Brake carriers and methods for manufacturing brake carriers.

Abstract

Provided is a brake carrier that movably supports a caliper which applies a braking force to a vehicle, the brake carrier comprising: a first fixed part fixed to a non-rotating part of the vehicle; a second fixed part fixed to a non-rotating part of the vehicle and separated from the first fixed part with a maximum distance between mutual opposite ends thereof being a predetermined distance; a first arm part extending from the first fixed part; a second arm part extending from the second fixed part, with a maximum distance from the first arm part between mutual opposite ends thereof being smaller than the predetermined distance; a slide pin storage part which extends from the first arm part and in which a slide pin of the caliper is movably stored; a hot water mark provided on a surface of the slide pin storage part along a movement axis direction of the slide pin; a first parting line provided on a surface of the first fixed part along the movement axis direction; and a second parting line provided on a surface along the movement axis direction so as to be in contact with a part of the hot water mark.

Description

Brake carrier and method of manufacturing the brake carrier

[0001] The present invention relates to a brake carrier and a method for manufacturing the brake carrier. This application claims priority to Japanese Patent Application No. 2023-112165, filed on July 7, 2023, the contents of which are incorporated herein by reference.

[0002] A technology for manufacturing a caliper body using a caliper body casting mold that includes a lower mold that forms at least the bottom side of the cylinder bore of the working portion of the caliper body, and a first upper mold and a second upper mold that can be separated horizontally vertically above the lower mold has been disclosed (see, for example, Patent Document 1).

[0003] Japanese Patent Application Publication No. 2009-299891

[0004] Caliper bodies and brake carriers are generally formed by casting, followed by machining of the necessary parts. When manufacturing brake carriers, there is a demand for reducing product costs.

[0005] An object of the present invention is to provide a brake carrier and a method for manufacturing the brake carrier that can reduce production costs.

[0006] A first aspect of the present invention is a brake carrier that movably supports a caliper that applies braking force to a vehicle, the brake carrier comprising: a first fixed part fixed to a non-rotating part of the vehicle; a second fixed part fixed to the non-rotating part of the vehicle, the second fixed part having a maximum distance between opposite ends of the first fixed part that is a predetermined distance apart; a first arm extending from the first fixed part; a second arm extending from the second fixed part, the maximum distance between opposite ends of the first arm being shorter than the predetermined distance; a slide pin storage part extending from the first arm and in which a slide pin of the caliper is movably stored; a gate mark provided on a surface of the slide pin storage part that is aligned with the direction of movement of the slide pin; a first parting line provided on a surface of the first fixed part that is aligned with the direction of movement of the slide pin; and a second parting line provided on the surface that is aligned with the direction of movement of the slide pin, in contact with a portion of the gate mark.

[0007] A second aspect of the present invention is a method for manufacturing a brake carrier that movably supports a caliper that applies braking force to a vehicle, and includes a gate installation step of installing a gate opposite a surface along the axial direction of movement of a slide pin of a slide pin storage section in which the slide pin of the caliper is movably stored; a core installation step of installing a core in contact with the gate at a position between the gate and a vehicle fixed section that is fixed to a non-rotating section of the vehicle; a first mold splitting step of splitting a mold based on an end of the core that does not have the gate installed; and a second mold splitting step of splitting the mold based on the end of the core on the gate side.

[0008] According to the above aspects of the present invention, it is possible to provide a brake carrier and a method for manufacturing the brake carrier that can reduce production costs.

[0009] 1 is a perspective view showing a disc brake including a brake carrier of a first embodiment of the present invention; FIG. 2 is a view showing a disc brake including a brake carrier of the first embodiment as seen from the inner side; FIG. 3 is a view showing the brake carrier of the first embodiment as seen from the inner side; FIG. 4 is a view showing the brake carrier of the first embodiment as seen from the arrow IV in FIG. 3; FIG. 5 is a view showing the brake carrier of the first embodiment as seen from the arrow V in FIG. 3; FIG. 6 is a view showing the brake carrier of the first embodiment as seen from the arrow VI in FIG. 3, with the outlines of the parting line and the gate marks indicated by thick lines; FIG. 7 is a view showing the relationship between the brake carrier of the first embodiment and a casting mold used in the casting process thereof, as seen from the inner side; FIG. 8 is a side view showing the brake carrier of a second embodiment of the present invention, with the outlines of the parting line and the gate marks indicated by thick lines; FIG. 9 is a view showing the relationship between the brake carrier of the second embodiment of the present invention and a casting mold used in the casting process thereof, as seen from the inner side; FIG. 10 is a side view showing the brake carrier of a third embodiment of the present invention, with the outlines of the parting line and the gate marks indicated by thick lines. FIG. 10 is a view showing the relationship between the brake carrier of the third embodiment and a casting mold used in the casting process thereof, as viewed from the inner side.

[0010] [First Embodiment] A first embodiment of the present invention will be described below with reference to Figures 1 to 7. The disc brake 1 shown in Figures 1 and 2 includes a brake carrier 10 of the first embodiment. The disc brake 1 applies braking force to a vehicle such as an automobile. Specifically, the disc brake 1 is used for braking a four-wheeled vehicle. The disc brake 1 brakes the vehicle by stopping the rotation of a circular disc 11 that rotates together with a wheel (not shown).

[0011] As shown in FIG. 1, the disc brake 1 includes a brake carrier 10, a caliper 21, a pair of first and second pin boots 22 and 23, a pair of first and second pad springs 24 and 25, and a pair of first and second friction pads 26 and 27.

[0012] Hereinafter, the central axis of the disc 11 will be referred to as the disc axis. The direction in which the disc axis extends will be referred to as the disc axial direction. The radial direction of the disc 11 within the disc brake 1 will be referred to as the disc radial direction. The circumferential direction of the disc 11 within the disc brake 1, i.e., the direction of rotation, will be referred to as the disc circumferential direction. The center side of the disc 11 in the disc radial direction will be referred to as the disc radial inner side. The opposite side of the center of the disc 11 in the disc radial direction will be referred to as the disc radial outer side. The center side in the disc circumferential direction will be referred to as the disc circumferential inner side. The opposite side of the center in the disc circumferential direction will be referred to as the disc circumferential outer side. A line passing through the disc axis and the disc circumferential center of the brake carrier 10 and the caliper 21 along the disc radial direction will be referred to as the radial reference line. This radial reference line is perpendicular to the disc axis. A plane including this radial reference line and the disc axis will be referred to as the radial reference plane. The outer side in the vehicle width direction of a vehicle to which this disc brake 1 is provided will be referred to as the outer side. The inside of the vehicle in the vehicle width direction on which this disc brake 1 is provided is referred to as the inner side.

[0013] The brake carrier 10 is fixed to a non-rotating portion of the vehicle while straddling the outer periphery of the disc 11. The brake carrier 10 includes an inner-side arrangement portion 31, an outer-side arrangement portion 32, and a pair of first slide pin storage portions 33 (slide pin storage portions) and second slide pin storage portions 34 that connect the inner-side arrangement portion 31 and the outer-side arrangement portion 32. The brake carrier 10 has a shape that is approximately mirror-symmetrical with respect to a radial reference plane. In other words, the radial reference line and the radial reference plane pass through the center position of the brake carrier 10 in the disc circumferential direction.

[0014] The inner-side portion 31 is disposed on one side of the disk 11 in the disk axial direction and attached to a non-rotating portion of the vehicle. Here, the non-rotating portion of the vehicle to which the brake carrier 10 is attached is disposed on the inner side of the disk 11. Therefore, the inner-side portion 31 attached to this non-rotating portion is also disposed on the inner side of the disk 11. The inner-side portion 31 faces the disk 11 in the disk axial direction. The inner-side portion 31 movably supports the first friction pad 26. The first friction pad 26 is disposed on the inner side of the disk 11. The first friction pad 26 is disposed facing the disk 11 in the disk axial direction.

[0015] The outer-side portion 32 is disposed on the other side of the disk 11 in the disk axial direction. The outer-side portion 32 is disposed on the outer side of the disk 11. The outer-side portion 32 faces the disk 11 in the disk axial direction. The outer-side portion 32 movably supports the second friction pad 27. The second friction pad 27 is disposed on the outer side of the disk 11. The second friction pad 27 is disposed facing the disk 11 in the disk axial direction.

[0016] The first slide pin storage section 33 and the second slide pin storage section 34 both extend in the disk axial direction. The first slide pin storage section 33 and the second slide pin storage section 34 both cross the outer periphery of the disk 11 in the disk axial direction. The first slide pin storage section 33 connects the ends of the inner-side portion 31 and the outer-side portion 32 on the outer side in the disk radial direction and on the same side in the disk circumferential direction. The second slide pin storage section 34 connects the ends of the inner-side portion 31 and the outer-side portion 32 on the outer side in the disk radial direction and on the same side in the disk circumferential direction.

