and the pair of first ear portions 222 and second ear portions 223. The main surface portion 232 has a planar shape that extends parallel to the adhesive surface 231 shown in Figure 7. The first projection 224 shown in Figure 3 and the second projection 225 shown in Figure 8 protrude from this main surface portion 232 in the direction opposite to the adhesive surface 231.

[0099] As shown in Figure 7, the substrate portion 221 has a pair of side portions 233 on both ends in the longitudinal direction of the outer friction pad 23. The pair of side portions 233 are aligned with the thickness direction of the outer friction pad 23 and are also substantially aligned with the height direction of the outer friction pad 23.

[0100] As shown in Figure 8, the base portion 221 has a bulging surface portion 235 and a chamfered portion 236 on one side in the height direction of the outer friction pad 23. The base portion 221 also has an engaging surface portion 257 on the side opposite to the bulging surface portion 235 in the height direction of the outer friction pad 23.

[0101] The bulging surface portion 235 has a shape that bulges out on one side in the height direction of the outer friction pad 23. The bulging surface portion 235 has the shape of a part of a cylindrical surface. The chamfered portion 236 connects the bulging surface portion 235 and the main surface portion 232. The chamfered portion 236 forms an obtuse angle with respect to the bulging surface portion 235 and also forms an obtuse angle with respect to the main surface portion 232.

[0102] As shown in Figure 7, the substrate portion 221 has an outer engagement recess 238 that is recessed from the bulging surface portion 235 toward the inner surface portion 237 in the height direction of the outer friction pad 23. The outer engagement recess 238 is located at the center of the substrate portion 221 in the longitudinal direction of the outer friction pad 23.

[0103] The substrate portion 221 has a pair of inner engagement recesses 239 that are recessed from the inner surface portion 237 in the direction of the bulging surface portion 235 in the height direction of the outer friction pad 23. The pair of inner engagement recesses 239 are spaced apart in the longitudinal direction of the outer friction pad 23.

[0104] The first ear portion 222 protrudes from one of the pair of side portions 233 of the substrate portion 221, in the longitudinal direction of the outer friction pad 23. The first ear portion 222 has a first tip surface portion 241, a first outer surface portion 242, and a first inner surface portion 243.

[0105] The first tip surface portion 241 is located at the end of the first lug portion 222 opposite to the base portion 221. The first tip surface portion 241 is planar, extending perpendicular to the longitudinal direction of the outer friction pad 23. In other words, the first tip surface portion 241 has a planar shape that is aligned with the thickness direction of the outer friction pad 23 and also aligned with the height direction of the outer friction pad 23.

[0106] The first outer surface portion 242 is located at the end of the first lug portion 222 on the bulging surface portion 235 side in the height direction of the outer friction pad 23. The first outer surface portion 242 has a planar shape that extends perpendicular to the height direction of the outer friction pad 23. In other words, the first outer surface portion 242 has a planar shape that is along the thickness direction of the outer friction pad 23 and along the longitudinal direction of the outer friction pad 23.

[0107] The first inner surface portion 243 is located at the end of the first lug portion 222 on the inner surface portion 237 side in the height direction of the outer friction pad 23. The first inner surface portion 243 has a planar shape that extends perpendicular to the height direction of the outer friction pad 23. In other words, the first inner surface portion 243 has a planar shape that is along the thickness direction of the outer friction pad 23 and along the longitudinal direction of the outer friction pad 23. To put it another way, the first inner surface portion 243 has a planar shape that extends parallel to the first outer surface portion 242. The first inner surface portion 243 also has a planar shape that extends perpendicular to the first tip surface portion 241.

[0108] A first edge portion 245 is formed at the boundary between the first outer surface portion 242 and the adhesive surface 231. This first edge portion 245 has a linear shape that extends in the longitudinal direction of the outer friction pad 23.

[0109] The second ear portion 223 protrudes from the other side portion 233 in the longitudinal direction of the outer friction pad 23, which is one of a pair of side portions 233 of the substrate portion 221. The second ear portion 223 has a second tip surface portion 251, a second outer surface portion 252, and a second inner surface portion 253.

[0110] The second tip surface portion 251 is located at the end of the second ear portion 223 opposite to the base portion 221. The second tip surface portion 251 has a planar shape that extends perpendicular to the longitudinal direction of the outer friction pad 23. In other words, the second tip surface portion 251 has a planar shape that is along the thickness direction of the outer friction pad 23 and along the height direction of the outer friction pad 23. The second tip surface portion 251 has a planar shape that extends parallel to the first tip surface portion 241.

[0111] The second outer surface portion 252 is located at the end of the second ear portion 223 on the bulging surface portion 235 side in the height direction of the outer friction pad 23. The second outer surface portion 252 has a planar shape that extends perpendicular to the height direction of the outer friction pad 23. In other words, the second outer surface portion 252 has a planar shape that is along the thickness direction of the outer friction pad 23 and along the longitudinal direction of the outer friction pad 23. The second outer surface portion 252 is arranged in the same plane as the first outer surface portion 242.

[0112] The second inner surface portion 253 is located at the end of the second ear portion 223 on the inner surface portion 237 side in the height direction of the outer friction pad 23. The second inner surface portion 253 has a planar shape that extends perpendicular to the height direction of the outer friction pad 23. In other words, the second inner surface portion 253 has a planar shape that is along the thickness direction of the outer friction pad 23 and along the longitudinal direction of the outer friction pad 23. The second inner surface portion 253 is arranged in the same plane as the first inner surface portion 243.

[0113] A second edge portion 255 is formed at the boundary between the second outer surface portion 252 and the adhesive surface 231. The second edge portion 255 is a straight line extending in the longitudinal direction of the outer friction pad 23. The second edge portion 255 is arranged in the same straight line as the first edge portion 245.

[0114] As shown in Figures 1 and 2, the shim 202 has a shim body 261 and a cover shim 262.

[0115] The shim body 261 has a mirror-symmetric shape. The shim body 261 has a main plate portion 271 and an outer engaging plate portion 272 as shown in Figure 2, and a pair of inner engaging plate portions 273 as shown in Figure 1. The main plate portion 271 shown in Figure 2 has a flat plate shape. The main plate portion 271 is positioned to cover the main surface portion 232 of the plate 211. In this state, the main plate portion 271 is in surface contact with the main surface portion 232. In this state, the thickness direction of the main plate portion 271 coincides with the thickness direction of the outer friction pad 23.

[0116] The outer engaging plate portion 272 protrudes from the main plate portion 271 to one side along the thickness direction of the main plate portion 271. The outer engaging plate portion 272 engages with the outer engaging recess 238 of the plate 211. As shown in Figure 1, the pair of inner engaging plate portions 273 protrude from the main plate portion 271 along the thickness direction of the main plate portion 271 on the same side as the outer engaging plate portion 272 shown in Figure 2. As shown in Figure 1, the pair of inner engaging plate portions 273 engage with the portion of the pair of side portions 233 of the substrate portion 221 that is on the inner side portion 237 side as shown in Figure 7, rather than the pair of first ear portions 222 and second ear portions 223.

