Caliper cover arrangement for a brake caliper, brake caliper assembly for a motor vehicle disc brake and utility vehicle disc brake

Abstract

The invention relates to a caliper cover arrangement (50', 50'', 50''') for a brake caliper assembly (1) for a utility vehicle disc brake (100), at least comprising a caliper cover (5', 5'', 5''', 5'''') or at least comprising the caliper cover (5', 5'', 5'''') and one or more attachment parts such as a vehicle-remote support plate (9), in particular additionally an opposing brake-disc-side housing wall (17) and / or vehicle-side housing wall (7) of a caliper housing (103), which caliper cover (5', 5'', 5'''') is designed to cover a caliper housing (103) on the upper side, wherein a brake disc can be straddled by a frame contour (KR) of the caliper cover (5', 5'', 5'''') along an axis of rotation (R) from an application side (I) to a reaction side (0), and wherein the caliper cover (5', 5'', 5'''') has a vehicle-remote outer side (A) associated with the reaction side (O), and is formed with a curved contour (KB) in the direction of a rotational direction (D) of the brake disc, which extends between opposing (in the rotational direction) edges (R1, R2) of the caliper cover. According to the invention, the caliper cover (5', 5'', 5''', 5'''') is formed as a one-piece metal molded part forming the frame contour (KR) and the curved contour (KB) of a frame section (52), in particular a molded sheet metal part, in particular formed partially or entirely from sheet metal, wherein the one-piece molded part has a shape-deviating protrusion (E1) on the curved contour (KB), in particular on at least one of the edges (R1, R2), and / or the vehicle-remote support plate (9) has a shape-deviating protrusion and / or a raised part protruding into the interior space (24).

Description

[0001] Caliper cover assembly for a brake caliper, brake caliper assembly for a

[0002] Motor vehicle disc brake and commercial vehicle disc brake

[0003] The present invention relates to a saddle cover arrangement according to the preamble of claim 1 for a brake caliper for a motor vehicle disc brake, comprising at least a saddle cover.

[0004] The present invention also relates to a brake caliper assembly - or hereinafter also brake caliper - for a motor vehicle disc brake, in particular for a commercial vehicle disc brake with a brake disc moved about an axis of rotation, in particular for a sliding caliper brake, with a caliper housing with a cavity for receiving a clamping mechanism, and with a caliper cover which covers a brake carrier on the upper side and extends over the brake disc from a clamping side of the brake disc to a reaction side of the brake disc.

[0005] Preferably, the cavity serves to accommodate a clamping mechanism that includes a brake lever pivotable about a lever axis. The caliper housing has a vehicle-side housing wall made of a single piece of bent sheet metal, on the inside of which at least one support element is provided for supporting the brake lever. Preferably, the caliper housing is designed for a retaining bracket that can be reversibly and detachably attached to a bracket on the reaction side of the caliper cover to span the brake disc from the clamping side to the reaction side. Preferably, the caliper cover is made partially or completely of sheet metal.

[0006] From WO2016 / 135316 A1, a brake caliper for a disc brake is known in principle, in which a caliper cover and a caliper housing are assembled from segments, each segment being made of sheet metal. However, caliper housings and caliper covers for motor vehicle disc brakes are generally used for brake calipers in which the caliper housing or caliper covers and / or the brake caliper are cast parts. Those functional elements of the brake caliper and the caliper housing and / or the caliper cover, in particular, that require very precise alignment and surface finishing because they movably mount or hold functionally critical components, are mechanically post-processed in these cast parts to enable them to perform the required functions.Manufacturing these components from cast metal is fundamentally justified because castings can be produced efficiently in large quantities and possess outstanding mechanical stability. A disadvantage is generally their high weight. The cost-effectiveness of using castings is sometimes limited depending on the molds used, especially with expendable molds. Therefore, there is a general effort, particularly for the caliper housing but also for the brake caliper itself, to find alternatives that allow for cost-effective production and a reduction in the weight of the vehicle's disc brakes without compromising brake stability, and, in particular for sliding caliper brakes, to improve safety.

[0007] From the aforementioned WO2016 / 135316 A1, a brake caliper for a disc brake is known in which the caliper housing or caliper cover is formed from an outer segment, an inner segment running essentially parallel to the outer segment, and two bases extending between the outer and inner segments with corresponding cover elements, each made of sheet metal. It is proposed therein to form at least two of these segments from a single sheet metal element. To attach at least one support element, it is proposed to bring it into contact with the vehicle-side housing wall and then weld them together from the outside through the housing wall. This is said to have the advantage that the vehicle-side housing wall is easily accessible from the outside for a welding robot.

[0008] The reliability of such a joint is questionable. It is desirable to make the operation and / or manufacture of the brake caliper safer yet simpler. Particularly with regard to a caliper cover assembly—i.e., a caliper cover and its attachments, such as a vehicle-side housing wall or a support plate on the opposite side—it is desirable to make operation safer for the brake carrier and / or to simplify the manufacture of the caliper cover and its attachments. Preferably, the caliper cover, and optionally its attachments, should be designed in such a way that operation is safer for the brake carrier and the manufacture of the caliper cover is simplified. This is particularly desirable for a sliding caliper brake, where the safety needs to be improved primarily with regard to a brake caliper that is initially free to move axially.

[0009] This is where the invention comes in, the object of which is to further develop a brake caliper, in particular a caliper cover arrangement or caliper cover, of the type described above, preferably for a sliding caliper brake, in such a way that the disadvantages described above are overcome as far as possible.

[0010] The invention was based in particular on the objective of providing a caliper cover arrangement, especially a caliper cover, which enables a reduction in the weight of the vehicle disc brake without compromising the stability of the brakes. In particular, the safety of a sliding caliper brake should be improved, and it should preferably also be easier to manufacture.

[0011] The problem relating to the saddle cover arrangement, in particular a saddle cover, is solved in a first aspect of the invention by a saddle cover arrangement according to claim 1.

[0012] The invention solves the underlying problem primarily by means of a saddle cover arrangement, in particular a saddle cover of the type described above, which according to the invention is designed with the features of the characterizing part of claim 1.

[0013] The invention thus relates to a caliper cover arrangement for a brake caliper assembly for a commercial vehicle disc brake, comprising at least a caliper cover or at least the caliper cover and one or more attachments such as a vehicle-side support plate, in particular also a brake disc-side housing wall opposite this and / or a vehicle-side housing wall of a caliper housing, which caliper cover is designed to cover a caliper housing from above, wherein

[0014] - a brake disc along a rotational axis from a clamping side to a reaction side with a frame contour of the caliper cover can be overlapped, and wherein the caliper cover has a vehicle-side outer surface associated with the reaction side, and

[0015] - formed with an arc contour in the direction of rotation of the brake disc, extending between opposite edges of the caliper cover in the direction of rotation.

[0016] According to the invention, the saddle cover is formed as a one-piece metallic molded part forming the frame contour and the arc contour of a frame section, in particular as a molded sheet metal part, in particular as being formed partially or completely from sheet metal, wherein

[0017] - the one-piece molded part has a deviating projection at the arc contour, in particular at at least one of the edges, and / or

[0018] - the support plate away from the vehicle has a non-standard projection and / or a raised part extending into the interior.

