Cover mounting interface solution for automotive caliper brakes (product + process)

Abstract

Cover (20,200) with automotive disk brake caliper assembly, comprising a fist type disk brake caliper housing with actuator section, bridge section and fist section, the fist section comprising abutment for carrying the cover (20,200), the caliper housing (10,100) comprising an axial actuator axis 03 that is in parallel with an axis of wheel rotation, the assembly comprising releasable fastening means in cooperation with abutment for the cover (20,200), the fastening means is at least a bolt comprising an axis that is essentially radially, the cover (20,200) comprising a visible frontside face with invisible back face behind the frontside face, the backface serving for locking contact with the caliper housing (10,100) together with the bolt as releasable fastening means and the bolt hidden behind the frontside of the cover (20,200), wherein the fist section comprises interface orifice for reception of an interface protrusion that erects from the cover backside and cooperates with the interface orifice of the fist.

Description

[0001] 202402734

[0002] 1

[0003] Description

[0004] Cover solution for automotive disk brake caliper housing

[0005] The present invention concerns automotive caliper disc brakes for application in vehicles. Automotive disk brakes generally comprise a brake caliper housing which can be of a fist type caliper or fix type caliper type. Disk brakes are supplied with brake pads for their relative interaction with a friction surface of a brake disk and the space efficient + cost efficient fist type caliper type comprises a specific brake support or corner module for supporting and guiding brake caliper as well as brake pads for their cooperation with the disk. In contrast concerning the fist type caliper design, the fix type caliper brakes comprise a housing that is fix and receiving opposed pistons. Caliper housing is covered behind so called “design plate” or “symbol cover plate”. Such cover comprises a visible front face as a visuable screen or shell when implemented in use position of automotive wheel brake caliper housing. The covers attachment / placement to the housing is required to be safe and stable - say in lock status in the mounting position - so that danger or damage due to uncontrolled loss of the cover is prohibited. However cover assembly and disassembly should still be as easy as possible e.g. for brake service reasons. A smooth look is received when the cover fastening means are hidden e.g. implemented at least partly from a backside of the front cover face that is opposite (behind) the normally visuable front side of the cover. The cover can especially be arranged as multipart assembly.

[0006] A cover assembly can ensure efficient aerodynamic and self cleaning function in cooperation with automotive brake caliper, also together with stylish look and allowing rationalized customer adaptions with each customers corporate family designs or logo adaptions. Construction and shape of so called design covers shall meet with defined customer’s requirements, one important customer requirement is invisible and safe locking and unlocking properties with the caliper housing. Good design is understood to be free from visible locking means. However cover function should be without unwanted rattling noise production when the vehicle is in rough road condition. Design cover can be produced as combination of various 202402734

[0007] 2 components, technologies and materials. A cover front side may individually be assigned to each use case and can visibly carry / hold customer emblem / logo reproduction.

[0008] An object of the invention is the need for alternative interface solution as a cover improvement with drawbacks of the prior art cover solutions. Improved Interfaces aim for better security against unwanted loss of a cover, avoiding of rattling noise for reason of rough road driving conditions also in connection with more comfort in terms of cover assembly or cover disassembly especially resulting from “blind” mounting situations in connection with invisible, hidden, locking structure.

[0009] The following specification on basis of a drawing describes more details of improved embodiments of the invention together with various modifications according to such embodiments. That is in connection with design variation but also with variation of mounting process. The invention allows for precise and fast, selfguided automatic prepositioning, e.g. with selflocking. Mounting capabilities are consequently improved according to the present invention. Invention is based on new appropriate improved interface design with advanced automatized assembly processes including automatic prepositioning. Improved disassembly is achieved. The interfaces allow self-finding and self-adjustment in cooperation of components (component and countercomponent). The invention consequently allows a new improved hidden, screw-bolted fixing connection between components (design plate cover component and caliper housing component). Although the cover plate is in the following description always described as being mounted to a caliper housing it may be in alternative be that the cover plate is mounted to a brake holder (bracket component).

[0010] The valuable assembly process improvement of the invention allows valuable automatized holding function between housing component and cover component by the suitable arrangement and interaction between the cooperating interfaces of housing (or bracket respectively) and the cover. With this the automatized prepositioning cooperation may be achieved for example with the use of natural weight and gravity force when the housing is for example oriented with its bridge 202402734

[0011] 3 portion downwards so that it rests in abutment and the cover is automatically held prepositioned by its natural weight and rests in abutment on the housing. Alternatively or in any combination among each of options the function can be achieved via automatic form locking interaction between cooperating interfaces of cover and housing. More alternatively or in still any other combination among each of options the automatic prepositioning cooperation between housing and cover may be based on adhesive interaction between housing and cover insofar that for example a glue substance or a tape, as for example a double-sided tape may be used.