[0117] The shim body 261 shown in Figures 1 and 2 has an outer engaging plate portion 272 shown in Figure 2 that engages with an outer engaging recess 238, and a pair of inner engaging plate portions 273 shown in Figure 1 that engage with a pair of side portions 233 of the base portion 221. As a result, the shim body 261 is positioned and attached to the plate 211.

[0118] The cover shim 262 has a mirror-symmetric shape. As shown in Figure 2, the cover shim 262 has a cover plate portion 281, an outer locking plate portion 282, and a pair of inner locking plate portions 283. The cover plate portion 281 has a flat plate shape. The cover plate portion 281 is positioned to cover the main plate portion 271 of the shim body 261 from the opposite side of the plate 211. At this time, the cover plate portion 281 is in surface contact with the main plate portion 271 of the shim body 261. In this state, the thickness direction of the cover plate portion 281 coincides with the thickness direction of the outer friction pad 23.

[0119] The outer locking plate portion 282 protrudes from the cover plate portion 281 along the thickness direction of the cover plate portion 281 to one side. The outer locking plate portion 282 covers the outer engaging plate portion 272 of the shim body 261 and engages with the outer engaging recess 238 of the plate 211. The pair of inner locking plate portions 283 protrude from the cover plate portion 281 along the thickness direction of the cover plate portion 281 on the same side as the outer locking plate portion 282. The pair of inner locking plate portions 283 engage with the pair of inner engaging recesses 239 of the inner surface portion 237 of the substrate portion 221 shown in Figure 7.

[0120] As shown in Figure 2, the cover shim 262 is positioned and attached to the plate 211 by covering the shim body 261, with the outer locking plate portion 282 engaging with the outer engagement recess 238, and the pair of inner locking plate portions 283 engaging with the pair of inner engagement recesses 239 on the inner surface portion 237 of the plate 211 shown in Figure 7.

[0121] In this way, the shim 202, consisting of the shim body 261 and the cover shim 262, is positioned and attached to the plate 211 of the friction pad body 201.

[0122] As shown in Figures 8 and 9, a body notch 291 is formed in the main plate portion 271 of the shim body 261. Assume that the shim body 261 is positioned and attached to the friction pad body 201. Then, the body notch 291 is formed recessed in the direction of the outer engagement plate portion 272, from the edge of the main plate portion 271 opposite to the outer engagement plate portion 272, in the height direction of the outer friction pad 23. The body notch 291 is formed at the center of the shim body 261 in the longitudinal direction of the outer friction pad 23. The body notch 291 is formed between a pair of inner engagement plate portions 273 of the main plate portion 271 in the longitudinal direction of the outer friction pad 23. The body notch 291 penetrates the main plate portion 271 in the thickness direction.

[0123] The main body cutout 291 has an inner edge 292 and a pair of side edges 293. The inner edge portion 292 is located at the end of the main body notch portion 291 on the side of the outer engagement plate portion 272. The inner edge portion 292 has a linear shape that extends in the longitudinal direction of the outer friction pad 23. The pair of side edges 293 extend from both ends of the outer friction pad 23 of the inner edge 292 in the longitudinal direction, away from the outer engagement plate 272.

[0124] A cover notch 301 is formed in the cover plate portion 281 of the cover shim 262. Assume that the cover shim 262 is positioned and attached to the friction pad body 201. Then, the cover notch 301 is formed recessed in the height direction of the outer friction pad 23, from the edge of the cover plate portion 281 opposite to the outer locking plate portion 282 toward the outer locking plate portion 282. The cover notch 301 is formed at the center of the cover shim 262 in the longitudinal direction of the outer friction pad 23. The cover notch 301 is formed between a pair of inner locking plate portions 283 of the cover plate portion 281 in the longitudinal direction of the outer friction pad 23. The cover notch 301 penetrates the cover plate portion 281 in the thickness direction.

[0125] The cover cutout 301 has an inner edge portion 302 and a pair of side edges 303. The inner edge portion 302 is located at the end of the cover notch portion 301 on the side of the outer locking plate portion 282. The inner edge portion 302 is a straight line extending in the longitudinal direction of the outer friction pad 23. The pair of side edges 303 extend from both ends of the outer friction pad 23 of the inner edge 302 in the longitudinal direction, on the side opposite to the outer locking plate 282.

[0126] When the shim 202, positioned and attached to the friction pad body 201, is viewed in the thickness direction of the outer friction pad 23, the body notch 291 and the cover notch 301 have overlapping shapes. That is, the inner edge 292 of the body notch 291 and the inner edge 302 of the cover notch 301 align the longitudinal position of the outer friction pad 23, as well as the height position of the outer friction pad 23. Furthermore, one of the pair of side edges 293 of the body notch 291 and one of the pair of side edges 303 of the cover notch 301 align the longitudinal position of the outer friction pad 23, as well as the height position of the outer friction pad 23. Furthermore, the other side edge 293 of the pair of side edges 293 of the main body cutout 291 and the other side edge 303 of the pair of side edges 303 of the cover cutout 301 align the longitudinal position of the outer friction pad 23, as well as the height position of the outer friction pad 23.

[0127] The shim 202 has a notch 311. The notch 311 is composed of a main body notch 291 and a cover notch 301. The notch 311 is formed on one side of the shim 202 in the height direction of the outer friction pad 23. The notch 311 penetrates the shim 202 in the thickness direction of the outer friction pad 23. In the outer friction pad 23, the main surface portion 232 of the plate 211 is exposed within the range of the notch 311 of the shim 202. As shown in Figure 1, when the outer friction pad 23 is assembled to the carrier 11, the notch 311 is formed on the inner portion of the shim 202 in the disc diameter direction and exits the shim 202 in the disc diameter direction.

[0128] The friction material 212 shown in Figure 7 is attached to the adhesive surface 231 of the plate 211. The friction material 212 is provided within the range of the substrate portion 221 in both the longitudinal and height directions of the outer friction pad 23.

[0129] The friction material 212 has a contact surface 321 and a pair of inclined surfaces 322 on the side opposite to the plate 211 in the thickness direction of the outer friction pad 23.

[0130] The contact surface 321 is located at an intermediate position in the longitudinal direction of the friction material 212 of the outer friction pad 23. The contact surface 321 has a planar shape that extends perpendicular to the thickness direction of the outer friction pad 23. The friction material 212 contacts the disk 10 at the contact surface 321.

[0131] The pair of inclined surfaces 322 are provided on both sides of the contact surface 321 in the longitudinal direction of the outer friction pad 23. The pair of inclined surfaces 322 are provided at both ends of the friction material 212 in the longitudinal direction of the outer friction pad 23. The pair of inclined surfaces 322 have a planar shape along the height direction of the outer friction pad 23. The pair of inclined surfaces 322 are inclined with respect to the contact surface 321 such that the further they are from the contact surface 321 in the longitudinal direction of the outer friction pad 23, the closer they are to the adhesive surface 231 in the thickness direction of the outer friction pad 23.

[0132] The friction material 212 has a pair of inner end surfaces 325 and a concave surface 326 on the inner surface portion 237 side in the height direction of the outer friction pad 23.