[0019] The saddle cover assembly comprises, in particular, the saddle cover and one or more attachments such as a vehicle-side housing wall or a support plate on the opposite side of the vehicle. The saddle cover is, in particular, partially or completely made of sheet metal. The one-piece molded part has a deviating indentation, especially on the outside of the frame-like contour. The one-piece molded part has a deviating projection, especially at at least one of the edges of the arc-like contour.

[0020] The invention provides an advantageous design for a caliper cover assembly for a brake caliper of a motor vehicle disc brake, comprising at least one caliper cover in which the attachment of safety elements and manufacturing elements in the manner described is provided on the one-piece molded part – in particular partially or completely formed from a bent and shaped sheet metal – and which can be placed on the caliper housing. The operation of the brake caliper is considerably safer, and the manufacture of the caliper cover is considerably simplified.

[0021] In a second aspect, the invention also leads to a brake caliper assembly according to claim 16 in order to solve the problem.

[0022] The invention also relates to a brake caliper assembly for a motor vehicle disc brake, in particular for a commercial vehicle disc brake with a brake disc moving about an axis of rotation, in particular for a sliding caliper brake, with a brake carrier and with a caliper cover arrangement according to the concept of the invention and with a caliper housing with a cavity for receiving a clamping mechanism, in particular comprising the caliper cover and one or more attachments such as a vehicle-side support plate, in particular also comprising a brake disc-side housing wall and vehicle-side housing wall of the caliper housing opposite the brake disc, which caliper cover is designed to cover the brake carrier on the upper side and overlaps the brake disc from a clamping side to a reaction side and wherein the caliper cover has a vehicle-side outer side associated with the reaction side.

[0023] In particular, the brake carrier includes an outer stop, especially a protrusion. Specifically, the brake carrier has a horn or a knob on its outer surface. The outer stop on the brake carrier is designed to interact with the non-standard indentation or projection of the caliper cover to limit movement of the brake caliper, especially a sliding brake caliper.

[0024] In particular, the clamping mechanism can include a brake lever pivotable about a lever axis, wherein the caliper housing has a vehicle-side housing wall made of a one-piece bent sheet metal, on the inside of which at least one support element for supporting the brake lever is provided. To solve the problem, the invention, in a third aspect, also relates to a commercial vehicle disc brake according to claim 19. The invention thus also relates to a disc brake and / or a motor vehicle with a brake caliper assembly, i.e., with a brake caliper, of the aforementioned type according to the concept of the invention.

[0025] Further developments of the invention are specified in the dependent claims, which further develop the concept of the invention with regard to advantageous features within the scope of the problem statement and with regard to further advantages.

[0026] In a particularly preferred embodiment, it is provided that the one-piece molded part has a deviating protrusion on the frame contour, in particular on the outside, or that the one-piece molded part has a deviating indentation on the frame contour, in particular on the outside.

[0027] As part of a particularly preferred further development, it is provided that this further comprises a saddle housing, with a brake disc-side housing wall and a vehicle-side housing wall of the saddle housing.

[0028] As part of a particularly preferred further development, it is provided that the saddle cover is designed to cover a cavity of the saddle housing for receiving a clamping mechanism and that the saddle cover is designed to overlap an interior space for receiving a brake carrier.

[0029] A dome section is preferably provided to enlarge the cavity in order to allow the pivoting movement of a lever of the clamping mechanism (not shown). It has proven particularly advantageous that the saddle cover is formed as a one-piece molded part comprising a dome section and the frame section with the frame contour and the arch contour, wherein the dome section is convex outwards to cover the cavity, particularly for a clamping mechanism, and the frame section forms a window to an interior space, particularly for brake linings.

[0030] In a particularly preferred further development, it is provided that the saddle cover arrangement comprises the saddle cover and a support plate located away from the vehicle, wherein the support plate located away from the vehicle itself has a non-conforming indentation and / or a non-conforming projection.

[0031] As part of a particularly preferential further training program, it is planned that

[0032] - at least one of the edges of the arc-like contour or the arc-like contour itself on its inner side of the saddle cover, which is associated with the clamping side, bears the deviating projection as at least one downwardly projecting extension, which is designed to limit movement of the brake caliper, in particular a sliding brake caliper, towards the clamping side (i.e. towards the inside of the vehicle, inwards).

[0033] As part of a particularly preferential further training program, it is planned that

[0034] - at least the outer side of the frame-like contour or the frame-like contour itself bears the deviating indentation as at least one inwardly projecting indentation or depression designed to limit movement of the brake caliper, in particular sliding brake caliper, towards the reaction side (towards the outside of the vehicle, outwards).

[0035] Preferred embodiments are explained and described in particular in connection with FIGS. 4 to FIGS. 7. As described in detail by way of example in the embodiments, it has proven advantageous in a particularly preferred embodiment that the deviating indentation is formed as a planar depression or offset in the outer surface or support plate. As described in detail by way of example in the embodiments, it has also proven advantageous in a particularly preferred embodiment that the deviating projection is formed as a molded part on at least one of the edges or as an integral component of at least one of the edges.

[0036] In a particularly preferred embodiment, the saddle cover 5 is provided that, in the area of ​​an outer perimeter, in particular the edges of the dome section 51 and / or the frame section, the deviating projection has one or more flat sections, wherein a flat section is predefined and distinct from the shape of the one-piece molded part of the saddle cover, such that the flat section forms a contact surface for a clamping or holding tool. A preferred embodiment is explained and described in particular in connection with FIG. 8.

[0037] As described in detail by way of example in the embodiment, it has proven advantageous in a particularly preferred further development that the flat section is formed, attached or molded onto a semi-finished product of the molded part of the saddle cover, in particular embossed or pressed onto it.

[0038] Thus, as described in detail by way of example in the embodiment, it has proven advantageous in a particularly preferred further development that the flat section is formed as a surface flattened to a curved surface and with a predetermined boundary, and

[0039] - extends beyond a frame area of ​​the outer border, or

[0040] - flattens a curved corner of the frame area of ​​the outer rim.

[0041] In a particularly preferred embodiment, the frame section, especially towards a window, has one or more edge sections which, in particular at least one lower edge section of a window-side edge of the frame section facing the interior, are flattened in a predetermined manner. A preferred embodiment is explained and described in particular in connection with FIG. 9.

[0042] Thus, as described in detail by way of example in the embodiment, it has proven advantageous in a particularly preferred further development that

[0043] - one or more edge sections of the frame section to the window are chamfered with a predetermined chamfer, in particular the chamfer is formed at a predetermined angle to the window surface and / or with a predetermined chamfer width, and / or

[0044] - one or more edge sections of the frame section to the window are rounded and flattened with a predetermined radius, in particular the radius has a predetermined radius value.

[0045] As described in detail by way of example in the embodiment, it has proven advantageous in a particularly preferred further development that one or more edge sections of the frame section to the window form an edge of the frame section to the window that is oriented transversely to the direction of rotation of a brake disc, in particular not forming an edge of the frame section to the window that runs from the support plate and / or from the vehicle-side housing wall.