[0017] As shown in FIG. 2 , the inner-side portion 31 includes a first fixing portion 42 (vehicle fixing portion) having a first screw hole 41, a second fixing portion 44 having a second screw hole 43, and a main beam 45 connecting the first fixing portion 42 and the second fixing portion 44. The inner-side portion 31 also includes a first arm 46 extending from the first fixing portion 42 and a second arm 47 extending from the second fixing portion 44. As shown in FIG. 1 , the first fixing portion 42, the second fixing portion 44, the main beam 45, the first arm 46, and the second arm 47 are all positioned on the inner side of the disk 11. The first fixing portion 42, the second fixing portion 44, the main beam 45, the first arm 46, and the second arm 47 all face the inner surface of the disk 11 in the disk axial direction.

[0018] The first fixing portion 42 is provided at one end of the inner-side portion 31 in the disk circumferential direction (hereinafter referred to as the first end in the disk circumferential direction). The second fixing portion 44 is provided at the other end of the inner-side portion 31 in the disk circumferential direction opposite the first fixing portion 42 (hereinafter referred to as the second end in the disk circumferential direction). The main beam 45 extends in the disk circumferential direction. The first screw hole 41 is drilled in the first fixing portion 42 along the disk axial direction. The second screw hole 43 is drilled in the second fixing portion 44 along the disk axial direction.

[0019] The brake carrier 10 is attached to a mounting portion (not shown), which is a non-rotating portion of the vehicle, with bolts threaded into the first screw holes 41 and the second screw holes 43, respectively, with the first fixing portion 42 and the second fixing portion 44 abutting against this mounting portion. In other words, the first fixing portion 42 and the second fixing portion 44 of the brake carrier 10 are fixed to the non-rotating portion of the vehicle. The first fixing portion 42 and the second fixing portion 44 fixed to the non-rotating portion of the vehicle are aligned with each other in the disc axial direction. In this state, the main beam 45 is aligned with the first fixing portion 42 and the second fixing portion 44 in the disc axial direction.

[0020] The first arm 46 overlaps with the first fixing portion 42 in the disk axial direction and extends radially outward from the first fixing portion 42. The second arm 47 shown in Figure 2 overlaps with the second fixing portion 44 in the disk axial direction and extends radially outward from the second fixing portion 44. The first arm 46 is positioned closer to the first end in the disk circumferential direction than the second arm 47.

[0021] A first locking portion 51 is formed on the first arm portion 46 on its inner side in the disk circumferential direction. The first locking portion 51 is recessed from the inner surface of the first arm portion 46 in the disk circumferential direction outward in the disk circumferential direction. The first locking portion 51 crosses the first arm portion 46 in the disk axial direction. A second locking portion 52 is formed on the inner side in the disk circumferential direction of the second arm portion 47. The second locking portion 52 is recessed from the inner surface of the second arm portion 47 in the disk circumferential direction outward in the disk circumferential direction. The second locking portion 52 crosses the second arm portion 47 in the disk axial direction. The first locking portion 51 and the second locking portion 52 face each other in the disk axial direction and disk radial direction and are aligned with each other in the disk circumferential direction. The first locking portion 51 and the second locking portion 52 are mirror images.

[0022] As shown in FIG. 1 , the first slide pin storage portion 33 extends from the radially outer end of the first arm portion 46 toward the outer side along the disk axial direction. The first slide pin storage portion 33 crosses the disk 11 in the disk axial direction, radially outer than its outer peripheral surface. The first slide pin storage portion 33 also protrudes from the first arm portion 46 toward the inner side along the disk axial direction. The second slide pin storage portion 34 extends from the radially outer end of the second arm portion 47 shown in FIG. 2 toward the outer side along the disk axial direction, as shown in FIG. 1 . The second slide pin storage portion 34 crosses the disk 11 in the disk axial direction, radially outer than its outer peripheral surface. The second slide pin storage portion 34 also protrudes from the second arm portion 47 shown in FIG. 2 toward the inner side along the disk axial direction.

[0023] The first slide pin storage section 33 shown in Fig. 1 is formed with a first pin insertion hole 55 shown in Fig. 3 extending along the disk axial direction. The first pin insertion hole 55 is formed from the inner end face of the first slide pin storage section 33 to a midpoint within the first slide pin storage section 33. The second slide pin storage section 34 is formed with a second pin insertion hole 56 extending along the disk axial direction. The second pin insertion hole 56 is formed from the inner end face of the second slide pin storage section 34 to a midpoint within the second slide pin storage section 34.

[0024] 1 and 3 to 6 includes a third arm 61 extending from the first slide pin storage section 33 as shown in Fig. 1, a fourth arm 62 as shown in Fig. 5 extending from the second slide pin storage section 34, and an outer beam 63 connecting the third arm 61 and the fourth arm 62. As shown in Fig. 1, the third arm 61, the fourth arm 62, and the outer beam 63 as shown in Fig. 5 are all disposed on the outer side of the disk 11. The third arm 61, the fourth arm 62, and the outer beam 63 all face the outer surface of the disk 11 in the disk axial direction.

[0025] As shown in FIG. 1 , the third arm 61 extends radially inward from the end of the first slide pin housing 33 opposite the first arm 46 in the disk axial direction. The fourth arm 62 shown in FIG. 5 extends radially inward from the end of the second slide pin housing 34 opposite the second arm 47 in the disk axial direction. The third arm 61 is located closer to the first end in the disk circumferential direction than the fourth arm 62. The outer beam 63 connects the radially inner ends of the third arm 61 and the fourth arm 62 to each other. The outer beam 63 extends in the disk circumferential direction.

[0026] Although not shown, the third arm 61 has a third locking portion similar to the first locking portion 51 shown in Fig. 3 formed on its inner side in the disk circumferential direction. The third locking portion (not shown) has a shape that is recessed from the inner surface of the third arm 61 in the disk circumferential direction toward the outer side in the disk circumferential direction. The third locking portion (not shown) crosses the third arm 61 in the disk axial direction. The third locking portion (not shown) is aligned with the first locking portion 51 shown in Fig. 3 in the disk radial direction and disk circumferential direction.

[0027] Although not shown, the fourth arm portion 62 shown in FIG. 5 has a fourth locking portion similar to the second locking portion 52 shown in FIG. 3 formed on its inner side in the disk circumferential direction. The fourth locking portion (not shown) is recessed from the inner surface of the fourth arm portion 62 shown in FIG. 5 toward the outer side in the disk circumferential direction. The fourth locking portion (not shown) crosses the fourth arm portion 62 in the disk axial direction. The fourth locking portion (not shown) is aligned with the second locking portion 52 shown in FIG. 3 in the disk radial direction and the disk circumferential direction. The third locking portion (not shown) and the fourth locking portion (not shown) face each other in the disk circumferential direction, aligned with each other in the disk axial direction and the disk radial direction. The third locking portion (not shown) and the fourth locking portion (not shown) are mirror images of each other.

[0028] As shown in Fig. 2, the inner-side portion 31 of the brake carrier 10 supports the first friction pad 26 with a first locking portion 51 provided on the first arm portion 46 and a second locking portion 52 provided on the second arm portion 47. Also, the outer-side portion 32 of the brake carrier 10 shown in Fig. 1 supports the second friction pad 27 shown in Fig. 1 with a third locking portion (not shown) provided on the third arm portion 61 and a fourth locking portion (not shown) provided on the fourth arm portion 62 shown in Fig. 5.

[0029] The brake carrier 10 has the first fixing portion 42, the first arm 46, the first slide pin housing portion 33, and the third arm 61 arranged on a first end side in the disc circumferential direction. The brake carrier 10 has the second fixing portion 44, the second arm 47 shown in Figure 3, the second slide pin housing portion 34, and the fourth arm 62 shown in Figure 5 arranged on a second end side in the disc circumferential direction.

[0030] The first friction pad 26 on the inner side and the second friction pad 27 on the outer side shown in Fig. 1 are components having substantially the same shape. The first friction pad 26 and the second friction pad 27 have a backing plate 81. The first friction pad 26 and the second friction pad 27 have a lining 82, as shown for the second friction pad 27 in Fig. 1. The lining 82 is attached to one surface of the backing plate 81 in the plate thickness direction.

[0031] The back plate 81 of the inner-side first friction pad 26 and the back plate 81 of the outer-side second friction pad 27 are common parts with the same shape. As shown in Figure 2 , the first friction pad 26 has a main body portion 85 and a pair of protrusions 86 that protrude in opposite directions along the disc circumferential direction from both ends of the main body portion 85 in the disc circumferential direction. A lining (not shown) similar to the lining 82 of the second friction pad 27 shown in Figure 1 is attached to the main body portion 85 of the back plate 81. The first pad spring 24 and the second pad spring 25 are both attached to the brake carrier 10.

[0032] The inner-side first friction pad 26 is placed in a state where its lining (not shown) faces the inner-side surface of the disc 11. In this state, as shown in FIG. 2 , the protruding portion 86 on the first end side of the back plate 81 in the disc circumferential direction of the inner-side first friction pad 26 is inserted into the first locking portion 51 of the first arm portion 46 via the first pad spring 24. Furthermore, the protruding portion 86 on the second end side of the back plate 81 in the disc circumferential direction of the inner-side first friction pad 26 is inserted into the second locking portion 52 of the second arm portion 47 via the second pad spring 25. As a result, the first friction pad 26 is supported by the brake carrier 10 via the first pad spring 24 and the second pad spring 25.