[0133] The pair of inner end surfaces 325 have a planar shape that extends perpendicularly to the height direction of the outer friction pad 23. In other words, the pair of inner end surfaces 325 extend along the thickness direction of the outer friction pad 23 and along the longitudinal direction of the outer friction pad 23. The pair of inner end surfaces 325 are arranged on the same plane.

[0134] The concave surface portion 326 is positioned between a pair of inner end surface portions 325 in the longitudinal direction of the outer friction pad 23. The concave surface portion 326 is recessed from the pair of inner end surface portions 325 toward the bulging surface portion 235 in the height direction of the outer friction pad 23. The concave surface portion 326 has the shape of a part of a cylindrical surface.

[0135] The friction material 212 has a pair of inner end surfaces 325 and a concave surface 326, a contact surface 321, and an edge portion 331 formed at the boundary between these surfaces.

[0136] This edge portion 331 has a pair of end edge components 332 and an intermediate edge component 333. The pair of end edge components 332 are located at both ends of the edge portion 331 in the longitudinal direction of the outer friction pad 23. The intermediate edge component 333 is located between the pair of end edge components 332 in the longitudinal direction of the outer friction pad 23.

[0137] The pair of end edge components 332 have a linear shape that extends in the longitudinal direction of the outer friction pad 23. The pair of end edge components 332 are arranged on the same straight line. The edge portion 331 is located at the end of the friction material 212 furthest away from the plate 211 in the thickness direction of the outer friction pad 23. The edge portion 331 is located at the end of the friction material 212 closest to the innermost surface portion 237 in the height direction of the outer friction pad 23.

[0138] As shown in Figure 8, the spring 203 is attached to the second projection 225 of the second lug 223 on the second side in the disc rotation direction of the friction pad body 201. The second projection 225 is crimped with the spring 203 in contact with the main surface 232. Then the spring 203 is fixed to the second lug 223. Before the second projection 225 is crimped in this way, the plate 211 is mirror-symmetrical with the first projection 224 shown in Figure 9 and the second projection 225 shown in Figure 8.

[0139] With the spring 203 attached to the second lug portion 223, it extends outward from the main surface portion 232 side in the thickness direction of the outer friction pad 23, then folds back and extends towards the friction material 212 side, passing on the opposite side of the base portion 221 from the second lug portion 223 in the longitudinal direction of the outer friction pad 23.

[0140] As shown in Figure 2, the outer friction pad 23 is positioned with the friction material 212 on the inner side relative to the plate 211. In this state, as shown in Figure 3, the first lug portion 222 of the outer friction pad 23 is fitted into the outer first groove portion 181 of the carrier 11, and as shown in Figure 4, the second lug portion 223 is fitted into the outer second groove portion 182 of the carrier 11. As a result, the outer friction pad 23 is supported by the carrier 11 so that it can slide in the axial direction of the disc.

[0141] At that time, the spring 203 contacts the intermediate plate portion 155 that constitutes the outer side second groove portion 182, pressing the outer side friction pad 23 toward the first side in the disc rotation direction.

[0142] In this state, as shown in Figure 3, the first inner surface portion 243 of the first lug portion 222 of the outer friction pad 23 comes into contact with the biasing plate portion 158 that constitutes the outer first groove portion 181 of the first pad spring 21. Also in this state, the biasing force of the biasing plate portion 158 causes the first outer surface portion 242 of the first lug portion 222 to come into surface contact with the outer support plate portion 152 that constitutes the outer first groove portion 181 of the first pad spring 21. Also in this state, the biasing force of the spring 203 shown in Figure 4 causes the first tip surface portion 241 of the first lug portion 222 shown in Figure 3 to come into surface contact with the intermediate plate portion 155 that constitutes the outer first groove portion 181 of the first pad spring 21.

[0143] Furthermore, in this state, as shown in Figure 4, the second inner surface portion 253 of the second lug portion 223 of the outer friction pad 23 abuts against the biasing plate portion 158 that constitutes the outer second groove portion 182 of the second pad spring 22. Also in this state, the biasing force of this biasing plate portion 158 causes the second outer surface portion 252 of the second lug portion 223 to abut in surface contact with the outer support plate portion 152 that constitutes the outer second groove portion 182 of the second pad spring 22. Also in this state, the second tip surface portion 251 of the second lug portion 223 faces the intermediate plate portion 155 that constitutes the outer second groove portion 182 of the second pad spring 22 with a slight gap between them.

[0144] The inner friction pad 24 shown in Figure 2 is a common part with the same shape as the friction pad body 201 of the outer friction pad 23 before the spring 203 shown in Figure 1 is attached. The inner friction pad 24 shown in Figure 2 is formed by attaching the spring 203 to the first projection 224 of the first lug portion 222 of the friction pad body 201.

[0145] As shown in Figure 2, the inner friction pad 24 is positioned with the friction material 212 on the outer side relative to the plate 211. In this state, the first lug portion 222 is fitted into the inner second groove portion (not shown) of the carrier 11, and the second lug portion 223 is fitted into the inner first groove portion (not shown) of the carrier 11. As a result, the inner friction pad 24 is supported by the carrier 11 so that it can slide in the disc axial direction. The inner friction pad 24 is biased in the first direction of disc rotation by the spring 203.

[0146] The caliper 12 comprises a caliper body 351 shown in Figure 1, and a pair of first slide pins and second slide pins (not shown). The first slide pins (not shown) are attached to the end of the caliper body 351 on the first side in the direction of disk rotation. The second slide pins (not shown) are attached to the end of the caliper body 351 on the second side in the direction of disk rotation.

[0147] The caliper 12 has a shape that is approximately mirror-symmetric. The disc radial reference line and the disc radial reference plane pass through the center of the caliper 12 in the circumferential direction of the disc. The caliper 12 is fixed to the caliper body 351 with a first slide pin (not shown) and a second slide pin (not shown) that are aligned axially and parallel to each other.

[0148] The caliper 12 has a first slide pin (not shown) that is slidably fitted into a first caliper support hole (not shown) formed in the first bridge portion 33 of the carrier body 20. As a result, the first slide pin (not shown) of the caliper 12 is movably housed in the first bridge portion 33. The axial direction of movement of the first slide pin (not shown) is the axial direction of the first caliper support hole (not shown), and coincides with the disk axial direction.

[0149] Furthermore, the caliper 12 has a second slide pin (not shown) that is slidably fitted into a second caliper support hole (not shown) formed in the second bridge portion 34 of the carrier body 20. As a result, the second slide pin (not shown) of the caliper 12 is movably housed in the second bridge portion 34. The axis of movement of the second slide pin (not shown) is the axis of the second caliper support hole (not shown), and coincides with the axis of movement of the disk.

[0150] As a result, the caliper 12 is supported such that the caliper body 351 is slidably supported in the disk axial direction by the first bridge portion 33 and the second bridge portion 34 of the carrier 11 via a first slide pin and a second slide pin (not shown).

[0151] The caliper body 351 has a nearly mirror-symmetric shape. The disc radial reference line and disc radial reference plane pass through the center of the caliper body 351 in the circumferential direction of the disc. The caliper body 351 includes a cylinder portion 361, an extension portion 362, and a claw portion 363 as shown in Figure 2, and a first pin mounting portion 364 and a second pin mounting portion 365 as shown in Figure 1.