[0046] Embodiments of the invention are now described below with reference to the drawings and comparison with the prior art, some of which is also shown. These drawings are not necessarily to scale; rather, where explanatory, they are presented in a schematic and / or slightly distorted form. For further details regarding the teachings directly apparent from the drawings, reference is made to the relevant prior art. It should be noted that numerous modifications and changes concerning the form and details of an embodiment can be made without deviating from the general idea of ​​the invention. The features of the invention disclosed in the description, the drawings, and the claims can be essential for the further development of the invention, both individually and in any combination.Furthermore, the invention encompasses all combinations of at least two of the features disclosed in the description, the drawing, and / or the claims. The general idea of ​​the invention is not limited to the exact shape or detail of the preferred embodiment shown and described below, nor is it limited to an object that would be restricted compared to the object claimed in the claims. Where specified dimensioning ranges are given, values ​​lying within the stated limits are also disclosed as limit values ​​and may be used and claimed as desired.

[0047] Further advantages, features and details of the invention will become apparent from the following description of the preferred embodiments and from the drawing; this shows in:

[0048] FIG. 1 shows a commercial vehicle disc brake in a schematic spatial view according to a preferred embodiment;

[0049] FIG. 2A, FIG. 2B show a first and second spatial schematic view of a brake caliper according to the basic concept of the invention with a caliper cover made partially or completely of sheet metal according to a comparative example;

[0050] FIG. 3 shows a detail of the saddle cover, partially or completely made of sheet metal, according to the comparative example in FIG. 2A and FIG. 2B;

[0051] FIG. 4A, FIG. 4B show a first preferred embodiment in which the one-piece molded part has a deviating projection on the arc-shaped contour, namely on at least one of its edges, which limits movement of the brake caliper towards the clamping side (inside of the vehicle, inwards) - FIG. 4A shows the embodiment in a perspective view and FIG. 4B in a side view;

[0052] FIG. 5A, FIG. 5B show the aforementioned first embodiment in detail, with FIG. 5A showing an underside view of the preferred saddle cover with its outer side and an attachment in the form of the support plate away from the vehicle, and FIG. 5B showing the deviating projection as a substantially downward-projecting extension in detail;

[0053] FIG. 6A, FIG. 6B,

[0054] FIG. 6C shows a particularly preferred embodiment of a brake caliper designed according to the first embodiment, i.e., with the aforementioned caliper cover arrangement of FIGS. 4A to 5B with a correspondingly advantageously designed caliper housing for a particularly preferred embodiment of a brake caliper - FIG. 6A shows a bottom view of a caliper housing together with the caliper cover arrangement and a brake carrier, and FIGS. 6B and 6C show details of the same in a modified perspective of the bottom view;

[0055] FIG. 7A, FIG. 7B particularly preferred variations to the first embodiment, wherein safety elements are provided to limit movement of the brake caliper, also with a support plate away from the vehicle (FIG. 7A) and an edge of a frame section of the caliper cover (FIG. 7B);

[0056] FIG. 7C, FIG. 7D show a further variation to the first embodiment in a perspective view from above (Fig. 7C) and a perspective view from below (Fig. 7D), wherein a safety element is realized by an extended carrier plate for a brake pad and a stop is located on the carrier plate;

[0057] FIG. 8A, FIG. 8B,

[0058] FIG. 8C shows a second embodiment according to the concept of the invention, in which the saddle housing has manufacturing elements that particularly advantageously support the manufacture of the saddle cover - FIG. 8A shows a perspective view; FIG. 8B a side view and FIG. 8C a perspective top view of the detail of the saddle housing on its frame section;

[0059] FIG. 9A, FIG. 9B, FIG. 9C show a third embodiment of a saddle housing according to the concept of the invention, in which, to further develop especially the first and second embodiments, the frame section towards a window has one or more edge sections which are flattened towards the interior on a window-side lower edge section of a window edge of the frame section with a predetermined chamfer and / or a predetermined radius.

[0060] FIG. 1 shows a commercial vehicle disc brake 100 (hereinafter also referred to as "brake 100") designed to decelerate a brake disc attached to a wheel of a motor vehicle (not shown). The brake 100 has a brake actuator 101 designed to generate a braking force in response to a control command. A pneumatic brake actuator is shown, but alternatively, other types of force generation can also be used. The brake 100 has a brake carrier 3 designed to be attached to the vehicle in the area of ​​the axle. The brake 100 has a first brake pad 107.1 on the clamping side and a second brake pad 107.2 on the reaction side. The brake pads 107.1 and 107.2 are attached to a brake caliper 1 according to the invention. The brake caliper 1 shown is a sliding caliper. However, the invention also relates equally to fixed caliper brakes.

[0061] Furthermore, the brake 100 has a caliper housing 103 with a caliper cover 105 made of bent sheet metal, which is mounted on the caliper housing 103 and is designed to engage a brake disc (not shown) that rotates about its axis of rotation R in the direction of rotation D. The caliper housing 103 with a caliper cover 105 made of bent sheet metal is explained in more detail below with reference to a caliper cover 5, 5', 5", 5'" with a brake carrier 3, 3' of a brake caliper assembly or, in short, "brake caliper" 1 according to the concept of the invention.

[0062] In FIGS. 2A and 2B, a brake caliper 1 is shown according to a comparative example, with the caliper cover 5 made of bent sheet metal, i.e., with a caliper cover 5 formed partially or completely from sheet metal. FIG. 2A shows that the brake caliper 1 has the caliper housing 103, which is formed at least partially from sheet metal segments. The caliper housing 103 has the caliper cover 5 made of bent sheet metal, which is placed on the caliper housing 103 and is configured to engage a brake disc (not shown) that rotates about its axis of rotation R. The brake caliper 1 has a first, vehicle-side, housing wall 7, which is designed as a bent sheet metal body. Preferably, the vehicle-side housing wall 7 is oriented at right angles to the axis of rotation R when the brake caliper 1 is mounted in its operating state.

[0063] The caliper cover 5 has an outer surface 6 and an inner surface 8 with respect to the axis of rotation R. The caliper cover 5 is further designed to accommodate a retaining bracket 31 shown in FIG. 2B, which extends from a clamping side 19 of the brake disc to a reaction side 21 of the brake disc and prevents the brake pads from falling out of the brake in a generally known manner.

[0064] On one side of the brake caliper 1 opposite the vehicle-side housing wall 7, a support plate 9 is provided for supporting a reaction-side brake pad (not shown), preferably also made of sheet metal – this support plate 9 is thus designed as a reaction-side pressure plate. Furthermore, on the reaction side 21 of the caliper housing 3, there is a (first) reaction-side bracket 11 for receiving the retaining bracket 31, see FIG. 2B.

[0065] Between the caliper housing 103 and the caliper cover 5, several sliding sleeves 13 are arranged to receive guide pins of the disc brake. The construction of the brake caliper 1 is preferably entirely without cast parts, but may include one or more forged or machined parts.

[0066] The brake caliper 1 has a mounting interface 15, which is designed for attaching a brake actuator, and a number of through-holes 29 for fastening means. The caliper housing 103 encloses a cavity 23 for receiving a clamping mechanism for the aforementioned clamping-side first brake pad 107.1 and reaction-side second brake pad 107.2, which is accessible from the vehicle side by means of a through-opening 25. In the operating state, a plunger of a brake cylinder of the aforementioned brake actuator 101, which is attached to the mounting interface 15, extends through this through-opening 25.