[0033] The first friction pad 26 supported by the brake carrier 10 in this manner is restricted from moving in the disc radial direction and disc circumferential direction relative to the brake carrier 10, but is allowed to move in the disc axial direction relative to the brake carrier 10. The first pad spring 24 and the second pad spring 25 guide this movement of the first friction pad 26 in the disc axial direction. When the brake carrier 10 is in a state in which it supports the first friction pad 26, the main beam 45 is positioned inside the first friction pad 26 in the disc radial direction. The main beam 45 is positioned so that its position in the disc axial direction overlaps with that of the first friction pad 26.

[0034] The outer-side second friction pad 27 shown in FIG. 1 is in a state where the lining 82 faces the outer-side surface of the disc 11. In this state, the protruding portion (not shown) on the first end side of the back plate 81 in the disc circumferential direction of the outer-side second friction pad 27 is inserted into the third locking portion (not shown) of the third arm portion 61 via the first pad spring 24. In addition, in this state, the protruding portion (not shown) on the second end side of the back plate 81 in the disc circumferential direction of the outer-side second friction pad 27 is inserted into the fourth locking portion (not shown) of the fourth arm portion 62 shown in FIG. 5 via the second pad spring 25. As a result, the second friction pad 27 shown in FIG. 1 is supported by the brake carrier 10 via the first pad spring 24 and the second pad spring 25.

[0035] The second friction pad 27 supported by the brake carrier 10 in this manner is restricted from moving in the disc radial direction and disc circumferential direction relative to the brake carrier 10, but is allowed to move in the disc axial direction relative to the brake carrier 10. The first pad spring 24 and the second pad spring 25 guide the movement of the second friction pad 27 in the disc axial direction.

[0036] The caliper 21 includes a caliper body 101, a pair of first and second slide pins 102 (slide pins), 103, a mounting bolt 104 that fixes the first slide pin 102 to the caliper body 101, and a mounting bolt 105 that fixes the second slide pin 103 to the caliper body 101. The caliper 21 has the first slide pin 102 disposed on a first end side in the disk circumferential direction and the second slide pin 103 disposed on a second end side in the disk circumferential direction.

[0037] The caliper 21 has a shape that is approximately mirror-symmetrical. Therefore, the radial reference line and the radial reference plane pass through the center position in the disk circumferential direction of the caliper 21. The caliper 21 is fixed to the caliper body 101 with the first slide pin 102 and the second slide pin 103 aligned with each other in the axial direction and arranged in parallel.

[0038] The first slide pin 102 of the caliper 21 is slidably fitted into the first pin insertion hole 55 shown in Fig. 3 formed in the first slide pin storage portion 33 of the brake carrier 10. As a result, the first slide pin 102 of the caliper 21 shown in Fig. 1 is movably stored in the first slide pin storage portion 33. The axial direction of movement of the first slide pin 102 (hereinafter referred to as the movement axial direction) is the axial direction of the first pin insertion hole 55 shown in Fig. 3 and coincides with the disc axial direction.

[0039] 1, the second slide pin 103 is slidably fitted into the second pin insertion hole 56 shown in FIG. 3 formed in the second slide pin storage portion 34 of the brake carrier 10. As a result, the second slide pin 103 of the caliper 21 shown in FIG. 1 is movably stored in the second slide pin storage portion 34. The movement axis direction of the second slide pin 103 is the axial direction of the second pin insertion hole 56 shown in FIG. 3, which coincides with the disc axis direction.

[0040] 1 has a caliper body 101 that is supported in the first slide pin storage portion 33 and the second slide pin storage portion 34 of the brake carrier 10 via a first slide pin 102 and a second slide pin 103 so as to be slidable in the disc axial direction. In other words, the brake carrier 10 supports the caliper 21 in the first slide pin storage portion 33 and the second slide pin storage portion 34 so as to be slidable in the disc axial direction. Thus, the caliper 21 is provided in the brake carrier 10 so as to be movable in the disc axial direction. The first pin boot 22 covers the portion of the first slide pin 102 that protrudes from the first slide pin storage portion 33. The second pin boot 23 covers the portion of the second slide pin 103 that protrudes from the second slide pin storage portion 34.

[0041] The caliper body 101 has a shape that is approximately mirror-symmetric. A radial reference line and a radial reference plane pass through the center position of the caliper body 101 in the disk circumferential direction. The caliper body 101 includes a cylinder portion 121, a bridge portion 122, a claw portion 123, a first pin mounting portion 124, and a second pin mounting portion 125.

[0042] The cylinder portion 121 is disposed on the inner side in the disk axial direction relative to the disk 11. The bridge portion 122 extends from the outer portion in the disk radial direction of the cylinder portion 121 to the outer side along the disk axial direction. The bridge portion 122 crosses the outer periphery of the disk 11 in the disk axial direction on the outer side of the disk radial direction.

[0043] The claw portion 123 extends radially inward from the end of the bridge portion 122 opposite the cylinder portion 121 in the disk axial direction and is positioned outer than the disk 11. The first pin mounting portion 124 extends from the cylinder portion 121 toward the first end in the disk circumferential direction. The second pin mounting portion 125 extends from the cylinder portion 121 toward the second end in the disk circumferential direction.

[0044] A piston (not shown) that constitutes the caliper 21 is housed in the cylinder portion 121 of the caliper body 101. The piston (not shown) is housed in the portion of the cylinder portion 121 on the disk 11 side so as to be movable in the disk axial direction. The piston (not shown) faces the inner surface of the disk 11. A first friction pad 26 is disposed between the inner surface of the disk 11 and the piston (not shown). When the piston (not shown) moves toward the disk 11 along the disk axial direction, it comes into contact with and presses the first friction pad 26.

[0045] In the disc brake 1, brake fluid is introduced into the cylinder portion 121 of the caliper 21 via brake piping (not shown). Brake fluid pressure then acts on a piston (not shown) in the cylinder portion 121. As a result, the piston (not shown) advances toward the disc 11, contacts an inner first friction pad 26 disposed between the piston and the disc 11, and presses the inner first friction pad 26 toward the disc 11. Then, the inner first friction pad 26 is guided by the brake carrier 10 via the first pad spring 24 and the second pad spring 25 and moves in the disc axial direction, until it comes into contact with the inner surface of the disc 11 at the lining 82.

[0046] The reaction force of this pressure causes the caliper body 101 to slide the first slide pin 102 and the second slide pin 103 relative to the brake carrier 10, moving in the disc axial direction. As a result, the claw portion 123 comes into contact with the outer-side second friction pad 27 arranged between the claw portion 123 and the disc 11, and presses it toward the disc 11. As a result, the outer-side second friction pad 27 is guided by the brake carrier 10 via the first pad spring 24 and the second pad spring 25 and moves in the disc axial direction, until the lining 82 comes into contact with the outer surface of the disc 11.

[0047] In this manner, the caliper 21 slidably supported on the brake carrier 10 clamps the pair of first and second friction pads 26 and 27 from both sides in the disc axial direction between the piston (not shown) and the claws 123 through the operation of the piston. The caliper 21 then presses the first and second friction pads 26 and 27 against both sides of the disc 11. As a result, the first and second friction pads 26 and 27 apply frictional resistance to the disc 11, thereby applying a braking force to the vehicle. In this manner, the disc brake 1 generates a braking force by the caliper 21 supported on the brake carrier 10 pressing the first and second friction pads 26 and 27, also supported on the brake carrier 10, against the disc 11. The caliper 21 is a so-called fist-type (slide-type) caliper. The brake carrier 10 movably supports the caliper 21, which applies a braking force to the vehicle.

[0048] As shown in FIG. 6 , the first fixing portion 42 of the brake carrier 10 is slightly offset toward the outer side from a first side surface 141 on the inner side of the first arm portion 46 in the disc axial direction. The first fixing portion 42 has a first mounting surface 142 on the inner side in the disc axial direction that is positioned toward the outer side from the first side surface 141. The first fixing portion 42 has this first mounting surface 142 that abuts against a mounting portion (not shown) that is a non-rotating portion of the vehicle. The first mounting surface 142 is flat and extends perpendicular to the disc axis. As shown in FIG. 3 , the first fixing portion 42 has a first screw hole 41 formed in an area inside the first mounting surface 142.

[0049] The first arm 46 has a first wall surface 144. The first wall surface 144 connects the radially inner edge of the first side surface 141 with the radially outer edge of the first mounting surface 142. The first wall surface 144 has an arc shape. The first wall surface 144 is formed at the radially inner end position of the first arm 46.

[0050] 1 , in the brake carrier 10, a first end surface 151 located at a first end in the disc circumferential direction of the first fixing portion 42, the first arm portion 46, and the first slide pin housing portion 33 is aligned along the axial direction of movement of the first slide pin 102. In other words, the first end surface 151 is aligned along the disc axial direction. The first end surface 151 has a first inner surface portion 152, a first intermediate surface portion 153, and a first outer surface portion 154.