[0152] As shown in Figure 2, the cylinder portion 361 is positioned on the inner side of the disk 10 in the disk axial direction. The cylinder portion 361 is a bottomed cylindrical shape and opens on the outer side in the disk axial direction.

[0153] The extension portion 362 extends outward from the outer portion of the cylinder portion 361 in the radial direction of the disk, along the disk axis. The extension portion 362 traverses the outer circumference of the disk 10 in the disk axis direction on its outer side in the radial direction of the disk.

[0154] The first pin mounting portion 364 and the second pin mounting portion 365 shown in Figure 1 are located on the inner side of the disk 10 in the disk axial direction. The first pin mounting portion 364 extends from the cylinder portion 361 shown in Figure 2 toward the first side in the disk rotation direction. A first slide pin (not shown) is fixed to the first pin mounting portion 364. The first slide pin (not shown) extends from the first pin mounting portion 364 toward the outer side along the disk axis direction.

[0155] The second pin mounting portion 365 shown in Figure 1 extends from the cylinder portion 361 shown in Figure 2 to the second side in the disk rotation direction. A second slide pin (not shown) is fixed to the second pin mounting portion 365. A second slide pin, not shown in the diagram, extends from the second pin mounting portion 365 toward the outer side along the disk axis.

[0156] As shown in Figure 2, the claw portion 363 extends inward in the disk radial direction from the outer end of the extension portion 362 in the disk axial direction and is positioned on the outer side of the disk 10.

[0157] The cylinder portion 361 of the caliper body 351 houses the piston 371 that constitutes the caliper 12. The piston 371 is housed in the cylinder portion 361 so as to be movable in the disc axial direction. The piston 371 faces the inner surface of the disc 10. An inner friction pad 24 is positioned between the inner surface of the disc 10 and the piston 371. As the piston 371 moves toward the disc 10 along the disc axial direction, it comes into contact with the inner friction pad 24, pressing it and bringing it into contact with the disc 10. The outer friction pad 23 is positioned between the outer surface of the disc 10 and the claw portion 363.

[0158] The outer beam portion 32 of the carrier 11 is positioned opposite the outer friction pad 23 in the disk axial direction. The outer beam portion 32 is positioned opposite the outer friction pad 23 in the disk axial direction, with its position overlapping with the outer friction pad 23 in the disk radial direction and its position overlapping with the disk circumferential direction.

[0159] The outer friction pad 23 includes a plate 211, a friction material 212 provided between the plate 211 and the disc 10, and a shim 202 provided on the main surface portion 232 of the plate 211 opposite to the friction material 212.

[0160] The shim 202 has a main plate portion 271 of the shim body 261 and a cover plate portion 281 of the cover shim 262 positioned between the plate 211 of the outer friction pad 23 and the outer beam portion 32 of the carrier 11. As shown in Figure 1, the shim 202 has a notch 311 formed on its inner side in the disk radial direction. The notch 311 is positioned to face the outer beam portion 32 in the disk axial direction, with its position overlapping with the outer beam portion 83 in the disk radial direction and its position overlapping with the outer beam portion 32 in the disk circumferential direction. At this time, the shim 202 and the outer beam portion 32 are provided at a predetermined distance apart. In other words, the outer beam portion 83 of the outer beam portion 32 is positioned to face the outer beam portion 32 in the disk axial direction, with its position overlapping with the main surface portion 232 of the plate 211 exposed within the notch 311 in the disk radial direction and its position overlapping with the main surface portion 232 of the plate 211 in the disk circumferential direction. A portion of the shim 202 is provided along the shape of the outer beam portion 32. Specifically, the inner edges 292 and 302, which are part of the shim 202 and are shown in Figures 8 and 9, are provided along the shape of the outer connection surface portion 105 of the outer beam portion 32. The longitudinal direction of the shim 202 coincides with the longitudinal direction of the outer beam portion 32. The outer-side connection portion 83 of the outer beam portion 32 has a shape that bulges outward in the disc radial direction as it approaches the center in the longitudinal direction of the outer-side friction pad 23.

[0161] Brake fluid is introduced into the cylinder portion 361 of the caliper 12 shown in Figure 2 via brake piping (not shown) in the disc brake 1. As a result, brake fluid pressure acts on the piston 371 in the cylinder portion 361. Consequently, the piston 371 advances toward the disc 10, contacts the inner friction pad 24 located between the piston 371 and the disc 10, and presses it toward the disc 10. The inner friction pad 24 is then guided by the inner first groove and inner second groove (not shown) of the carrier 11, moving in the disc axial direction, and the friction material 212 contacts the inner surface of the disc 10.

[0162] The reaction force of this pressing causes the caliper body 351 to slide a first slide pin (not shown) and a second slide pin (not shown) relative to the carrier 11, moving in the disc axial direction. As a result, the claw portion 363 contacts the cover shim 262 of the shim 202 of the outer friction pad 23, which is positioned between the claw portion 363 and the disc 10, pressing the outer friction pad 23 toward the disc 10. As a result, the outer friction pad 23 is guided by the outer first groove portion 181 and the outer second groove portion 182, moving in the disc axial direction, and the contact surface 321 of the friction material 212 contacts the outer surface of the disc 10.

[0163] The caliper 12, slidably supported on the carrier 11, thus, through the operation of the piston 371, clamps the pair of inner friction pads 24 and outer friction pads 23 from both sides in the disc axial direction with the piston 371 and the claw portion 363. In other words, the caliper 12 presses the pair of inner friction pads 24 and outer friction pads 23 toward the disc 10 in the disc axial direction. The caliper 12 then presses these inner friction pads 24 and outer friction pads 23 against the surfaces on both sides of the disc 10. As a result, the inner friction pads 24 and outer friction pads 23 provide frictional resistance to the disc 10, thereby providing braking force to the vehicle. In this way, the disc brake 1 generates braking force by having the caliper 12, supported on the carrier 11, press the inner friction pads 24 and outer friction pads 23, also supported on the carrier 11, toward the disc 10. The caliper 12 is a so-called fist-type (slide-type) caliper. The carrier 11 movably supports the caliper 12, which thus applies braking force to the vehicle.

[0164] As a result, the plate 211 of the outer friction pad 23 is pressed toward the disc 10 by the thrust of the piston 371, causing the outer friction pad 23 to move. The carrier 11 supports the plate 211 of the outer friction pad 23 so that it can move in this manner.

[0165] When assembling the disc brake 1 to a knuckle (not shown), first, the carrier 11, in its state before the caliper 12, inner friction pad 24, and outer friction pad 23 are assembled, is attached to the knuckle (not shown). That is, the carrier 11 is positioned so that the outer beam portion 32 is on the outer side and the fixing portion 31 is on the inner side relative to the disc 10, and the first bridge portion 33 and the second bridge portion 34 straddle the disc 10, and are attached to the knuckle (not shown) at the first mounting portion 41 and the second mounting portion 42.