[0067] As can be seen from FIG. 2A, and even more so from FIG. 2B, the caliper housing 103 has a second housing wall 17 opposite the vehicle-side housing wall 7, on the brake disc side, on which a second bracket 27 is provided. The second bracket 27 is shown in a simplified manner in FIG. 2A and FIG. 2B. The hold-down bracket 31 is engaged with the second bracket 27 on the clamping side 19, and with the first support 11 on the reaction side 21, as can be seen particularly in FIG. 2B.

[0068] This first bracket 11 has a hook 11.1 bent away from the clamping side 19, which is integrally formed on the support plate 9, preferably by bending. Once the hold-down bracket 31 is hooked in the manner shown in FIG. 2B, it can be fixed to the saddle cover 5 by inserting a fastener, for example in the form of a screw, into a fastening opening 12 provided for this purpose in the saddle cover 5. The support plate 9, particularly visible in FIG. 2A, is in contact with the inside 8 of the saddle cover 5 with a corresponding contour 33, particularly visible in FIG. 2B, and is positionally aligned by this contour. The support plate 9 is preferably bonded to the saddle cover 5, preferably by welding. The alignment of the support plate 9 on the saddle cover 5 is preferably achieved using a guide shown in FIG.The positioning collar 35 shown in Figure 2B is formed on the support plate 9 by bending it along a bending edge. Preferably, the positioning collar 35 extends in the same direction, namely away from the clamping side 19, along the support plate 9. The bending edge is preferably formed as a circular arc. The contour 33 can be designed for point contact of the positioning collar 35, or for line or surface contact. However, a two-point contact will be sufficient for basic positioning.

[0069] FIG. 3 shows the saddle cover 5 of the comparative example as a one-piece molded part according to the basic concept of the invention with the recognizable support plate 9 on the inside 8 of the saddle cover 5. The saddle cover 5 of the comparative example, in which a frame-like contour and the arc-like contour of a frame section 52 are already formed as a one-piece molded part, can be further improved within the scope of the invention, as will be explained with reference to the following exemplary embodiments of the views in FIGS. 4 to FIGS. 9.

[0070] The improvements are found, according to the following embodiments, particularly in the areas 10, 20, 30 of the saddle cover 5 marked with reference numerals 10, 20, 30, i.e., the outer edge areas 10.1, 10.2 (views of FIG. 4, FIG. 5, FIG. 8), the outer and inner area 20.1, which is associated with the side wall with the outer surface 6 of the saddle cover 5 (FIG. 4A, FIG. 4B and FIG. 5A, FIG. 5B) and the inner area 20.2, which is associated, among other things, with the support plate 9 (views of FIG. 6, FIG. 7), and the inner edge areas 30 of the saddle cover 5 towards the interior 24 (views of FIG. 9).

[0071] Advantageous saddle covers 5', 5", 5'" according to the concept of the invention are described below. These saddle covers have a deviating indentation on the frame-like contour, particularly on the outer surface, and / or a deviating projection on the arc-like contour, particularly at least one of the edges. Furthermore, the advantageous saddle covers 5', 5", 5'" allow for the attachment of safety elements and manufacturing elements to the one-piece molded part in accordance with the invention. For the sake of simplicity, reference is made to existing reference numerals, and the essential improvements relating to the further developed saddle covers 5', 5", 5'" according to the concept of the invention and corresponding to the saddle cover arrangements 50', 50", 50'" of the first, second, and third embodiments are discussed below.

[0072] FIG. 4A shows a first preferred embodiment of a caliper cover assembly 50' improved compared to the comparative example of the caliper cover, with an improved caliper cover 5' which is explained below. This embodiment also has, as explained, a dome section 51 and a frame section 52, with particular reference being made below to the frame section. The frame section 52 is advantageously modified with respect to the aforementioned outer and inner areas 20.1 and the outer edge area 10.1 in order to limit movement of the brake caliper 1. FIG. 4B shows a corresponding side view of the improved caliper cover 5' as part of the improved caliper cover assembly 50', where “O” denotes an outer reaction side (i.e., the outside of the vehicle or facing away from the vehicle), and “I” denotes a clamping side (i.e., the inside of the vehicle or opposite the clamping side).Both FIG. 4A and FIG. 4B are referred to together in the following.

[0073] As can be clearly seen there, the improved saddle cover 5' in the frame section 52 of the one-piece molded part of the saddle cover 5' has a frame-like contour KR with an outer surface A as well as an arc-like contour KB that curves between two edges R1, R2 - a first front edge R1 in the direction of rotation D and a second rear edge R2 in the direction of rotation D. The frame-like contour KR encompasses or borders, so to speak, the saddle cover 5' as its outer contour, and the arc-like contour KB extends in a curved shape between the first and second edges R1, R2 over the underlying interior space 24 of the saddle cover 5'.

[0074] The interior 24, in particular for the brake pads 107.1, 107.2, is accessible via a window F; the window F can be understood as a recess in the arc-shaped contour KB and thus provides access to the interior 24. As can be seen in FIG. 1 and FIG. 6, the window essentially provides a view of a brake carrier 3, 3'. In the side view of FIG. 4B, both the frame-like contour KR and the arc-shaped contour KB are visible from the side, each with the aforementioned outer surface A of the frame-like contour KR and the leading edge R1 of the arc-shaped contour KB in the direction of rotation D, respectively, and the recess in the form of the window F. In other words, the arc-shaped contour KB extends approximately over a caliper housing in the direction of rotation D, and the frame-like contour KR extends circumferentially around the caliper housing above a brake carrier 3, 3'. The frame-like contour KR and the arc-like contour KB merge into each other, especially in the area of ​​their edges R1 and R2, respectively.R2. The arc-like contour KB is also formed on the dome section 51; likewise, the frame-like contour KR can be found on the dome section 51, as can be seen in FIG. 4B.

[0075] According to the concept of the invention, safety elements E1, E2 are now provided on the caliper cover 5' or the caliper cover arrangement 50' in order to limit movement of the brake caliper 1 along the axis of rotation R, which is particularly relevant in the present case for the brake caliper 1 in the form of a sliding brake caliper.

[0076] The first safety element E1 in the outer edge region 10, 10.1 is formed as a projection deviating from the contours KR, KB, namely as a downwardly projecting extension, which is shown in detail in FIG. 5B at the edge R1 of the arc-shaped contour KB. The corresponding further safety element E1 of this type formed at the second edge R2 – specifically designated E1.2 – is visible in FIG. 4A and is designed analogously to safety element E1.1 as a projection deviating from the shape, which is formed as a downwardly projecting extension at the second edge R2.

[0077] Both safety elements E1.1 and E1.2 have a stop B, visible in FIG. 5B, which projects into the interior space 24 on the inside "I" of frame section 52. For the brake caliper 1, designed as a sliding brake caliper, this means that when moving along the axis of rotation R, it cannot move (or slide) further towards the clamping side (i.e., towards the inside of the vehicle) than is permitted by the stop B of the extension of the safety element E1, E1.2, E1.2. The inner boundary surface BFI formed by the stop surface of the stop B is shown as a dashed line in FIG. 4B and is aligned with the stop surface of the stop B of the safety element E1.