[0012] In the following some alternative solutions or embodiments of the invention are herewith explained in more detail but still in principle, using reduced drawing scale, simplified in shape, if not concretely otherwise expressed as follows:

[0013] Fig.1 a, Fig. 1 b reduced perspective and exploded view of a disc brake caliper subassembly comprising components: caliper housing 10, cover 20 and locking screw 30 implemented radially from below (orientations in radial 01 , tangential 02 and axial 03 direction (the latter arranged in parallel with brake actuation = brake rotor / wheel rotation axis) all axis relationship is understood in cartesian coordinate system terms,

[0014] Fig.2a, b in reduced view a caliper housing component 10 ready for assembly of its cover 20; in Fig. 2a a caliper housing 10 - that is placed and held in the working room of its assembly street with the housings upper side down (housing bridge portion down) - and wherein g symbolizes the natural gravity in the working room and wherein radial axis 01 is parallel with g for automatic prepositioning function when a cover is fed and placed in position, further showing radial interface 11 as form locking recess cavity that is duct-like and in the cabriolet style (open top) configuration together with further tangential 13 and axial 12 interfaces; more over this in Fig. 2b radial fixation hole 14 for reception of a bolt 30,

[0015] Fig.3 - a reduced perspective view of casted (plastic or light metal material) cover plate rear view with details concerning a very special lightweight design alternative that is comprising plate thickness variation and comprising inclined reinforcing ribs. 202402734

[0016] 4

[0017] The latter may alternatively arranged or combined with special backside profiling structures that may be inclined with angle a, may in variation or alternatively be configured as ribs in honeycomb shape, checkerboard pattern, or other intelligent structure for improved stiffness of the cover 20. Shown examples may also be configured in preference with any other innovative rib pattern or structure. It is possible that a cover body may be manufactured - at least partly - hollow for best stiffness in connection with material and / or weight savings. The result is improved vibration / noise prevention with a lightweight cover body by this special structure. New structure may be applicable for the complete cover or partly only. New structured lattice pattern as 3-D-backside profiling is possible (preferably via forming, molding, casting) as embodiment with expressive preference for new vacant design cover components - such body structure may for example be manufactured in molding technology with metal or plastic material. Forming technology can involve use of ductile metal material such as steel metal material or alternatively via squeeze casting of, for example, aluminum material.

[0018] Fig. 3 further details of a suitable cover with other interface features that can serve in various cooperation with counterpart interface features of applicable brake caliper housing, e.g. with lattice profiled backside surface in a bottom section followed by a section comprising a flat axial (contact) surface 22 and therefrom orthogonally erected a post that comprises a radial contact surface 21 , a tangential guiding surface 23, a cover guiding hole 24, and in the head section an axial stepped protrusion 25 which are all in alignment and ready for cooperation with front of caliper housing 10 ,

[0019] Fig.4 a,b,c - a preferred design cover modification as under Fig. 3 in three more alternative embodiments, various axial stepped protrusions 22 for precise definition of contact with axial contact surface for housing 10,

[0020] Fig.5a, b Cross-sectional view of subassembly with gap 26 and subassembly without gap 27, 202402734

[0021] 5

[0022] Fig.6 a,b - Perspective view of subassembly of housing 10, design cover 20 and screw 30,

[0023] Fig.7 a,b - Exploded and cross-sectional view of further improved brake subassembly embodiment comprising housing 10, design cover 20, screw 30 and fixation element 40 as screw bolt - that embodiment allows for a through bore without thread means in the housing and its drilling process could either start from radially outward aiming radially inward or vice versa, the cover interface can integrate counterthread means for the bolt or alternatively other part than may be a nut, a thread-insert or other counterpart is placed as suitable locking counterpart for the bolt - thereunder the Fig. 7 b shown almost in the natural scale,

[0024] Fig.8 a,b - alternative covered brake caliper embodiment that essentially follows mounting strategies and embodiments as disclosed with Fig. 1 and 5 but more over this the cover comprising sheet metal multipart structure instead of casting from metal or plastic in exploded and cross-sectional view of housing 100, sheet-metal design cover 200, screw 300 and protrusion interface 400, thereunder the Fig. 8b shown almost in the natural scale.

[0025] Fig.1 a, b represent wholly new plate + caliper designs. The shown interconnection allows not only rattle noise-free contact but also smooth assembly process between design cover 20 and the respective brake caliper housing 10. Design cover subassembly 20 comprises an erected post or bar shape protrusion means that is reaching into a reception cavity or at least towards a mounting surface of the caliper housing 10 e.g. The cavity is preferred though for appropriate and robust reception of the protrusion / bar. The interface construction is able to serve as guiding means for simplified handling during the pairing of components. For this reason the interface cavity of the housing 10 can especially be arranged as partly open duct (e.g. cabriolet shape) as a guiding channel or at least partly configured alike such. Said cover protrusion is preferably configured in the form of a mounting post / mounting bar that is arranged essentially orthogonal, preferably in right angles with a front plate face and can comprise radial contact surface 21 , axial contact surface 22 and tangential guiding surface 23 for simplified positioning process with 202402734