[0051] The first inner surface portion 152 is formed on the first fixing portion 42. The first intermediate surface portion 153 is formed on the first arm portion 46. The first outer surface portion 154 is formed on the first slide pin storage portion 33. Therefore, the first intermediate surface portion 153 is located further outward in the disc radial direction than the first inner surface portion 152, and the first outer surface portion 154 is located further outward in the disc radial direction than the first intermediate surface portion 153. The first inner surface portion 152, first intermediate surface portion 153, and first outer surface portion 154 are all aligned along the axial direction of movement of the first slide pin 102, in other words, the disc axial direction.

[0052] 6 , when the brake carrier 10 is viewed from a direction perpendicular to the radial reference plane, the portion of the first slide pin storage section 33 that does not overlap with the first arm 46 in its extension direction (the left-right direction in FIG. 6 ) and the portion that overlaps with the first arm 46 in its extension direction (the up-down direction in FIG. 6 ) (the portion above the two-dot chain line X in FIG. 6 ) constitutes the first slide pin storage section 33. At this junction, the portion of the first slide pin storage section 33 that does not overlap with the first arm 46 in its extension direction and does not overlap with the first arm 46 in its extension direction either (the portion below the two-dot chain line X in FIG. 6 ) constitutes the first arm 46.

[0053] 3, the first inner side surface portion 152 of the first fixing portion 42 has a first inner curved surface portion 161 and a first inner inclined surface portion 162. Both the first inner curved surface portion 161 and the first inner inclined surface portion 162 are aligned along the axial direction of movement of the first slide pin 102 shown in FIG. 1, in other words, the disc axial direction.

[0054] As shown in FIG. 3 , the first inner curved surface portion 161 is located radially inward of the first inner inclined surface portion 162. The first inner curved surface portion 161 has the shape of a portion of a cylindrical surface coaxial with the first screw hole 41. In other words, the first inner curved surface portion 161 has the shape of a portion of a cylindrical surface having a central axis within the first fixing portion 42. The first inner curved surface portion 161 is provided on the radially inner side of the first fixing portion 42 and the circumferentially outer side of the first fixing portion 42. The first inner inclined surface portion 162 extends radially outward from the radially outer edge of the first inner curved surface portion 161. The first inner inclined surface portion 162 is flat and inclined with respect to the radial reference plane. The first inner inclined surface portion 162 is inclined so as to approach the radial reference plane as it moves radially outward in the direction of the radial reference line.

[0055] 6, the boundary line between the first inner curved surface portion 161 and the first inner sloped surface portion 162 of the first inner side surface portion 152 is a first parting line 165. The first parting line 165 is linear and rises slightly outward from the first inner curved surface portion 161 and the first inner sloped surface portion 162 on either side of the first parting line 165.

[0056] 1 , the first parting line 165 is aligned along the axial direction of the first slide pin 102, in other words, the disc axial direction. The first parting line 165 is provided on the first inner side surface portion 152 of the first fixing portion 42, which is aligned along the axial direction of the first slide pin 102. The first parting line 165 is located at the position on the brake carrier 10 that is farthest from the radial reference plane.

[0057] The first intermediate surface portion 153 of the first arm portion 46 has a first intermediate inclined surface portion 171 and a first intermediate base surface portion 172. The first intermediate inclined surface portion 171 and the first intermediate base surface portion 172 are both aligned along the axial direction of movement of the first slide pin 102, in other words, the disk axial direction.

[0058] The first intermediate slope portion 171 is located radially outward of the first inner slope portion 162. The first intermediate slope portion 171 extends radially outward from the radially outer edge of the first inner slope portion 162. The first intermediate slope portion 171 is flat and is continuous with and flush with the first inner slope portion 162. The first intermediate slope portion 171 is inclined with respect to the radial reference plane. The first intermediate slope portion 171 is inclined in the direction of the radial reference line so as to approach the radial reference plane as it moves radially outward in the disk direction.

[0059] The first intermediate base surface portion 172 is located radially outward of the first intermediate slope portion 171. The first intermediate base surface portion 172 extends radially outward from the radially outer edge of the first intermediate slope portion 171. The first intermediate base surface portion 172 is planar and parallel to the radial reference plane. A boundary line 175 between the first intermediate slope portion 171 and the first intermediate base surface portion 172 is linear and extends along the axial direction of movement of the first slide pin 102, in other words, the axial direction of the disk.

[0060] The first outer side surface portion 154 of the first slide pin storage portion 33 has a first outer base surface portion 181 and a first outer inclined surface portion 182. The first outer base surface portion 181 is located radially outward of the first intermediate base surface portion 172. The first outer base surface portion 181 extends radially outward from the radially outer edge of the first intermediate base surface portion 172. The first outer base surface portion 181 is flat and is continuous with and coplanar with the first intermediate base surface portion 172. The first outer base surface portion 181 is parallel to the radial reference plane.

[0061] The first outer slope portion 182 is located radially outward of the first outer base surface portion 181 in the disc radial direction. The first outer slope portion 182 extends radially outward from the radially outer edge of the first outer base surface portion 181. The first outer slope portion 182 is inclined with respect to the radial reference plane. The first outer slope portion 182 is inclined in the direction of the radial reference line so as to approach the radial reference plane as it moves radially outward in the disc direction. The first outer slope portion 182 is provided in a portion of the first slide pin storage portion 33 radially outward and circumferentially outward in the disc direction. A boundary line 185 between the first outer base surface portion 181 and the first outer slope portion 182 is linear and extends along the axial direction of movement of the first slide pin 102, in other words, the disc axial direction.

[0062] In the brake carrier 10, a gate trace 191 is formed from a portion of the first intermediate base surface portion 172 on the first outer base surface portion 181 side to a portion of the first outer base surface portion 181 on the first intermediate base surface portion 172 side. In other words, the gate trace 191 is formed continuously across both the first intermediate base surface portion 172 and the first outer base surface portion 181. In yet other words, the gate trace 191 is provided continuously across both the first outer surface portion 154 of the first slide pin storage portion 33 that is aligned with the axial direction of movement of the slide pin 102, and the first intermediate surface portion 153 of the first arm portion 46 that is aligned with the axial direction of movement of the slide pin 102. The gate trace 191 is separated from the first outer slope portion 182 and the first intermediate slope portion 171 in the disc radial direction. The gate trace 191 is provided at an intermediate position between the first outer base surface portion 181 and the first intermediate base surface portion 172 in the axial direction of movement of the first slide pin 102, in other words, in the disk axial direction.

[0063] As its outline is shown by a thick line in Figure 6, the gate trace 191 is rectangular and has an inner edge 192 on the inner side in the disk radial direction, an outer edge 193 on the outer side in the disk radial direction, one side edge 194 on the inner side in the disk axial direction, and the other side edge 195 on the outer side in the disk axial direction. The inner edge 192 and the outer edge 193 are both linear and extend along the axial direction of the first slide pin 102 shown in Figure 1, in other words, the disk axial direction. The one side edge 194 and the other side edge 195 shown in Figure 6 are both linear and extend along the disk radial direction.

[0064] As shown in FIG. 1 , the first end surface 151 has a second parting line 201 on the first intermediate base surface portion 172 of the first intermediate surface portion 153 of the first arm portion 46, which is aligned along the axial direction of the slide pin 102. The second parting line 201 is linear and slightly raised outward from the first intermediate base surface portions 172 on both sides of the second parting line 201. The second parting line 201 is aligned along the axial direction of the first slide pin 102, in other words, along the disk axial direction. As shown by the bold line in FIG. 6 , the second parting line 201 is in contact with an inner edge portion 192 on the radially inner side of the disk, which is part of the gate mark 191. The second parting line 201 is aligned on both outer sides of the gate mark 191 in the disk axial direction. The inner edge portions 192 of the gate mark 191 are aligned in the same straight line as the second parting line 201 and are continuous with the second parting line 201.

[0065] 3, in the brake carrier 10, the second end face 211 at the second end side in the disk circumferential direction of the second fixing portion 44, the second arm portion 47, and the second slide pin housing portion 34 is substantially mirror-symmetric with the first end face 151. However, the second end face 211 does not have a portion that is mirror-symmetric with the gate mark 191 shown in FIG.

[0066] The second end surface 211 shown in Figure 3 has a second inner surface portion 212 shown in Figure 3 that is mirror-symmetrical to the first inner surface portion 152, except that there is no portion that is mirror-symmetrical to the gate trace 191 shown in Figure 6. The second end surface 211 also has a second intermediate surface portion 213 shown in Figure 3 that is mirror-symmetrical to the first intermediate surface portion 153, except that there is no portion that is mirror-symmetrical to the gate trace 191 shown in Figure 6. The second end surface 211 also has a second outer surface portion 214 shown in Figure 3 that is mirror-symmetrical to the first outer surface portion 154, except that there is no portion that is mirror-symmetrical to the gate trace 191 shown in Figure 6.