[0078] Furthermore, the one-piece molded part of the further developed saddle cover 5' is provided on its outer surface A of the frame-like contour KR with a deviating indentation W, which forms, so to speak, the second safety element E2. In this case, the deviating indentation W extends from the outer surface A of the frame-like contour KR towards corner E; i.e., towards corner E of the frame-like contour KR or of the saddle cover 5'. The safety element E2 thus comprises a safety element E2.1 located at the front in the direction of rotation and a safety element E2.2 located at the rear in the direction of rotation. Both safety elements E2.1 and E2.2 are formed as so-called deviating indentations relative to the otherwise one-piece molded part of the saddle cover 5'. The outer surface A therefore has a raised portion, which is clearly visible in FIGS. 4A and FIGS. 4B at the location of reference numeral A, and also has an inwardly curved area W towards corner E.

[0079] The concave area – i.e., the concave W – is clearly visible in FIG. 4A at the aforementioned corner E of the frame-like contour KR, or the saddle cover 5', whereby the deviating concave W is recognizably formed as an inwardly projecting indentation or depression. This inwardly projecting indentation or depression resulting from the concave W thus forms a second safety element E2, a boundary located on the outside of the vehicle (i.e., in area 0 of the frame section 52). This therefore limits the movement of a brake caliper 1, which is designed as a sliding brake caliper, towards the reaction side (marked 0 on this side).

[0080] The corresponding outer boundary surface BFO is shown in dashed lines in FIG. 4B together with the inner boundary surface BFI. It can therefore be said that the outer indentation W on the outer side A of the frame-like contour KR forms a boundary in the form of the boundary surface BFO for a sliding brake caliper 1 on the outer side 0 – i.e., towards the reaction side – with a corresponding stop for the sliding brake caliper 1 being created by the inwardly projecting indentation or depression of the indentation W. Similarly, the movement of a sliding brake caliper 1 is limited by the safety elements E1, E1.1, E1.2, which are the deviating projections of the downwardly projecting extensions with a corresponding stop surface on the inner side I – i.e., towards the clamping side.

[0081] A sliding brake caliper 1 is positioned in the sliding area BFS shown in FIG. 4B along the axis of rotation R. This protects, firstly, the clamping device in the cavity 23 of the caliper housing 103 on the inside I and, secondly, prevents damage to the caliper cover 5' or to the caliper housing shown in FIG. 1 and at least recognizable in FIG. 4B on its outside 0. In particular, the brake caliper 1 can move slightly forward (against the direction of rotation D) and relatively more backward (in the direction of rotation D) with respect to the center line shown in FIG. 4B as a reference, in order to accommodate the wear of brake pads (e.g., the brake pads 107.1, 107.2 of FIG. 1) and a brake disc. Only limited movement in the forward direction (against the direction of rotation D) protects the boot visible on the right side below the safety element E1.1 in FIG. 6A from damage.Limited backward movement (in the direction of rotation D) protects against excessive wear of the outer brake pad and the outer surface of the rotor. One could also say that, among other things, the indentation W reinforces the caliper cover 5' on the outer surface A, which is structurally evident from the indentation W embossed or dented against the raised outer surface A.

[0082] Thus, the saddle cover 5' offers an improved safety structure in operation, which is ultimately realized by the safety elements E1 and E2 in the manner previously explained.

[0083] Regarding this first embodiment of an improved saddle cover 5', this requirement is illustrated in its functionality in FIGS. 6A to 6C, which are referred to in their entirety in the following explanation. FIGS. 6A to 6C show how a sliding brake caliper 1 is limited in its movement towards the clamping side (i.e., on the inside I) and towards the reaction side (i.e., on the outside 0) along the axis of rotation R.

[0084] The brake caliper 1 is shown here with the brake carrier 3', on which the direction of rotation D for the brake disc (not shown) is also indicated. Also shown for this arrangement of a brake caliper 1 with a further developed caliper cover 5', as described in the first embodiment, are the previously explained safety elements E1 and E2 in the form, on the one hand, the deviating projection as at least one downwardly projecting extension (E1, E1.1) in the outer edge region 10.1 on the inner side I, and the indentation W in comparison to the raised outer side A on that same outer side A of the frame-like contour KR.

[0085] The brake carrier 3', which in this case is specially prepared for the sliding brake caliper according to the further development shown here, has protrusions C1 assigned to the safety elements E1 , E2, i.e. formed for the stop with the aforementioned stop surfaces B for precisely this stop on the outside, for the first safety element E1 and the second safety element E2 respectively.

[0086] In FIG. 6B this is shown more specifically for a position of the brake carrier 3' on the inside I where the protrusion C1 is in contact K1, i.e. in the stop, with the stop surface BF of the safety element E1.

[0087] In FIG. 6C, the corresponding protrusion C2 on the brake carrier 3' is shown for the indentation W forming the second safety element E2. This protrusion is formed here more like a nub or horn on the brake carrier 3'; that is, it abuts the contact surface K2 with the indentation formed by the indentation W. It can thus be seen that the second contact K2 defines the second contact surface for the second, i.e., outer, contact surface BFO, and the first contact K1 defines the first, i.e., inner, contact surface BFI.

[0088] Referring to FIG. 7 A and FIG. 7B, an embodiment modified from the first embodiment is shown for forming a first safety element E1 or a second safety element E2 with corresponding stops B.

[0089] Figure 7A shows that, in addition to or alternatively (in this case additionally) to a concave section W on the outer surface A of a saddle cover 5', 5", a raised portion can be formed on the saddle cover 5', 5" or on a support plate 9 itself, and / or it is the support plate 9 itself that rests on the raised portion on the saddle cover 5', 5" to serve as a second safety element E2. This may, but does not necessarily, involve a corresponding concave section W on the outer surface A of a saddle cover 5', 5" or the support plate 9.

[0090] A stop can therefore be formed by means of a bead (e.g. in the form of the aforementioned raised part on the outside A or the support plate 9 itself).

[0091] In general, however, an area serving as a second safety element E2 - so to speak as a forward-positioned contact area K2 located on the outside 0 - can be designed to limit the outward movement of a brake caliper even without the indentation W on the outside A of a caliper cover 5', 5".

[0092] Figure 7B further shows a first safety element E1, which is also formed as a non-standard projection. Here, the downwardly projecting extension is visibly attached to the frame contour KR in a joining area FB with a corresponding element (for example, by welding or brazing – thus attached and less integrally formed with the frame contour KR of frame section 52). Such an extension can also be attached to the support plate 9 itself.

[0093] In an embodiment shown in more detail in FIGS. 7C and 7D, a safety element E2, E2.1 can also be implemented simply by an extended support plate 9 for a brake pad; a stop forming the safety element E2, E2.1 is then located on the support plate 9 itself or is formed by means of the support plate 9 itself, so that the aforementioned indentation W on the outer surface A in conjunction with the protrusion on the caliper cover 5"" (for realizing the aforementioned raised part of the support plate 9, which projects into the interior 24) is essentially unnecessary. FIG. 7C shows this embodiment in which the caliper cover 5"" does without indentation W and the support plate 9 has a non-standard projection and / or a raised part projecting into the interior 24 to form a safety element E2, E2.1.

[0094] In other words, the support plate 9 shown in FIGS. 7C and 7D can point towards the location of the contact surface K2 of FIG. 7A; the contact surface K2 points towards the bearing surface of a brake pad. The aforementioned indentation W on the outer surface A in conjunction with the protrusion can then, in my opinion, be omitted. The embodiment shown here in FIGS. 7C and 7D therefore optionally includes a separate plate or alternative support plate that closes a gap between the caliper cover 5 and the support plate 9 – as can be seen in FIGS. 2A, 4A, 6A and 7A.