[0166] Next, the outer friction pad 23 is moved from the outer side to the inner side in the radial direction of the disc and inserted between the outer beam portion 32 of the carrier 11 and the disc 10, as shown in Figures 8 to 10. At this time, the outer friction pad 23 is oriented so that the friction material 212 is on the disc 10 side in the disc axial direction and the shim 202 is on the outer beam portion 32 side in the disc axial direction. In this configuration, the outer friction pad 23 is oriented such that the first lug portion 222 is located at the end on the first side in the disc rotation direction, as shown in Figure 9, and the second lug portion 223 is located at the end on the second side in the disc rotation direction, as shown in Figure 8. Furthermore, in order to avoid interference with the pair of first pad springs 21 and second pad springs 22, the outer friction pad 23 is inserted at an inclination with respect to the disc diameter such that the outer portion in the disc diameter direction is further away from the disc 10 in the disc axis direction than the inner portion in the disc diameter direction.

[0167] During insertion in this inclined state, as shown in Figure 10, at least one point of the edge portion 331 located at the axial end of the disk 10 on the contact surface 321 of the friction material 212 of the outer friction pad 23 on the disk 10 side is brought into contact with the disk 10, thereby providing these contact portions 381. Furthermore, during insertion in this inclined state, as shown in Figure 9, the position of the first lug 222 of the outer friction pad 23 in the circumferential direction of the disc is aligned with the outer first groove 181. At the same time, as shown in Figure 10, the position of the second lug 223 of the outer friction pad 23 in the circumferential direction of the disc is aligned with the outer second groove 182. Furthermore, during insertion in this inclined state, as shown in Figure 9, the position of the first edge portion 245 of the first lug portion 222 in the disc radial direction is aligned with the position of the outer support plate portion 152 of the outer side first groove portion 181. At the same time, as shown in Figure 8, the position of the second edge portion 255 of the second lug portion 223 in the disc radial direction is aligned with the position of the outer support plate portion 152 of the outer side second groove portion 182.

[0168] Then, as shown in Figure 10, with the contact portion 381 in place, the first edge portion 245 of the outer friction pad 23 is brought into contact with the outer support plate portion 152 of the outer first groove portion 181 at at least one point, thereby creating the first contact portion 382 (contact portion). Alternatively, as shown in Figure 8, the second edge portion 255 of the outer friction pad 23 is brought into contact with the outer support plate portion 152 of the outer second groove portion 182 at at least one point, thereby creating the second contact portion 383 (contact portion). Both the first contact portion 382 and the second contact portion 383 may be provided. That is, at least one of the first contact portion 382 and the second contact portion 383 is provided.

[0169] The notch 311 of the shim 202 is formed in such a way that, in this state, the shim 202 does not come into contact with the outer beam portion 32 at the position where the outer beam portion 32 and the outer friction pad 23 come into contact. In other words, depending on the angle with respect to the disc 10, the outer friction pad 23 will come into contact with the outer beam portion 32 with at least one of the first contact portion 382 and the second contact portion 383, and the contact portion 381. In that case, as shown in Figure 10, the main surface portion 232 of the plate 211 comes into contact with the outer beam portion 32, but the shim 202 does not. The notch 311 is formed in the shim 202 in a range that avoids interference between the shim 202 and the outer beam portion 32 when the outer friction pad 23 is assembled to the carrier 11.

[0170] Here, we will explain how to set the notch 311. As described above, with the outer friction pad 23 positioned at a predetermined angle of inclination with respect to the disc diameter, the edge portion 331 of the friction material 212 is located at the end of the contact surface 321 that is pressed against the disc 10, on the side of the central axis of the disc 10. In this state, at least one point of the edge portion 331 and the disk 10 are brought into contact, thereby creating a contact portion 381 (first contact portion) where only these two contact points.

[0171] In the state having this contact portion 381, as shown in Figure 9, the outer friction pad 23 and the outer first groove 181 are brought into contact at at least one point to form a first contact portion 382 where they make contact. Alternatively, as shown in Figure 8, the outer friction pad 23 and the outer second groove 182 are brought into contact at at least one point to form a second contact portion 383 where they make contact. At least one of the first contact portion 382 and the second contact portion 383 is provided.

[0172] Then, in a state having at least one of the first contact portion 382 and the second contact portion 383 and the abutment portion 381, as shown in Figure 10, the edge portion 115 of the outer beam portion 32 and the outer side friction pad 23 are brought into contact at at least one point to provide a second abutment portion 384 where they abut. That is, the outer side friction pad 23 is restrained by having at least one of the first contact portion 382 and the second contact portion 383, the abutment portion 381 and the second abutment portion 384. If this condition is met, the shim 202 is provided with a notch 311 so that the second abutment portion 384 does not contact the shim 202 but abuts against the main surface portion 232 of the plate 211. In other words, if this condition is met, the notch 301 is provided at the location where the outer beam portion 32 and the outer side friction pad 23 abut.

[0173] To satisfy this, the outer friction pad 23 is constrained by the provision of at least one of the first contact portion 382 and the second contact portion 383, the abutment portion 381 and the second abutment portion 384, as shown in Figure 11, with the second abutment portion 384 as the intersection point, the angle (θ) formed between the thickness direction of the plate 211 and the axial direction of the disk 10 is set to the thickness (t) of the shim 202, and with the outer friction pad 23 constrained to form an angle θ, as shown in Figure 1, the displacement (x) of the outer beam portion 32 in the radial direction of the disk from the central axis of the disk 10 is taken with respect to the central axis of the disk 10. This displacement (x) is such that the position of the disk radial reference plane is 0.

[0174] At this time, the partial derivative (F(x)) of the second contact portion 384 in the disk radial direction in the disk axial direction is, At any position x, the notch 311 of shim 202 > F(x) To achieve this, notches 311 are provided in the shim 202 according to the displacement (x).

[0175] That is, let's assume that the shim 202 does not have a notch 311, and for example, has a first contact portion 382, ​​a second contact portion 383, and a contact portion 381, and that the outer peripheral side portion 111 of the outer beam portion 32, including the edge portion 115, is in contact with the shim 202, as shown in Figure 12. Then, a notch 311 is provided in the shim 202, as shown by hatching in Figure 13, extending to a position greater than the distance t × sinθ from the edge portion on the outer connecting surface portion 105 side of the outer peripheral side portion 111 of the outer beam portion 32. Then, as shown in Figure 14, the shim 202 and the outer beam portion 32 do not interfere with each other, and the outer beam portion 32 can contact the main surface portion 232 of the plate 211.

[0176] Furthermore, since the shape of the outer beam portion 32 differs depending on the position of the displacement (x) shown in Figure 1, if the notches 311 of the shim 202 are provided according to the displacement (x) so that the notches 311 of the shim 202 > F(x) at all positions where there are second contact portions 384, the outer beam portion 32 can contact the main surface portion 232 of the plate 211 without interfering with the shim 202.

[0177] With the aforementioned contact portion 381, the first contact portion 382, ​​and the second contact portion 383 in place, as shown in Figure 9, the first edge portion 245 is brought into contact with the outer support plate portion 152 of the outer side first groove portion 181, and the first ear portion 222 is pushed into the outer side first groove portion 181 to fit it in place. In parallel with this, as shown in Figure 8, the second edge portion 255 is brought into contact with the outer support plate portion 152 of the outer side second groove portion 182, and the second ear portion 223 is pushed into the outer side second groove portion 182 to fit it in place. As a result, the outer side friction pad 23 is assembled to the carrier 11.