[0067] The second fixing portion 44 is provided such that the maximum distance between the opposite ends thereof is a first predetermined distance from the first fixing portion 42. In other words, the maximum distance between the opposite ends of the first inner surface portion 152 of the first fixing portion 42 and the second inner surface portion 212 of the second fixing portion 44 is the first predetermined distance. The maximum distance between the opposite ends of the second arm portion 47 and the first arm portion 46 is smaller than the first predetermined distance. In other words, the maximum distance between the opposite ends of the first intermediate surface portion 153 of the first arm portion 46 and the second intermediate surface portion 213 of the second arm portion 47 is shorter than the first predetermined distance. In other words, the maximum distance between the opposite ends of the first inner surface portion 152 and the second inner surface portion 212 is greater than the maximum distance between the opposite ends of the first intermediate surface portion 153 and the second intermediate surface portion 213.

[0068] Next, a manufacturing method of the brake carrier 10 of the first embodiment will be described. As shown in Figure 7, the casting mold 231 used in this manufacturing method is a sand mold, and has a first mold 232, a second mold 233, and a core 234. The first mold 232, the second mold 233, and the core 234 form the portion of the brake carrier 10 on the first end face 151 side, including the first end face 151.

[0069] The first die 232 is a portion of the casting mold 231 that forms the first inner curved surface portion 161 of the brake carrier 10. The second die 233 is a portion of the casting mold 231 that forms the first outer slope portion 182, the first outer base surface portion 181, and a portion of the first intermediate base surface portion 172 that faces the first outer base surface portion 181. The core 234 is a portion of the casting mold 231 that forms the first inner slope portion 162, the first intermediate slope portion 171, and a portion of the first intermediate base surface portion 172 that faces the first intermediate slope portion 171.

[0070] In the manufacturing method of brake carrier 10, when casting mold 231 is clamped, mating surface 241 on the core 234 side of first mold 232 and mating surface 242 on the first mold 232 side of core 234 are butted together. Both mating surfaces 241 and 242 extend along the disc axial direction and perpendicular to the radial reference line. Mating surfaces 241 and 242 are located in a portion of casting mold 231 that forms first inner surface portion 152 of brake carrier 10. Mating surfaces 241 and 242 are located in a portion of casting mold 231 that forms the boundary between first inner curved surface portion 161 and first inner inclined surface portion 162.

[0071] Furthermore, when the casting mold 231 is clamped, a mating surface 246 on the core 234 side of the second mold 233 and a mating surface 247 on the core 234 side of the second mold 233 are butted against each other. Both mating surfaces 246 and 247 extend along the disc axial direction and perpendicular to the radial reference line. Mating surfaces 246 and 247 are located in a portion of the casting mold 231 that will form the first intermediate surface portion 153 of the brake carrier 10. Mating surfaces 246 and 247 are located in a portion of the casting mold 231 that will form the first intermediate base surface portion 172.

[0072] Furthermore, when the casting mold 231 is clamped, the second mold 233 has a sprue 235 formed in a portion that forms a part of the first outer base surface portion 181 on the first intermediate base surface portion 172 side and a part of the first intermediate base surface portion 172 on the first outer base surface portion 181 side. The sprue 235 is formed in a middle portion in the extension direction of the first slide pin storage section 33, of the portion of the second mold 233 that forms the first outer base surface portion 181 and the first intermediate base surface portion 172. The end of the sprue 235 on the core 234 side is formed by a middle portion of the mating surface 247 of the core 234 in the extension direction of the first slide pin storage section 33. In other words, the sprue 235 is formed by the portion that is recessed from the mating surface 246 of the second mold 233 in the direction away from the core 234, and the mating surface 247 of the core 234.

[0073] In the manufacturing method of the brake carrier 10, the mold clamping step of the casting mold 231 is a gating step of providing a gate 235 shown in Figure 7 so as to face the first outer base surface portion 181 of the first slide pin storage section 33 that is aligned with the axial direction of movement of the first slide pin 102 shown in Figure 1. In addition, in the manufacturing method of the brake carrier 10, the mold clamping step of the casting mold 231 also serves as a core placement step of providing a core 234 in contact with the gate 235 at a position between the gate 235 and the first fixing portion 42.

[0074] In the manufacturing method of brake carrier 10, molten metal is poured into closed casting mold 231 through sprue 235. Then, a parting line 251 is formed on first end surface 151 of brake carrier 10 by parting casting mold 231. This parting line 251 includes first parting line 165 and second parting line 201.

[0075] Here, the first slide pin storage section 33 has a base end protruding portion 252, an intermediate connecting portion 253, an intermediate extending portion 254, and a tip connecting portion 255. The base end protruding portion 252 protrudes further from the first arm portion 46 on the side opposite the third arm portion 61 in the extension direction of the first slide pin storage section 33. The intermediate connecting portion 253 extends from the base end protruding portion 252 toward the third arm portion 61 in the extension direction of the first slide pin storage section 33. The intermediate connecting portion 253 overlaps with the first arm portion 46 in the extension direction of the first slide pin storage section 33. The intermediate extending portion 254 extends from the intermediate connecting portion 253 on the side opposite the base end protruding portion 252 in the extension direction of the first slide pin storage section 33. The tip connecting portion 255 extends from the intermediate extending portion 254 to the opposite side of the intermediate connecting portion 253 in the extension direction of the first slide pin housing portion 33. The tip connecting portion 255 overlaps with the third arm portion 61 in the extension direction of the first slide pin housing portion 33.

[0076] The parting line 251 has a base line portion 261 and an intermediate line portion 262. The base line portion 261 is located at the position furthest from the radial reference plane in the base protruding portion 252. When viewed in a direction perpendicular to the radial reference plane, the base line portion 261 is linear and extends in the direction in which the first slide pin housing portion 33 extends. The base line portion 261 is continuous with the boundary line 185 between the first outer base surface portion 181 and the first outer inclined surface portion 182 of the first outer surface portion 154. When viewed in a direction perpendicular to the radial reference plane, the base line portion 261 is aligned in the same line as the boundary line 185. The intermediate line portion 262 is located on the edge of the intermediate extending portion 254 that is on the outer side in the disk circumferential direction and on the inner side in the disk radial direction. When viewed in a direction perpendicular to the radial reference plane, the intermediate line portion 262 is linear and extends in the direction in which the first slide pin housing portion 33 extends. In the direction of the radial reference line, the intermediate line portion 262 is located radially inward of the base end line portion 261 , and the second parting line 201 is located radially inward of the intermediate line portion 262 .

[0077] 7, the first parting line 165 is formed by a slight gap between the brake carrier 10 side edge of the mating surface 241 of the first die 232 and the brake carrier 10 side edge of the mating surface 242 of the core 234. The second parting line 201 is formed by a slight gap between the brake carrier 10 side edge of the mating surface 246 of the second die 233 and the brake carrier 10 side edge of the mating surface 247 of the core 234. In addition, a runner 271 is formed inside the gate 235 by the gate 235.

[0078] The manufacturing method for brake carrier 10 then performs a first mold splitting process in which the casting mold 231 is split based on the end of the core 234 where the gate 235 is not provided, and a second mold splitting process in which the casting mold 231 is split based on the end of the core 234 on the gate 235 side. In the first mold splitting process, the mating surface 241 of the first mold 232 on the core 234 side and the mating surface 242 on the first mold 232 side, which is the end of the core 234 where the gate 235 is not provided, which have been butted together until then, are separated in a direction perpendicular to these surfaces. In other words, the first mold 232 and the core 234 are separated in a direction along the radial reference line. At this time, the first mold 232 is moved relative to the core 234 in the direction of arrow Z1 shown in FIG. 7 .

[0079] In the second mold splitting step, the mating surface 246 of the second mold 233 on the core 234 side and the mating surface 247 on the second mold 233 side, which is the end of the core 234 on the gate 235 side, which had been butted together until then, are separated in a direction perpendicular to these surfaces. That is, the second mold 233 and the core 234 are separated in a direction along the radial reference line. At this time, the second mold 233 is moved relative to the core 234 in the direction of arrow Z2 shown in FIG. 7. That is, the directions of relative movement during mold splitting are aligned in a straight line for the three molds, the first mold 232, the second mold 233, and the core 234.

[0080] Thereafter, the runner 271 formed by the gate 235 is removed. As a result, a gate mark 191 is formed on the first end face 151 of the brake carrier 10, as shown in FIG. 6. The portion of the gate mark 191 formed by the mating surface 247 of the core 234 shown in FIG. 7 becomes the inner edge portion 192 shown in FIG. 6. The inner edge portion 192 is formed on the same straight line as the second parting line 201 and is continuous with the second parting line 201. Therefore, the second parting line 201 is in contact with a portion of the gate mark 191. The second parting line 201 is in contact with the end of the gate mark 191 on the first fixing portion 42 side.