[0095] FIGS. 8A, 8B, and 8C show a second embodiment of a saddle cover assembly 50" for a saddle cover 5". Here, too, the same or similar features or features with the same or similar function are used, and reference is again made to the previously mentioned reference numerals. In the following, particular reference is made to the differences compared to the example in FIGS. 2 and 3.

[0096] The second embodiment of a saddle cover 5" is further developed in a particularly advantageous way for manufacture by means of the manufacturing elements H1 , H2 shown here on the frame-like contour KR, wherein here too a shape-deviating indentation is provided on the frame-like contour or a shape-deviating projection is provided on the arch-like contour.

[0097] These areas 10, 20 are – as already shown in FIG. 3 – marked with corresponding outer edge areas 10.2 and inner area areas 20.2. At least in part, the manufacturing elements H1, H2 shown here can also be used on the frame-like contour KR as safety elements E1 and E2, respectively.

[0098] It is provided that the further developed saddle cover 5” in the area of ​​an outer perimeter, i.e. at the edges R1 , R2 - in this case of the dome section 51 with regard to the manufacturing elements H1 and of the frame section 52 with regard to the manufacturing elements H2 - has precisely that shape-deviating projection as one or more flat sections.

[0099] The flat sections are shown in FIGS. 8A, 8B, and 8C as the front flat section H1.1 in the direction of rotation D and as the rear flat section H1.2 or H2.1 / H2.2 in the direction of rotation D. Specifically, a flat section H1, H2 is always edged in a predetermined manner and is distinct from the shape of a one-piece molded part of the saddle cover 5". The separation is such that the flat section H1, H2 forms a contact surface on which a clamping or holding tool can engage—or, more generally, be applied.

[0100] It has been shown that, in the case of a one-piece forming process, it should nevertheless be ensured during manufacturing that the saddle cover 5" can be gripped by appropriate machine gripping or holding tools, even with its radii of curvature and bulges. Less curved areas are preferably suitable for this purpose; however, these are only partially present or accessible in the further developed saddle cover 5" as a one-piece molded part. The advantageously designed flat sections H1, H2, however, can also be gripped by appropriate machine gripping or holding tools.

[0101] A flat section H1, H2 shown here can be molded onto, attached to, or embedded in a semi-finished product of the saddle cover 5", in particular pressed onto, attached to, or embedded in the molded part. A molded-on manufacturing element H1 and a pressed-in manufacturing element H2 are clearly visible in the view of FIG. 8C at the edge R1 of the frame contour KR.

[0102] A third preferred further embodiment shows a saddle cover 5'" of a saddle cover arrangement 50'", wherein the saddle cover 5'" is again formed with a dome section 51 and a frame section 52. The frame section 52 again has, as previously described, an arc contour KB extending between two edges R1, R2 and thus arches over a saddle housing (not shown) and therefore overlaps the interior 24.

[0103] Access to the brake carrier 3, 3' (as shown in Fig. 1) or the brake linings (not shown) is provided by a window F in the arc contour KB of the frame section 52, wherein the window F forms one or more edge sections of the frame section as a recess in the arc contour KB. As can be seen in FIGS. 9A, 9B and FIG. 90, the edge sections are formed in the direction of rotation (i.e., running transversely to the direction of rotation D) by means of the rear edge section FK2 or the front edge section FK1 (not shown). FIG. 9B shows a first modification of the third embodiment in which such an edge section FK2 is flattened in a predetermined manner. Accordingly, in a first variant, a flattening is provided in a predetermined manner on the rear edge section FK2 by means of a predetermined radius, i.e.in this case as a radius FKR formed in a predetermined manner at the edge section of the frame section 52.

[0104] FIG. 90 shows a second modification of the third embodiment, in which such an edge section FK2 is flattened in a predetermined manner. In the case of FIG. 9C, the edge section FK2 is provided with a chamfer FKF formed in a predetermined manner towards the window F, i.e., practically as a chamfered edge section. The chamfer FKF can be seen in FIG. 9C on the rear edge section FK2.

[0105] In summary, the present embodiments describe a further development of a saddle cover arrangement for a brake caliper for a motor vehicle disc brake, comprising at least a saddle cover.

[0106] In the embodiments, the caliper cover assembly comprises the caliper cover and one or more attachments, such as optionally a vehicle-side housing wall or, as in the present case, a support plate opposite it on the vehicle side. The caliper cover is designed to cover a brake carrier of the brake caliper, in particular a sliding brake caliper, from above, wherein

[0107] - a brake disc along a rotational axis R of the brake disc from a clamping side of the brake disc to a reaction side of the brake disc with a frame-like contour of the caliper cover overlaps, which is closed off by an outer side of the caliper cover associated with the reaction side,

[0108] - formed with an arc-shaped contour in the direction of rotation D of the brake disc, extending between opposite edges of the caliper cover in the direction of rotation.

[0109] According to the concept of the invention, the saddle cover is designed to solve the problem by being formed as a one-piece molded part forming the frame-like contour and the arc-like contour of a frame section 52, in particular partially or completely made of sheet metal. Furthermore, according to the invention, the one-piece molded part has a deviating indentation on the frame-like contour, in particular on the outside, and / or

[0110] - on the arc-shaped contour, in particular at least one of the edges, a deviating projection.

[0111] In detail, embodiments are described in the views of FIGS. 4 to FIGS. 7, in which

[0112] - at least one of the edges of the arc-shaped contour or the arc-shaped contour itself on its inner side of the caliper cover, which is associated with the clamping side, bears the deviating projection as at least one downwardly projecting extension, which is designed to limit movement of the brake caliper, in particular a sliding brake caliper, towards the clamping side (towards the inside of the vehicle, inwards), and

[0113] - at least the outer side of the frame-like contour or the frame-like contour itself bears the deviating indentation as at least one inwardly projecting indentation or depression designed to limit movement of the brake caliper, in particular sliding brake caliper, towards the reaction side (towards the outside of the vehicle, outwards).

[0114] In detail, an embodiment is described in the views of FIG. 8 in which the saddle cover 5 in the area of ​​an outer perimeter, in particular the edges of the dome section 51 and / or the frame section 52, has the shape-deviating projection as one or more flat sections, wherein a flat section is predetermined by its edge and stands out from the shape of the one-piece molded part of the saddle cover, such that the flat section forms a contact surface for a clamping or holding tool.

[0115] In detail, an embodiment is described in FIG. 9A, FIG. 9B and FIG. 90 in which the frame section 52, in particular towards a window, has one or more edge sections of the frame section 52 which, in particular at least one window-side lower edge section of a window edge of the frame section 52 towards the interior 24, are flattened in a predetermined manner.