[0178] As shown in Figure 2, the outer friction pad 23, assembled to the carrier 11, has the friction material 212 positioned on the inner side relative to the plate 211. At this time, the friction material 212 faces the disc 10. In this state, the spring 203 shown in Figure 4 of the outer friction pad 23 contacts the intermediate plate portion 155 of the outer side second groove portion 182 of the second pad spring 22. Also in this state, the first lug portion 222 shown in Figure 3 contacts the biasing plate portion 158 that constitutes the outer side first groove portion 181 at its first inner surface portion 243. Furthermore, in this state, the first lug portion 222 contacts the outer support plate portion 152 that constitutes the outer side first groove portion 181 at its first outer surface portion 242 by surface contact due to the biasing force of the biasing plate portion 158. Furthermore, in this state, the outer friction pad 23 has its first lug portion 222 in surface contact with the intermediate plate portion 155 that constitutes the outer first groove portion 181 at its first tip surface portion 241 due to the biasing force of the spring 203.

[0179] Furthermore, in this state, as shown in Figure 4, the second lug portion 223 of the outer friction pad 23 abuts against the biasing plate portion 158 that constitutes the outer second groove portion 182 at its second inner surface portion 253. Also, in this state, the second lug portion 223 of the outer friction pad 23 abuts against the outer support plate portion 152 that constitutes the outer second groove portion 182 at its second outer surface portion 252 by the biasing force of the biasing plate portion 158. Also, in this state, the second lug portion 223 of the outer friction pad 23 faces the intermediate plate portion 155 that constitutes the outer second groove portion 182 at its second tip surface portion 251 with a slight gap between them.

[0180] Patent Document 1, mentioned above, discloses a technique for providing a shim between the backing plate of the friction pad and the member that presses the friction pad in order to stabilize the behavior of the friction pad during braking and suppress the occurrence of brake squeal. In Patent Document 1, the shim is provided with through holes or notches to reduce the pressing force on the friction pad. This increases the pressing force acting on both ends of the friction pad in the circumferential direction of the disc compared to the center, improving the stability of the behavior of the center of the friction pad and suppressing brake squeal.

[0181] Incidentally, there is a need to suppress the deterioration of the ease of assembling friction pads to the carrier. In other words, for example, there is a demand for miniaturization of calipers for light vehicles, etc. To meet this demand, there is a growing need to provide the outer beam portion of the carrier in a transverse manner relative to the outer friction pad. In this structure, where the outer beam portion of the carrier is provided in a transverse manner relative to the outer friction pad, if a shim interferes with the outer beam portion when attaching the outer friction pad to the carrier, the shim will be damaged. To avoid this situation, the assembly of the outer friction pad to the carrier must be done carefully, which may lead to a deterioration in the ease of assembling the outer friction pad to the carrier.

[0182] In contrast, the disc brake 1 of the first embodiment is provided with a notch 311 in the shim 202 to avoid interference with the outer beam portion 32 when assembling the outer friction pad 23 to the carrier 11, as described above. As a result, when assembling the outer friction pad 23 to the carrier 11, the notch 311 prevents the shim 202 from interfering with the outer beam portion 32. Therefore, the disc brake 1 can easily avoid damaging the shim 202 when assembling the outer friction pad 23 to the carrier 11. Consequently, the disc brake 1 can suppress a decrease in the ease of assembling the outer friction pad 23 to the carrier 11.

[0183] Furthermore, the disc brake 1 has an outer-side connecting portion 83 in which at least a part of the outer beam portion 32 is a protrusion in the disc radial direction. As a result, the disc brake 1 has a structure in which the outer-side friction pad 23 is more likely to interfere with the outer beam portion 32 when assembled to the carrier 11. Therefore, the disc brake 1 is highly effective in suppressing the decrease in the ease of assembling the outer-side friction pad 23 to the carrier 11 due to the provision of the notch portion 311.

[0184] Furthermore, in the first embodiment, the disc brake 1 has an outer-side connecting portion 83 which is an arc-shaped portion that is convex outward in the radial direction of the disc, at least a part of the outer beam portion 32. As a result, the disc brake 1 has a structure in which the outer-side friction pad 23 is more likely to interfere with the outer beam portion 32 when assembled to the carrier 11. Therefore, the disc brake 1 is highly effective in suppressing the decrease in the ease of assembling the outer-side friction pad 23 to the carrier 11 due to the provision of the notch portion 311.

[0185] Furthermore, the disc brake 1 of the first embodiment has a first base extension 81 and a second base extension 82, which are straight sections, at least part of which is a straight shape of the outer beam portion 32. As a result, the outer beam portion 32 can be made lighter, and consequently the carrier 11 can be made lighter.

[0186] Furthermore, in the disc brake 1 of the first embodiment, the outer-side connection portion 83, which is an arc-shaped portion, has a shape that bulges towards the center in the longitudinal direction of the outer-side friction pad 23. As a result, the disc brake 1 has a structure in which the outer-side friction pad 23 is more likely to interfere with the outer beam portion 32 when assembled to the carrier 11. Therefore, the disc brake 1 is highly effective in suppressing the decrease in the ease of assembling the outer-side friction pad 23 to the carrier 11 due to the provision of the notch portion 311.

[0187] Furthermore, in the disc brake 1 of the first embodiment, the outer-side connecting portion 83, which is at least a part of the outer beam portion 32, has a constant cross-sectional shape perpendicular to the extending direction of the outer beam portion 32. Therefore, the disc brake 1 can increase the strength of the outer beam portion 32.

[0188] Furthermore, in the disc brake 1 of the first embodiment, a portion of the shim 202 is provided to conform to the shape of the outer beam portion 32. As a result, the shim 202 of the disc brake 1 is prone to interference with the outer beam portion 32. Therefore, the disc brake 1 is highly effective in suppressing the decrease in the ease of assembling the outer friction pad 23 to the carrier 11 due to the provision of a notch 311 in the shim 202.

[0189] Furthermore, in the first embodiment, the disc brake 1 has a shim 202 and an outer beam portion 32 that are spaced a predetermined distance apart. Therefore, the disc brake 1 can further suppress the decrease in the ease of assembling the outer friction pad 23 to the carrier 11.

[0190] [Second Embodiment] Next, the second embodiment will be described, primarily based on Figures 15 to 19, focusing on the differences from the first embodiment. Parts common to both the first and second embodiments will be represented by the same designations and reference numerals.

[0191] In the disc brake 1A of the second embodiment, as shown in Figures 15 and 16, an outer friction pad 23A (friction pad) which is partially different from the outer friction pad 23 of the first embodiment is provided in place of the outer friction pad 23.

[0192] The outer friction pad 23A has a friction pad body 201 similar to that of the outer friction pad 23. In the outer friction pad 23A as well, the direction connecting the first ear portion 222 and the second ear portion 223 is the longitudinal direction. Also in the outer friction pad 23A, the thickness direction of the base portion 221, the first ear portion 222, and the second ear portion 223 is the thickness direction. Furthermore, in the outer friction pad 23A, the direction perpendicular to the longitudinal direction and perpendicular to the thickness direction is the height direction.