[0081] The aforementioned Patent Document 1 discloses a technique for manufacturing a caliper body using a caliper body casting mold including a lower mold that forms at least the bottom side of the cylinder bore of the working portion of the caliper body, and first and second upper molds that are separable horizontally above the lower mold. With this type of casting mold, when removing the product, the first and second upper molds must be moved upward relative to the lower mold to separate the mold, and the first and second upper molds must be moved horizontally relative to the lower mold. This requires three separate molds, which increases the space required for the separate molds. This increases the required land area per product and increases the production cost per product.

[0082] The brake carrier 10 of the first embodiment is shaped so that the maximum distance between the opposite ends of the first arm portion 46 and the second arm portion 47 is smaller than the maximum distance between the opposite ends of the first fixed portion 42 and the second fixed portion 44. The brake carrier 10 having this shape is provided with: a gate mark 191 provided on a first outer base surface portion 181 of the first slide pin storage portion 33 that is aligned with the axial direction of movement of the first slide pin 102; a first parting line 165 provided on a first inner side surface portion 152 of the first fixed portion 42 that is aligned with the axial direction of movement; and a second parting line 201 provided in contact with a portion of the gate mark 191 on a first intermediate base surface portion 172 that is aligned with the axial direction of movement. In the brake carrier 10 configured as described above, the first end surface 151, including the first inner surface portion 152, the first intermediate base surface portion 172, and the first outer base surface portion 181, can be formed using three dies, namely, the first die 232, the second die 233, and the core 234, which enable the direction of relative movement during die splitting to be in a straight line. This makes it possible to reduce the space required for manufacturing the brake carrier 10. This reduces the site area required per brake carrier 10, and enables the production cost per brake carrier 10 to be reduced.

[0083] The manufacturing method of the brake carrier 10 of the first embodiment includes a gating step of providing a gate 235 opposite the first outer base surface portion 181 along the axial direction of movement of the first slide pin 102 of the first slide pin storage portion 33 of the caliper 21, a core placement step of providing a core 234 between the gate 235 and the first fixed portion 42 so as to contact the gate 235, a first mold splitting step of splitting the casting mold 231 based on the end of the core 234 where the gate 235 is not provided, and a second mold splitting step of splitting the casting mold 231 based on the end of the core 234 on the gate 235 side. This makes it possible to split the casting mold 231, which forms the first end surface 151 on the gate 235 side of the brake carrier 10, in a linear direction relative to the core 234, in a direction away from the side where the gate 235 is not provided and in a direction away from the gate 235 side. Therefore, it is possible to reduce the space required for manufacturing the brake carrier 10. As a result, it is possible to reduce the site area required for each brake carrier 10, and it is possible to reduce the product cost per brake carrier 10.

[0084] In the manufacturing method of the brake carrier 10 of the first embodiment, an example has been described in which one gate 235 is provided for the brake carrier 10, but another gate that is mirror-symmetrical to the gate 235 may be provided for the brake carrier 10 in addition to the gate 235. In this case, in addition to the gate mark 191, another gate mark that is mirror-symmetrical to the gate mark 191 is provided for the brake carrier 10.

[0085] Second Embodiment Next, a second embodiment of the present invention will be described, focusing on differences from the first embodiment, mainly with reference to Figures 8 and 9. Note that parts common to the first embodiment will be described using the same names and reference numerals.

[0086] 8, the brake carrier 10A of the second embodiment has an inner-side arranged portion 31A that is partially different from the inner-side arranged portion 31 in place of the inner-side arranged portion 31. The inner-side arranged portion 31A has a first arm portion 46A that is partially different from the first arm portion 46 in place of the first arm portion 46. The brake carrier 10A also has a first slide pin storing portion 33A that is partially different from the first slide pin storing portion 33 in place of the first slide pin storing portion 33.

[0087] The first arm portion 46A has a first intermediate surface portion 153A that is partially different from the first intermediate surface portion 153 in place of the first intermediate surface portion 153. The first intermediate surface portion 153A has a first intermediate base surface portion 172A that is partially different from the first intermediate base surface portion 172 in place of the first intermediate base surface portion 172. The first intermediate base surface portion 172A differs from the first intermediate base surface portion 172 in that it does not have a second parting line 201.

[0088] The first slide pin storage section 33A has a first outer surface section 154A that is partially different from the first outer surface section 154 in place of the first outer surface section 154. The first outer surface section 154A has a first outer base surface section 181A that is partially different from the first outer base surface section 181 in place of the first outer base surface section 181. A second parting line 201A, shown by a thick line in Fig. 8, is provided on the first outer base surface section 181A that is aligned along the axial direction of movement of the slide pin 102 (see Fig. 1).

[0089] The second parting line 201A is linear and slightly protrudes outward from the first outer base surface portions 181A on both sides. The second parting line 201A is aligned along the axial direction of the first slide pin 102 (see FIG. 1), in other words, along the disk axial direction. The second parting line 201A contacts the radially central portion of the gate mark 191, the outline of which is indicated by a bold line in FIG. 8. The second parting line 201A merges with the radially central portion of the gate mark 191, one side edge 194, and the other side edge 195. The second parting line 201A is located on both axially outer sides of the gate mark 191. The second parting line 201A is located between the inner edge 192 and the outer edge 193 of the gate mark 191. The second parting line 201A is parallel to the inner edge 192 and the outer edge 193.

[0090] The brake carrier 10A has a parting line 251A, shown by a thick line in Figure 8, which differs from the parting line 251 in that it has a second parting line 201A instead of the second parting line 201. The second parting line 201A is continuous with an intermediate line portion 262 provided in the intermediate extension portion 254 of the first slide pin storage portion 33A. When viewed from a direction perpendicular to the radial reference plane, the second parting line 201A and the intermediate line portion 262 are arranged in the same straight line. In other words, the second parting line 201A and the intermediate line portion 262 are aligned in the direction of the radial reference line.

[0091] The brake carrier 10A has a first end face 151A which differs from the first end face 151 in that it has a first intermediate surface portion 153A instead of the first intermediate surface portion 153 as described above, and a first outer surface portion 154A instead of the first outer surface portion 154.

[0092] Next, a method for manufacturing the brake carrier 10A of the second embodiment will be described. As shown in Figure 9, in this manufacturing method, a casting mold 231A that is partially different from the casting mold 231 is used in place of the casting mold 231. The casting mold 231A has a second mold 233A that is partially different from the second mold 233 in place of the second mold 233, and has a core 234A that is partially different from the core 234 in place of the core 234.

[0093] The second mold 233A is a part of the casting mold 231A that forms the first outer slope portion 182 and most of the first outer base surface portion 181A except for a portion on the first intermediate base surface portion 172A side. The core 234A is a part of the casting mold 231A that forms the first inner slope portion 162, the first intermediate slope portion 171, the first intermediate base surface portion 172A, and a portion of the first outer base surface portion 181A on the first intermediate base surface portion 172A side.

[0094] In the manufacturing method of the brake carrier 10A, when the casting mold 231A is clamped, a mating surface 241 on the core 234A side of the first mold 232 and a mating surface 242 on the first mold 232 side, which is similar to the core 234 of the core 234A, are butted together.

[0095] Furthermore, when the casting mold 231A is clamped, a mating surface 246A on the core 234A side of the second mold 233A and a mating surface 247A on the core 234A side of the second mold 233A are butted against each other. Both mating surfaces 246A and 247A extend along the disc axial direction and perpendicular to the radial reference line. The mating surfaces 246A and 247A are located in the portion of the casting mold 231A that will form the first outer surface portion 154A of the brake carrier 10A. The mating surfaces 246A and 247A are located in the portion of the casting mold 231A that will form the first outer base surface portion 181A.

[0096] Furthermore, when the casting mold 231A is in a mold-clamped state, the second mold 233A has a portion of the sprue 235A in a portion that forms part of the first outer base surface portion 181A on the first intermediate base surface portion 172A side. The sprue 235A is formed in a middle portion, in the extension direction of the first slide pin storage portion 33A, of the portion of the second mold 233A that forms the first outer base surface portion 181A. Furthermore, when the casting mold 231A is in a mold-clamped state, the core 234A has the remaining portion of the sprue 235A in a portion that forms part of the first outer base surface portion 181A on the first intermediate base surface portion 172A side and part of the first intermediate base surface portion 172A on the first outer base surface portion 181A side. The gate 235A is formed in a middle portion of the portion of the core 234A that forms the first outer base surface portion 181A and the first intermediate base surface portion 172A, in the extension direction of the first slide pin storage portion 33A.

[0097] That is, the gate 235A is formed by a portion that is recessed from the mating surface 246A of the second die 233A in the direction away from the core 234A, and a portion that is recessed from the mating surface 247A of the core 234 in the direction away from the second die 233A. The gate 235A is recessed on both the inner and outer sides in the disk radial direction relative to the mating surface 246A of the second die 233A and the mating surface 247A of the core 234A. In other words, the gate 235A is recessed on both sides relative to the mating surface 246A and the mating surface 247A along the extension direction of the first arm portion 46A.