[0116] In summary, various embodiments of a caliper cover arrangement 50', 50", 50'" for a brake caliper assembly 1 for a commercial vehicle disc brake 100 have been described. The caliper cover arrangement 50', 50", 50'" comprises at least one caliper cover 5', 5", 5'", 5"" or at least the caliper cover 5', 5", 5'", 5"" and one or more attachments such as a vehicle-side support plate 9. In particular, the caliper cover 5', 5", 5'", 5"" also comprises a brake disc-side housing wall 17 opposite this vehicle-side support plate 9 and / or a vehicle-side housing wall 7 of a caliper housing 103, which caliper cover 5', 5", 5'", 5"" is designed to cover a caliper housing 103 from above, wherein

[0117] - a brake disc along a rotational axis R from a clamping side I to a reaction side 0 with a frame contour KR of the caliper cover 5',5", 5'", 5"" overhangs can be made, and wherein the caliper cover 5',5", 5'", 5"" has a vehicle-side outer surface A associated with the reaction side 0, and

[0118] - with an arc contour KB formed in the direction of a rotation direction D of the brake disc, which extends between opposite edges R1, R2 of the caliper cover in the direction of rotation. According to the concept of the invention, in the embodiments, the caliper cover 5',5", 5'", 5"" is formed as a one-piece metallic molded part forming the frame contour KR and the arc contour KB of a frame section 52, in particular a sheet metal molded part, in particular partially or completely formed from sheet metal, wherein

[0119] - the one-piece molded part has a non-standard projection E1 on the arc contour KB, in particular on at least one of the edges R1, R2, and / or

[0120] - the support plate 9 away from the vehicle has a non-standard projection and / or a raised part projecting into the interior 24.

[0121] In some of the different embodiments, it is also provided that

[0122] - the one-piece molded part has a shape-deviating protrusion (Fig. 7C) on the frame contour KR, in particular on the outside A, or.

[0123] - the one-piece molded part has a shape-deviating indentation W, E2 on the frame contour KR, in particular on the outside A.

[0124] The embodiments further comprise a caliper housing 103, with a brake disc-side housing wall 17 and a vehicle-side housing wall 7 of the caliper housing 103. In some of the various embodiments, it is also provided that the caliper cover 5',5", 5'", 5"" is designed to cover a cavity 23 of the caliper housing 103 for receiving a clamping mechanism and that the caliper cover is designed to overlap an interior space 24 for receiving a brake carrier 3, 3', and that the caliper cover 5',5", 5'", 5"" is formed as a one-piece molded part forming a dome section 51 and the frame section 52 with the frame contour and the arc contour KR, KB, wherein the dome section 51 is convex outwards to cover the cavity 23, in particular for a clamping mechanism, and the frame section 52 has a window F to an interior space 24, in particular for brake pads 107.1. 107.2, bordered.

[0125] In some of the various embodiments, the saddle cover arrangement also includes the saddle cover 5',5", 5'", 5"" and the vehicle-side support plate 9, wherein the vehicle-side support plate 9 itself has a non-conforming indentation and / or the non-conforming projection.

[0126] The concept of the invention is also described with reference to an embodiment with a brake caliper assembly 1, in particular a brake caliper for a motor vehicle disc brake 100, in particular for a commercial vehicle disc brake with a brake disc moved around a rotational axis R, in particular for a sliding caliper brake, with a brake carrier 3, 3' and with a caliper cover arrangement 50'; 50", 50'" according to the embodiments described above in accordance with the concept of the invention, with a caliper housing 103 with a cavity 23 for receiving a clamping mechanism.In particular, the caliper cover assembly 50'; 50", 50'" comprises the caliper cover 5'; 5", 5'" and one or more attachments such as a vehicle-side support plate 9, and in particular also a brake-disc-side housing wall 17 opposite this and a vehicle-side housing wall 7 of the caliper housing 103, which caliper cover 5', 5", 5'", 5"" is designed to cover the caliper housing 103 from above, and is also designed to overlap the brake disc from a clamping side I to a reaction side O, and wherein the caliper cover 5', 5", 5'", 5"" has a vehicle-side outer surface A associated with the reaction side O. Other variations of the disclosed embodiments can be understood and carried out by a person skilled in the art when carrying out the claimed invention with reference to the drawings, the disclosure and the appended claims.It is possible and provided for in the invention to combine the features of the various embodiments described above, as long as they do not technically exclude each other.

[0127] In the claims, the word "comprehensive" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality.

[0128] A single unit or device can perform the functions of several elements listed in the claims. The fact that certain measures are listed in different interdependent claims does not mean that a combination of these measures cannot be advantageous.

[0129] Any reference numerals in the claims are not to be understood as limiting the scope of application.

[0130] Reference symbol list (part of the description)

[0131] 1 Brake caliper assembly, or brake caliper for short

[0132] 3, 3' Brake carrier

[0133] 5, 5', 5", 5'" saddle cover

[0134] 6. Outside of the saddle cover

[0135] 7 Housing wall, vehicle side

[0136] 8 Inside of the saddle cover

[0137] 9 Support plate, reaction-side pressure plate

[0138] 11, 11.1 Bracket, hook for hold-down device, reaction side

[0139] 12 Mounting opening

[0140] 13 sliding sleeves for guide pins

[0141] 15 Mounting interface

[0142] 17 brake disc side housing wall

[0143] 19 Tensioning side

[0144] 10, 20, 30 areas of saddle cover 5

[0145] 10.1, 10.2 Outer edge areas

[0146] 20.1, 20.2 Exterior and interior areas

[0147] 30 Inner edge area towards the interior 24

[0148] 21 reaction page

[0149] 23 Cavity

[0150] 24 Interior

[0151] 25 Through opening, vehicle-side housing wall

[0152] 27 Bracket 27 on the clamping side 19

[0153] 29 through holes

[0154] 31 hold-down brackets

[0155] 33 Contour

[0156] 35 positioning collars

[0157] 51 Cathedral section

[0158] 52 Frame section

[0159] 50', 50", 50'" Saddle cover arrangement

[0160] A Exterior surface / outside

[0161] R, D axis of rotation, direction of rotation R1, R2, edges, front, rear

[0162] F, E window, corner of frame section

[0163] E1.1, E1.2, E2, E2.1, E2.2 safety elements

[0164] H1, H1.1, H1.2, H2, H2.21, H2.2 Manufacturing elements, flat sections

[0165] B Stop, stop surface

[0166] BF boundary area

[0167] W Indented area

[0168] BFO boundary surface outside

[0169] BFI boundary surface inside

[0170] BFS Glide Range

[0171] Inside, tensioning side

[0172] 0 Outside, reaction side

[0173] C1, O2 protrusions

[0174] K Contact

[0175] K1, K2 contact surface

[0176] FB joining area

[0177] KR frame contour

[0178] KB arch contour

[0179] FK1, FK2 edge sections

[0180] FKF phase

[0181] FKR Radius

[0182] 100 Motor vehicle disc brake, in short: brake

[0183] 101 Brake actuator

[0184] 103 Saddle housing

[0185] 105 Saddle cover, comparative example of FIG. 1

[0186] 107.1, 107.2 Brake pad tension side, brake pad reaction side

Claims

Patent claims 1. Caliper cover assembly (50',50", 50'") for a brake caliper assembly (1) for a commercial vehicle disc brake (100), comprising at least one caliper cover (5',5", 5'", 5"") or at least comprising the caliper cover (5',5", 5'", 5"") and one or more attachments such as a vehicle-side support plate (9), in particular also a brake disc-side housing wall (17) and / or vehicle-side housing wall (7) of a caliper housing (103) opposite this, which caliper cover (5',5", 5'", 5"") is designed to cover a caliper housing (103) on the upper side, wherein - a brake disc along a rotational axis (R) from a clamping side (I) to a reaction side (0) with a frame contour (KR) of the caliper cover (5',5", 5'", 5"") attacks can occur, and wherein the saddle cover (5',5", 5'", 5"") is a vehicle-side outer surface associated with the reaction side (0). (A) exhibits, and - is formed with an arc contour (KB) in the direction of a rotation direction (D) of the brake disc, which extends between opposite edges (R1 , R2) of the caliper cover in the direction of rotation, characterized in that the caliper cover (5',5", 5'", 5"") is formed as a one-piece metallic molded part forming the frame contour (KR) and the arc contour (KB) of a frame section (52), in particular a sheet metal molded part, in particular partially or completely formed from sheet metal, wherein - the one-piece molded part has a non-standard projection (E1) on the arc contour (KB), in particular on at least one of the edges (R1, R2), and / or - the support plate (9) away from the vehicle has a non-standard projection and / or a raised part projecting into the interior (24).