[0193] The outer friction pad 23A has a first shim 261A and a second shim 262A (shim), which are different from the shim 202, and replaces the shim 202. The first shim 261A has a mirror-symmetric shape and is flat overall.

[0194] The second shim 262A has a mirror-symmetric shape. The second shim 262A has a main plate portion 281A, an outer locking plate portion 282A, and a pair of inner locking plate portions 283A. The main plate portion 281A has a flat plate shape. The main plate portion 281A is positioned to cover the first shim 261A and is in surface contact with the first shim 261A. The first shim 261A is integrated with the main plate portion 281A by adhesive or the like while positioned relative to the second shim 262A.

[0195] The first shim 261A is positioned to cover the main surface portion 232 of the plate 211. In this state, the first shim 261A is in surface contact with the main surface portion 232. In this state, the thickness direction of the first shim 261A coincides with the thickness direction of the outer friction pad 23A. The second shim 262A is positioned such that its main plate portion 281A covers the first shim 261A from the side opposite to the plate 211. In this state, the thickness direction of the main plate portion 281A coincides with the thickness direction of the outer friction pad 23.

[0196] The outer locking plate portion 282A protrudes from the main plate portion 281A toward the first shim 261A along the thickness direction of the main plate portion 281A. The outer locking plate portion 282A engages with the outer engagement recess 238 of the plate 211. The pair of inner locking plate portions 283A protrude from the main plate portion 281A along the thickness direction of the main plate portion 281A on the same side as the outer locking plate portion 282A. The pair of inner locking plate portions 283A engage with the portion of the pair of side portions 233 of the substrate portion 221 that is on the inner side surface portion 237 side than the pair of first ears 222 and second ears 223.

[0197] The integrated first shim 261A and second shim 262A are positioned and mounted relative to the plate 211. The outer locking plate portion 282A of the second shim 262A engages with the outer engagement recess 238, and the pair of inner locking plate portions 283A of the second shim 262A engage with the portion of the pair of side portions 233 of the plate 211 that is on the inner side portion 237 side of the pair of first ears 222 and second ears 223.

[0198] As shown in Figures 17 and 18, a notch 301A is formed in the main plate portion 281A of the second shim 262A. As shown in Figures 15 and 16, the second shim 262A is positioned and attached to the plate 211 of the friction pad body 201 together with the first shim 261A. Then, the notch 301A is formed in the height direction of the outer friction pad 23A, recessed from the edge of the main plate portion 281A opposite to the outer locking plate portion 282A toward the outer locking plate portion 282A. The notch 301A penetrates the outer friction pad 23A on the opposite side of the outer locking plate portion 282A in the height direction. The notch 301A is formed between the pair of inner locking plate portions 283A and inner locking plate portions 283A of the main plate portion 281A in the longitudinal direction of the outer friction pad 23A. The notch 301A is formed at the center of the second shim 262A in the longitudinal direction of the outer friction pad 23A. The notch 301A penetrates the main plate portion 281A in the thickness direction.

[0199] The notch 301A has an inner edge 302A and a pair of side edges 303A. The inner edge portion 302A is located at the end of the notch portion 301A on the side of the outer locking plate portion 282A. The inner edge portion 302A has a linear shape that extends in the longitudinal direction of the outer friction pad 23A. The pair of side edges 303A extend from both ends in the longitudinal direction of the outer friction pad 23A of the inner edge 302A, on the side opposite to the outer locking plate 282A.

[0200] With the integrated first shim 261A and second shim 262A positioned and mounted on the friction pad body 201, when viewed in the thickness direction of the outer friction pad 23A, the notch 301A is formed on one side of the second shim 262A in the height direction of the outer friction pad 23A. As shown in Figure 17, the first shim 261A is exposed within the range of the notch 301A. As shown in Figures 17 and 18, when the outer friction pad 23A is assembled to the carrier 11, the notch 301A is formed on the inner portion of the first shim 261A in the disc diameter direction.

[0201] The outer friction pad 23A is also positioned on the carrier 11 in the same way as the outer friction pad 23. This allows the outer friction pad 23A to slide in the axial direction of the disc. As a result, the outer beam portion 32 of the carrier 11 is positioned opposite the outer friction pad 23A in the axial direction of the disc. The outer beam portion 32 is positioned opposite the outer friction pad 23A in the axial direction of the disc, with its position overlapping with the outer friction pad 23A in the radial direction of the disc and its position overlapping with the outer friction pad 23A in the circumferential direction of the disc.

[0202] The outer friction pad 23A includes a plate 211, a friction material 212 provided between the plate 211 and the disc 10, and a first shim 261A and a second shim 262A provided on the main surface portion 232 of the plate 211 opposite to the friction material 212. The main plate portion 281A of the second shim 262A and the first shim 261A are positioned between the plate 211 of the outer friction pad 23A and the outer beam portion 32 of the carrier 11. The second shim 262A has a notch 301A formed on its inner side in the disc radial direction. The notch 301A is positioned in the disc radial direction and also in the disc circumferential direction relative to the outer connection portion 83 of the outer beam portion 32, and faces it in the disc axial direction. At this time, the second shim 262A and the outer beam portion 32 are provided at a predetermined distance apart. In other words, the outer-side connection portion 83 of the outer beam portion 32 is positioned opposite the first shim 261A, which is exposed within the notch portion 301A, in the disk radial direction and also in the disk circumferential direction, facing it in the disk axial direction. A portion of the second shim 262A is provided along the shape of the outer beam portion 32. The longitudinal direction of the second shim 262A coincides with the longitudinal direction of the outer beam portion 32. The outer-side connection portion 83 of the outer beam portion 32 has a shape that bulges outward in the disk radial direction as it approaches the center in the longitudinal direction of the outer-side friction pad 23A.

[0203] When assembling the disc brake 1A to a knuckle (not shown), first attach the carrier 11 to the knuckle (not shown) in the same manner as the disc brake 1. Next, the outer friction pad 23A is inserted between the outer beam portion 32 of the carrier 11 and the disc 10 in the same manner as the outer friction pad 23. During this insertion, as shown in Figure 19, at least one point of the edge portion 331 located at the axial end of the disc 10 on the contact surface 321 of the friction material 212 of the outer friction pad 23A on the disc 10 side is brought into contact with the disc 10, thereby creating these contact portions 381.

[0204] Then, with the contact portion 381 in place, as shown in Figure 16, the first edge portion 245 of the outer friction pad 23A is brought into contact with the outer support plate portion 152 of the outer first groove portion 181 at at least one point, thereby providing the first contact portion 382. Alternatively, as shown in Figure 15, the second edge portion 255 of the outer friction pad 23A is brought into contact with the outer support plate portion 152 of the outer second groove portion 182 at at least one point, thereby providing the second contact portion 383. At least one of the first contact portion 382 and the second contact portion 383 is provided.