[0098] In the manufacturing method of the brake carrier 10A, the mold clamping step of the casting mold 231A serves as a gating step of providing a gate 235A opposite the first outer base surface portion 181A that is aligned with the axial direction of the first slide pin 102 (see FIG. 1 ) of the first slide pin storage section 33A. In addition, in the manufacturing method of the brake carrier 10A, the mold clamping step of the casting mold 231A also serves as a core placement step of providing a core 234A in contact with the gate 235A at a position between the gate 235A and the first fixing portion 42.

[0099] In the manufacturing method of the brake carrier 10A, molten metal is poured into the closed casting mold 231A through the sprue 235A. As a result, a parting line 251A is formed on the first end surface 151A of the brake carrier 10A by the parting of the casting mold 231A. This parting line 251A includes the first parting line 165 and the second parting line 201A.

[0100] 9, the second parting line 201A is formed by a slight gap between the edge of the mating surface 246A of the second die 233A on the brake carrier 10A side and the edge of the mating surface 247A of the core 234A on the brake carrier 10A side. Also, a runner 271 is formed inside the gate 235A by the gate 235A.

[0101] The manufacturing method for the brake carrier 10A then includes a first mold splitting process in which the casting mold 231A is split along the end of the core 234A where the gate 235A is not provided, and a second mold splitting process in which the casting mold 231A is split along the end of the core 234A where the gate 235A is located. In the first mold splitting process, the mating surface 241 of the first mold 232 on the core 234A side and the mating surface 242 on the first mold 232 side, which are the end of the core 234A on which the gate 235A is not provided, which had been butted together until then, are separated in a direction perpendicular to these surfaces. In other words, the first mold 232 and the core 234A are separated in a direction along the radial reference line. During this process, the first mold 232 is moved relative to the core 234A in the direction of arrow Z1 shown in FIG. 9 .

[0102] In the second mold splitting process, the mating surface 246A of the second mold 233A on the core 234A side and the mating surface 247A of the second mold 233A on the end of the core 234A on the gate 235A side, which had been butted together until then, are separated in a direction perpendicular to these surfaces. That is, the second mold 233A and the core 234A are separated in a direction along the radial reference line. At this time, the second mold 233A is moved relative to the core 234A in the direction of arrow Z2 shown in FIG. 9 . That is, the directions of relative movement during mold splitting are aligned in a straight line for the first mold 232, the second mold 233A, and the core 234A.

[0103] Thereafter, the runner 271 formed by the gate 235A is removed. As a result, a gate mark 191 is formed on the first end face 151A of the brake carrier 10A, as shown in FIG. 8 . The second parting line 201A extends from the middle of the gate mark 191 in the extension direction of the first arm portion 46A to both sides in the extension direction of the first slide pin storage portion 33A. Therefore, the second parting line 201A is in contact with a portion of the gate mark 191.

[0104] The brake carrier 10A of the second embodiment includes a gate mark 191 provided on a first outer base surface portion 181A along the axial direction of movement of the first slide pin 102 (see FIG. 1 ) in the first slide pin storage portion 33A, a first parting line 165 provided on a first inner side surface portion 152 along the axial direction of movement in the first fixing portion 42, and a second parting line 201A provided on the first outer base surface portion 181A along the axial direction, in contact with a portion of the gate mark 191. In the brake carrier 10A configured as described above, as shown in FIG. 9 , the first end surface 151A including the first inner side surface portion 152, the first intermediate base surface portion 172A, and the first outer base surface portion 181A can be formed using three dies, namely a first die 232, a second die 233A, and a core 234A, which enable the direction of relative movement during die splitting to be in a straight line. Therefore, it is possible to reduce the space required for manufacturing the brake carrier 10A, thereby reducing the site area required for each brake carrier 10A and reducing the production cost per brake carrier 10A.

[0105] The manufacturing method of the brake carrier 10A of the second embodiment includes a gate installation process of providing a gate 235A opposite the first outer base surface portion 181A that is aligned with the axial direction of movement of the first slide pin 102 (see FIG. 1) of the first slide pin storage portion 33A; a core installation process of providing a core 234A in contact with the gate 235A at a position between the gate 235A and the first fixed portion 42; a first mold splitting process of splitting the casting mold 231A based on the end of the core 234A where the gate 235A is not provided; and a second mold splitting process of splitting the casting mold 231A based on the end of the core 234A on the gate 235A side. This allows the casting mold 231A, which forms the first end surface 151A of the brake carrier 10A on the gate 235A side, to be split in a straight line relative to the core 234A, in a direction away from the side where the gate 235A is not provided and in a direction away from the gate 235A side. This makes it possible to reduce the space required for manufacturing the brake carrier 10A. This reduces the site area required for each brake carrier 10A, and also reduces the production cost per brake carrier 10A.

[0106] In the manufacturing method of the brake carrier 10A of the second embodiment, an example has been described in which one gate 235A is provided for the brake carrier 10A, but another gate that is mirror-symmetrical to the gate 235A may be provided for the brake carrier 10A in addition to the gate 235A. In this case, in addition to the gate mark 191A, another gate mark that is mirror-symmetrical to the gate mark 191A is provided for the brake carrier 10A.

[0107] [Third Embodiment] Next, a third embodiment of the present invention will be described, focusing on differences from the first embodiment, mainly with reference to Figures 10 and 11. Note that parts common to the first embodiment will be described using the same names and reference numerals.

[0108] 10 , the brake carrier 10B of the third embodiment has an inner-side arranged portion 31B that is partially different from the inner-side arranged portion 31, instead of the inner-side arranged portion 31. The inner-side arranged portion 31B has a first arm portion 46B that is partially different from the first arm portion 46, instead of the first arm portion 46. Furthermore, the brake carrier 10B has a first slide pin storing portion 33B that is partially different from the first slide pin storing portion 33, instead of the first slide pin storing portion 33.

[0109] The first arm portion 46B has a first intermediate surface portion 153B that is partially different from the first intermediate surface portion 153, instead of the first intermediate surface portion 153. The first intermediate surface portion 153B has a first intermediate base surface portion 172B that is partially different from the first intermediate base surface portion 172, instead of the first intermediate base surface portion 172. The first intermediate base surface portion 172B differs from the first intermediate base surface portion 172 in that it does not have a second parting line 201.

[0110] The first slide pin storage section 33B has a first outer surface section 154B that is partially different from the first outer surface section 154 in place of the first outer surface section 154. The first outer surface section 154B has a first outer base surface section 181B that is partially different from the first outer base surface section 181 in place of the first outer base surface section 181.

[0111] In the brake carrier 10B, a gate trace 191B, the outline of which is indicated by a bold line in FIG. 10 , is formed from the portion of the first intermediate base surface portion 172B on the first outer base surface portion 181B side to the first outer base surface portion 181B. In other words, the gate trace 191B is formed continuously across both the first intermediate base surface portion 172B and the first outer base surface portion 181B. In yet other words, the gate trace 191B is formed continuously across both the first outer surface portion 154B of the first slide pin storage portion 33B, which is aligned with the axial direction of the slide pin 102 (see FIG. 1), and the first intermediate surface portion 153B of the first arm portion 46B, which is aligned with the axial direction of the slide pin 102 (see FIG. 1). The gate trace 191B is formed across the entire length of the first outer base surface portion 181B in the extension direction of the first arm portion 46B. The gate trace 191B is adjacent to the first outer slope portion 182 in the extension direction of the first arm portion 46B and is spaced apart from the first intermediate slope portion 171.

[0112] The gate trace 191B is provided at an intermediate position between the first outer base surface portion 181B and the first intermediate base surface portion 172B in the axial direction of movement of the first slide pin 102 (see FIG. 1), in other words, in the disc axial direction. The gate trace 191B is rectangular and has an inner edge portion 192B on the inner side in the disc radial direction, an outer edge portion 193B on the outer side in the disc radial direction, one side edge portion 194B on the inner side in the disc axial direction, and another side edge portion 195B on the outer side in the disc axial direction. The inner edge portion 192B and the outer edge portion 193B are both linear and extend along the axial direction of movement of the first slide pin 102 (see FIG. 1), in other words, along the disc axial direction. The one side edge portion 194B and the other side edge portion 195B are both linear and extend along the disc radial direction.

[0113] The first slide pin storage section 33B is provided with a second parting line 201B, shown by a thick line in Fig. 10, which forms the boundary between the first outer base surface section 181B and the first outer slope section 182. The second parting line 201B is provided on the first outer base surface section 181B along the axial direction of movement of the slide pin 102 (see Fig. 1), at the boundary between the first outer slope section 182.

[0114] The second parting line 201B is linear and slightly protrudes outward relative to the first outer base surface portion 181B and the first outer slope portion 182 on either side of it. The second parting line 201B is aligned along the axial direction of the movement of the first slide pin 102 (see FIG. 1 ), in other words, along the disk axial direction. The second parting line 201B is in contact with an outer edge portion 193B, which is part of the gate trace 191B and is located on both sides of the gate trace 191B in the disk axial direction. The outer edge portions 193B of the gate trace 191B are aligned in the same straight line as the second parting line 201B and are continuous with the second parting line 201B. The outer edge portions 193B of the gate trace 191B also form a boundary between the first outer base surface portion 181B and the first outer slope portion 182.