2. Saddle cover arrangement according to claim 1, characterized in that - the one-piece molded part has a shape-deviating protrusion (Fig. 7C) on the frame contour (KR), in particular on the outside (A), or. - the one-piece molded part has a shape-deviating indentation (W, E2) on the frame contour (KR), especially on the outside (A).

3. Saddle cover arrangement (50', 50", 50'") according to claim 1 or 2, further comprising a saddle housing (103) with a brake disc side housing wall (17) and a vehicle side housing wall (7) of the saddle housing (103).

4. Saddle cover arrangement according to claim 3, characterized in that - the saddle cover (5',5", 5'", 5"") is designed to cover a cavity (23) of the saddle housing (103) for receiving a clamping mechanism and the saddle cover is designed to overlap an interior (24) for receiving a brake carrier (3, 3'), and. - the saddle cover (5',5", 5'", 5"") is formed as a one-piece molded part forming a dome section (51) and the frame section (52) with the frame contour and the arc contour (KR, KB), wherein the dome section (51) is convex to the outside to cover the cavity (23), in particular for a clamping mechanism, and the frame section (52) borders a window (F) to an interior space (24), in particular for brake linings (107.1, 107.2).

5. Saddle cover arrangement according to one of the preceding claims, characterized in that the saddle cover arrangement comprises the saddle cover (5',5", 5'", 5"") and the vehicle-side support plate (9), wherein the vehicle-side support plate (9) itself has a non-conforming indentation and / or the non-conforming projection.

6. Saddle cover arrangement (FIG. 4 to FIG. 7) according to one of the preceding claims, characterized in that - at least one of the edges (R1 , R2) of the arc-shaped contour (KB) or the arc-shaped contour itself on its inner side (I) of the saddle cover, which is associated with the clamping side, has the shape-deviating projection as at least one downwardly projecting extension (E1 ) which is designed to limit movement of the brake caliper, in particular sliding brake caliper, towards the clamping side.

7. Saddle cover arrangement according to claim 5, characterized in that - at least the outer side (A) of the frame-like contour (KR) or the frame-like contour itself the shape-deviating indentation (W) as at least one inward- The protruding indentation or depression (E2) is designed to limit movement of the brake caliper, in particular a sliding brake caliper, towards the reaction side.

8. Saddle cover arrangement according to claim 5 or 6, characterized in that the deviating indentation is formed as a planar depression or offset in the outer surface or support plate.

9. Saddle cover arrangement according to one of claims 5 to 7, characterized in that the deviating projection is formed as a molding on at least one of the edges or as an integral component of at least one of the edges.

10. Saddle cover arrangement (FIG. 8) according to one of the preceding claims, characterized in that the saddle cover 5 in the area of ​​an outer perimeter, in particular the edges (R1 , R2) of the dome section (51 ) and / or the frame section (52), has the shape-deviating projection as one or more flat sections (H1 , H2), wherein a flat section is predetermined by its edge and is set off from the shape of the one-piece molded part of the saddle cover, such that the flat section forms an engagement surface for a clamping or holding tool.

11. Saddle cover arrangement according to claim 9, characterized in that the flat section is formed, molded or embedded onto a semi-finished product of the molded part of the saddle cover, in particular embossed or pressed onto, molded or embedded.

12. Saddle cover arrangement according to claim 10 or 11, characterized in that the flat section is formed as a surface flattened to a curved surface and with a predetermined border, and - extends beyond a frame area of ​​the outer border, or - flattens a curved corner of the frame area of ​​the outer rim.

13. Saddle cover arrangement (FIG. 9) according to one of the preceding claims, characterized in that the frame section (52), in particular towards a window (F), has one or more edge sections (FK1 , FK2) of the frame section (52) has which, in particular at least one window-side lower edge section of a window edge of the frame section (52) towards the interior (24), are flattened in a predetermined manner.

14. Saddle cover arrangement according to claim 13, characterized in that - one or more edge sections of the frame section (52) are chamfered towards the window with a predetermined chamfer (FKF), in particular the chamfer is formed at a predetermined angle to the window surface and / or with a predetermined chamfer width, and / or - one or more edge sections of the frame section (52) to the window are rounded and flattened with a predetermined radius (FKR), in particular the radius has a predetermined radius value.

15. Saddle cover arrangement according to claim 13 or 14, characterized in that one or more edge sections of the frame section 52 form an edge of the frame section (52) towards the window that is oriented transversely to the direction of rotation of a brake disc, in particular not forming an edge of the frame section (52) towards the window that does not run from the support plate and / or from the vehicle-side housing wall.

16. Brake caliper assembly (1), in particular brake caliper, for a motor vehicle disc brake (100), in particular for a commercial vehicle disc brake with a brake disc moved about a rotational axis (R), in particular for a sliding caliper brake, with a brake carrier (3, 3') and with a caliper cover arrangement (50'; 50", 50"') according to one of the preceding claims, with a caliper housing (103) with a cavity (23) for receiving a clamping mechanism, in particular comprising the caliper cover (5';5“, 5'“) and one or more attachments such as a vehicle-side support plate (9), in particular further comprising a brake disc-side housing wall (17) and vehicle-side housing wall (7) of the caliper housing (103) opposite this, which is designed as a caliper cover (5',5“, 5'“, 5““), which covers the caliper housing (103) on the upper side and extends over the brake disc from a clamping side (I) to a reaction side (O) and wherein the caliper cover (5',5“, 5'“, 5““) has a vehicle-side outer surface (A) associated with the reaction side (O).

17. Brake caliper assembly (1 ) according to claim 16, characterized in that the clamping mechanism has a brake lever pivotable about a lever axis, wherein the caliper housing has a vehicle-side housing wall made of a one-piece bent sheet metal, on the inside of which at least one support element is provided for supporting the brake lever.

18. Brake caliper assembly (1 ) according to claim 16 or 17, characterized in that the caliper housing has on its outer side a stop, in particular a protrusion (C1 , C2), in particular a horn or a knob, which cooperates with the non-conforming indentation (E2) or the non-conforming projection (E1 ) of the caliper cover to limit movement of the brake caliper, in particular a sliding brake caliper.

19. Commercial vehicle disc brake (100) with a brake caliper assembly (1) according to one of claims 16 to 18.

Images