[0205] The notch 301A of the second shim 262A is formed so that, in this state, the second shim 262A and the outer beam portion 32 do not come into contact with each other at the position where the outer beam portion 32 and the outer side friction pad 23A come into contact. That is, depending on the angle with respect to the disk 10, the outer side friction pad 23A will come into contact with the outer beam portion 32 as shown in Figure 19, with at least one of the first contact portion 382 and the second contact portion 383 and the contact portion 381 provided. In that case, the first shim 261A will come into contact with the outer beam portion 32, but the second shim 262A will not. The notch 301A of the second shim 262A is formed in a range that avoids interference between the second shim 262A and the outer beam portion 32 when the outer side friction pad 23A is assembled to the carrier 11 in this way.

[0206] Now, let's explain the setting of the notch 301A. The setting of the notch 301A is almost the same as the setting of the notch 301.

[0207] As described above, with the outer friction pad 23A positioned at a predetermined angle of inclination with respect to the disc diameter, the edge portion 331 of the friction material 212 is located at the end of the contact surface 321 that is pressed against the disc 10, on the side of the central axis of the disc 10. In this state, a contact portion 381 (first contact portion) is provided, where only at least one point of the edge portion 331 and the disc 10 are in contact.

[0208] Furthermore, in the state having this contact portion 381, as shown in Figure 16, the outer friction pad 23A and the outer first groove 181 are brought into contact at at least one point to provide a first contact portion 382 where they make contact. Alternatively, as shown in Figure 15, the outer friction pad 23A and the outer second groove 182 are brought into contact at at least one point to provide a second contact portion 383 where they make contact. At least one of the first contact portion 382 and the second contact portion 383 is provided.

[0209] Then, in a state in which at least one of the first contact portion 382 and the second contact portion 383 and the abutment portion 381 are present, the edge portion 115 of the outer beam portion 32 and the outer side friction pad 23A are brought into contact at at least one point to provide a second abutment portion 384 in which they abut. That is, the outer side friction pad 23A is restrained in a state in which at least one of the first contact portion 382 and the second contact portion 383, the abutment portion 381 and the second abutment portion 384 are provided. If this condition is met, the second shim 262A is provided with a notch 301A such that the second abutment portion 384 does not contact the second shim 262A but abuts the first shim 261A. In other words, if this condition is met, a notch 301A is provided at the point where the outer beam portion 32 and the outer friction pad 23A come into contact.

[0210] To satisfy this, with at least one of the first contact portion 382 and the second contact portion 383, abutment portion 381, and a second abutment portion 384 provided, and the outer side friction pad 23 restrained, the angle (θ) formed between the thickness direction of the plate 211 and the axial direction of the disk 10, with the second abutment portion 384 as the intersection point, and the thickness (t) of the shim 202, and with the outer side friction pad 23 restrained forming an angle θ, the displacement (x) of the outer beam portion 32 in the radial direction of the disk from the central axis of the disk 10 is taken with respect to the central axis of the disk 10.

[0211] At this time, the partial derivative (F(x)) of the second contact portion 384 in the disk radial direction in the disk axial direction is, A notch 301A is provided in the second shim 262A according to the displacement (x) such that the notch 311 of shim 202 > F(x). This allows the outer beam portion 32 to contact the first shim 261A without interfering with the second shim 262A.

[0212] In the second embodiment of the disc brake 1A, a notch 301A is provided in the second shim 262A to avoid interference with the outer beam portion 32 when assembling the outer friction pad 23A to the carrier 11, as described above. As a result, when assembling the outer friction pad 23A to the carrier 11 of the disc brake 1, the notch 301A prevents the second shim 262A from interfering with the outer beam portion 32. Therefore, the disc brake 1A can easily avoid damaging the second shim 262A when assembling the outer friction pad 23A to the carrier 11. Consequently, the disc brake 1A can suppress a decrease in the ease of assembling the outer friction pad 23A to the carrier 11.

[0213] The disc brake 1A of the second embodiment can also achieve the same effects as the disc brake 1 of the first embodiment.

[0214] In the first and second embodiments described above, the case in which the outer-side first groove 181 and outer-side second groove 182 are formed in the first pad spring 21 and the second pad spring 22 was explained as an example. However, even without the first pad spring 21 and the second pad spring 22, the first outer-side locking portion 55 and the second outer-side locking portion 65 of the carrier body 20 may be used as grooves.

[0215] Furthermore, although the first and second embodiments described above have explained the case in which the outer friction pads 23 and 23A have a pair of first ears 222 and second ears 223, the present invention can also be applied to structures in which only one of the pair of first ears 222 and second ears 223 is provided. That is, the outer friction pads 23 and 23A only need to have ears that protrude from at least one side in the longitudinal direction of the plate 211. [Industrial applicability]

[0216] According to the above-described embodiment, it is possible to suppress a decrease in the ease of assembling the friction pad to the carrier. [Explanation of Symbols]

[0217] 1.1A Disc Brake 10 discs 11 Careers 23,23A Outer friction pad (friction pad) 32 Outer beam section 33. First Bridge Section (Bridge Section) 34. Second Bridge Section (Bridge Section) 81 First proximal extension part (straight line part) 82 2nd proximal extension part (straight line part) 83 Outer side connection part (protruding part, arc-shaped part) 181 Outer side first groove (groove) 182 Outer side second groove (groove) 202 Sims 211 Plate 212 Friction material 222 1st ear (ear) 223 Second ear (ear) 262A Second Shim (Shim) 301A, 311 Notches 371 Piston 381 Contact part (1st contact part) 382 1st contact part (contact part) 383 2nd contact part (contact part) 384 Second contact part.

Claims

1. A friction pad comprising: a plate moved toward the disk by the thrust of a piston; a friction material provided on the disk-side surface of the plate; a shim provided on the opposite surface of the plate from the friction material; a notch provided in the shim; and a lug protruding from at least one side in the longitudinal direction of the plate; A carrier having a pair of bridge portions that straddle the disk and are spaced apart in the circumferential direction of the disk, groove portions provided in the bridge portions, and an outer beam portion that connects the pair of bridge portions and is provided at a position facing the friction pad in the axial direction of the disk, A disc brake having, With the friction pad, which is provided in a position facing the outer beam portion in the axial direction of the disk, inclined at a predetermined angle with respect to the radial direction of the disk, the contact portion that comes into contact with the disk and the axial end of the disk on the disk-side surface of the friction material, The contact portion where the groove and the lug come into contact, In a state having, The notch is provided at the location where the outer beam portion and the friction pad come into contact. Disc brakes.

2. At least a portion of the outer beam section has a protrusion in the radial direction of the disk, The disc brake according to claim 1.

3. At least a portion of the outer beam section has a straight section that is linear in shape. The disc brake according to claim 1.

4. At least a portion of the outer beam section has an arc-shaped portion that is convex radially outward from the disk. The disc brake according to claim 1.

5. The arc-shaped portion has a shape that bulges towards the center in the longitudinal direction of the friction pad. The disc brake according to claim 4.

6. At least a portion of the outer beam portion has a constant cross-sectional shape in the direction perpendicular to the extending direction of the outer beam portion. The disc brake according to claim 1.

7. A portion of the shim is provided along the shape of the outer beam portion. The disc brake according to claim 1.

8. The shim and the outer beam portion are provided at a predetermined distance apart. The disc brake according to claim 1.

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