[0115] The brake carrier 10B has a parting line 251B, shown by a thick line in Figure 10, which differs from the parting line 251 in that it has a second parting line 201B instead of the second parting line 201. The second parting line 201B is continuous with a base end line portion 261 of the base end protrusion 252 of the first slide pin storage section 33B. The second parting line 201B is arranged in the same straight line as the base end line portion 261 when viewed from a direction perpendicular to the radial reference plane. In other words, the second parting line 201B and the base end line portion 261 are aligned in the direction of the radial reference line.

[0116] As described above, the brake carrier 10B has a first end face 151B which differs from the first end face 151 in that it has a first intermediate surface portion 153B instead of the first intermediate surface portion 153, and a first outer surface portion 154B instead of the first outer surface portion 154.

[0117] Next, a manufacturing method of the brake carrier 10B of the third embodiment will be described. As shown in FIG. 11 , in this manufacturing method, a casting mold 231B that is partially different from the casting mold 231 is used instead of the casting mold 231. The casting mold 231B has a second mold 233B that is partially different from the second mold 233 instead of the second mold 233, and a core 234B that is partially different from the core 234 instead of the core 234. The second mold 233B is the portion of the casting mold 231B that forms the first outer slope portion 182. The core 234B is the portion of the casting mold 231B that forms the first inner slope portion 162, the first intermediate slope portion 171, the first intermediate base surface portion 172B, and the first outer base surface portion 181B.

[0118] In the manufacturing method of the brake carrier 10B, when the casting mold 231B is clamped, the mating surface 241 on the core 234B side of the first mold 232 and the mating surface 242 on the first mold 232 side, which is the same as the core 234 of the core 234B, are butted together.

[0119] Furthermore, when the casting mold 231B is clamped, a mating surface 246B on the core 234B side of the second mold 233B and a mating surface 247B on the core 234B side of the second mold 233B are butted against each other. Both the mating surfaces 246B and 247B extend along the disc axial direction and perpendicular to the radial reference line. The mating surfaces 246B and 247B are located in portions of the casting mold 231B that form the boundary between the first outer base surface portion 181B and the first outer slope portion 182 of the brake carrier 10B. The mating surfaces 246B and 247B are located in portions of the casting mold 231B that form both the first outer base surface portion 181B and the first outer slope portion 182.

[0120] Furthermore, when the casting mold 231B is clamped, the core 234B has a portion of the gate 235B in the portion that forms the first outer base surface portion 181B and the first intermediate base surface portion 172B. The gate 235B is formed in the middle portion of the portion of the core 234B that forms the first outer base surface portion 181B and the first intermediate base surface portion 172B, in the extension direction of the first slide pin storage portion 33B. The end of the gate 235B on the second mold 233B side is formed by the middle portion of the mating surface 246B of the second mold 233B in the extension direction of the first slide pin storage portion 33B. In other words, the gate 235B is formed by the portion that is recessed from the mating surface 247B of the core 234B in the direction away from the second mold 233B and the mating surface 246B of the second mold 233B.

[0121] In the manufacturing method of brake carrier 10B, the mold clamping step of this casting mold 231B serves as a gating step of providing a gate 235B opposite the first outer base surface portion 181B that is aligned with the axial direction of movement of first slide pin 102 (see FIG. 1 ) of first slide pin storage section 33B. Also, in the manufacturing method of brake carrier 10B, the mold clamping step of casting mold 231B serves as a core placement step of providing a core 234B in a position between the gate 235B and first fixing portion 42 so as to be in contact with the gate 235B.

[0122] In the manufacturing method of the brake carrier 10B, molten metal is poured into the closed casting mold 231B through the sprue 235B. As a result, the casting mold 231B is split, forming a parting line 251B (shown in Figure 10) on the first end surface 151B of the brake carrier 10B. This parting line 251B includes the first parting line 165 and the second parting line 201B.

[0123] 11, the second parting line 201B is formed by a slight gap between the edge of the mating surface 246B of the second die 233B on the brake carrier 10B side and the edge of the mating surface 247B of the core 234B on the brake carrier 10B side. Also, a runner 271B is formed inside the gate 235B by the gate 235B.

[0124] The manufacturing method for the brake carrier 10B then includes a first mold splitting process in which the casting mold 231B is split based on the end of the core 234B where the gate 235B is not provided, and a second mold splitting process in which the casting mold 231B is split based on the end of the core 234B where the gate 235B is located. In the first mold splitting process, the mating surface 241 of the first mold 232 on the core 234B side and the mating surface 242 on the first mold 232 side, which are the end of the core 234B on which the gate 235B is not provided, which had been butted together until then, are separated in a direction perpendicular to these surfaces. In other words, the first mold 232 and the core 234B are separated in a direction along the radial reference line. At this time, the first mold 232 is moved relative to the core 234B in the direction of arrow Z1 shown in FIG. 11 .

[0125] In the second mold splitting step, the mating surface 246B of the second mold 233B on the core 234B side and the mating surface 247B of the second mold 233B on the end of the core 234B on the gate 235B side, which had been butted together until then, are separated in a direction perpendicular to these surfaces. That is, the second mold 233B and the core 234B are separated in a direction along the radial reference line. At this time, the second mold 233B is moved relative to the core 234B in the direction of arrow Z2 shown in FIG. 11 . That is, the directions of relative movement during mold splitting are aligned in a straight line for the first mold 232, the second mold 233B, and the core 234B.

[0126] Thereafter, the runner 271B formed by the gate 235B is removed. As a result, a gate mark 191B is formed on the first end face 151B of the brake carrier 10B, as shown in FIG. 10 . The second parting line 201B extends from the end position of the gate mark 191B opposite the first fixing portion 42 in the extension direction of the first arm portion 46B to both sides in the extension direction of the first slide pin storage portion 33B. Therefore, the second parting line 201B is in contact with a portion of the gate mark 191B.

[0127] The brake carrier 10B of the third embodiment includes a gate mark 191B provided on a first outer base surface portion 181B along the axial direction of movement of the first slide pin 102 (see FIG. 1 ) in the first slide pin storage portion 33B, a first parting line 165 provided on a first inner side surface portion 152 along the axial direction of movement in the first fixing portion 42, and a second parting line 201B provided on the first outer base surface portion 181B along the axial direction, in contact with a portion of the gate mark 191B. In the brake carrier 10B configured as described above, the first end surface 151B including the first inner side surface portion 152, the first intermediate base surface portion 172B, and the first outer base surface portion 181B can be formed using three dies, a first die 232, a second die 233B, and a core 234B shown in FIG. 11 , which enable the direction of relative movement during die splitting to be in a straight line. Therefore, it is possible to reduce the space required for manufacturing the brake carrier 10B, thereby reducing the site area required for each brake carrier 10B and reducing the production cost per brake carrier 10B.

[0128] The manufacturing method of the brake carrier 10B of the third embodiment includes a gate installation process of providing a gate 235B opposite the first outer base surface portion 181B that is aligned with the axial direction of movement of the first slide pin 102 (see FIG. 1) of the first slide pin storage portion 33B; a core installation process of providing a core 234B in a position between the gate 235B and the first fixed portion 42 so that it contacts the gate 235B; a first mold splitting process of splitting the casting mold 231B based on the end of the core 234B where the gate 235B is not provided; and a second mold splitting process of splitting the casting mold 231B based on the end of the core 234B on the gate 235B side. This allows the casting mold 231B, which forms the first end surface 151B of the brake carrier 10B on the gate 235B side, to be split in a straight line relative to the core 234B, in a direction away from the side where the gate 235B is not provided and in a direction away from the gate 235B side. This makes it possible to reduce the space required for manufacturing the brake carrier 10B. This reduces the site area required per brake carrier 10B, and also reduces the production cost per brake carrier 10B.

[0129] In the manufacturing method of the brake carrier 10B of the third embodiment, an example has been described in which one gate 235B is provided for the brake carrier 10B, but it is also possible to provide another gate that is mirror-symmetrical to the gate 235B for the brake carrier 10B in addition to the gate 235B. In this case, in addition to the gate mark 191B, another gate mark that is mirror-symmetrical to the gate mark 191B is provided for the brake carrier 10B.

[0130] According to the above aspects of the present invention, it is possible to provide a brake carrier and a method for manufacturing the brake carrier that can reduce production costs, and thus the industrial applicability is great.

[0131] DESCRIPTION OF SYMBOLS 10, 10A, 10B...Brake carrier 21...Caliper 42...First fixing portion (vehicle fixing portion) 44...Second fixing portion 46...First arm portion 47...Second arm portion 33, 33A, 33B...First slide pin storage portion (slide pin storage portion) 102...First slide pin (slide pin) 151, 151A, 151B...First end face (surface along the moving axis direction of the slide pin) 165...First parting line 191, 191B...Gate mark 201, 201A, 201B...Second parting line 234, 234A, 234B...Core 235, 235A, 235B...Gate

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