[0026] 6 radial contact surface 11 , axial contact surface 12 and tangential guiding surface 13 of housing 10. The post / bar can comprise a through hole in the radial direction so that elected locking means is invisible / hidden when regarded in front view. Locking means is in preference configured in shape of a screw or bolt with head and shaft that may in more detail be configured as a metric hexagon socket machine screw 30 that is to be positioned and reaching through cover guiding hole 24 and mounted in radial fixation hole 14 of caliper housing. Locking function may be safeguarded under fixed connection between radial contact surfaces and ensured by defined torque of screw 30. Nut thread as the locking counterpart for the bolt may be either integrated as a thread in a reception hole of the caliper housing, may be integrated as a thread in a reception hole of protrusion of cover or may be as extra nut component. Variation with alternative and / or additive locking means are possible if regarded useful. Alternative or additive locking means can involve snap-lock means. Alternative or additive security features can involve form locking means, force locking means, other means as well as various combination thereof. Preferred additive securing means may involve chemical substance for instance a dry, two component, self activating, screw locking, glue substance. Such chemical glue substance may preferably be deposited as thin layer structure on threads of bolt, threads of hole, threads of nut or alternatively both or else combination. Preferably when in fastening process, the design cover subassembly 20 is pushed axially towards caliper housing component 10. Axial motion with specific tension then ensures good contact between interfaces without gap between housing axial contact surface 12 and axial contact surface 22 of design cover 20. Further radial and / or axial pretensioning force can prevent for unwanted rattling noise during rough road driving. Figure 4 shows various axial stepped protrusions 22 to ensure precise contact interface with axial contact of the housing 12. Subassembly of the design cover 20 and housing 10 can be produced in two basic variants: subassembly with gap 26 and subassembly without gap 27. Subassembly with gap is ensured by precise axial stepped protrusion 25 of the design cover.

[0027] Figure 6 shows subassembly of design cover 20 and housing 10 in variant intended for using with brake calipers with multiple (more than single) brake piston solutions. Principle of assembly, installation and caliper fastening details are inline with explanation under Fig. 1 a,b. 202402734

[0028] 7

[0029] Figure 7 shows subassembly of housing 10, design cover 20, screw 30 and fixation element 40. Screw is installed from top side and fast connection is ensured by additional fixation element with thread 40. The screw with thread locker can be used to assure the proper connection of the design cover with caliper housing.

[0030] Figure 8 shows subassembly of housing 100, design cover 200, screw 300 and holder 400. Holder 400 is fixed together with design cover 200. Principle of installing and fastening is identical like explaining Figure 1 . This variant can be produced as combination of various components, technologies and materials as well.

[0031] 202402734

[0032] 8

[0033] List of references

[0034] 01 radial direction

[0035] 02 tangential direction

[0036] 03 axial direction

[0037] 10 caliper housing

[0038] 11 ,21 radial contact surface

[0039] 12, 22 axial contact surface

[0040] 13,23 tangential guiding surface

[0041] 14 hole

[0042] 20 cover / plate

[0043] 24 guiding hole

[0044] 25 stepped protrusion

[0045] 26 with gap

[0046] 27 without gap

[0047] 30 bolt

[0048] 40 fixation element

[0049] 100 housing

[0050] 200 sheet metal cover

[0051] 300 bolt

[0052] 400 cover protrusion interface a angle for rib / pattern inclination g natural gravity (force)

Claims

2024027349Patent claims1. Cover (20,200) mounting process for automotive disk brake caliper assembly, comprising especially a fist type brake caliper housing (10,100) with actuator section, bridge section and fist section wherein the bridge section is placed downside in a working room, the fist section comprising abutment for carrying the cover (20,200), the caliper housing (10, 100)comprising an axial actuator axis 03 that is in parallel with an axis of wheel rotation, the assembly comprising releasable fastening means in cooperation with abutment for the cover, the fastening means having at least one bolt (30,300) comprising an axis that is essentially radially, the cover (20,200)comprising a visible frontside face with invisible back face behind the frontside face, the backface serving for locking contact with the caliper housing (10,100) together with the bolt (30,300) as releasable fastening means and the bolt(30.300) is invisible, hidden, behind the frontside of the cover (20,200), wherein the fist section comprises an interface orifice for reception of an interface protrusion that erects from the cover backside and cooperates with the interface orifice of the fist so that the assembly process comprises a prepositioning step that with placement of the cover (20,200) on the housing (10,100) the cover (20,200) is and remains automatically held and correctly prepositioned in connection with the housing (10,100) by interaction, especially by interaction between cooperating interfaces of housing (10,100) and cover (20,200), prior to a final fastening step with the bolt(30.300).

2. Cover (20,200) mounting process for automotive disk brake caliper assembly according to claim 1 , wherein the automatic prepositioning cooperation between housing (10,100) and cover (20,200) comprises form locking means, preferably snaplock means, that interact as extra feature of cooperating interfaces concerning cover (20,200) and housing (10,100).

3. Cover (20,200) mounting process for automotive disk brake caliper assembly according to claim 1 , wherein the automatic prepositioning cooperation between housing (10,100) and cover (20,200) is based on natural gravity force g so that the cover (20,200) is automatically held prepositioned by its natural weight that rests in abutment on the housing (10,100).

4. Cover (20,200) mounting process for automotive disk brake caliper assembly according to one or more of the preceding claims 1 - 3, wherein the automatic prepositioning cooperation between housing (10,100) and cover (20,200) is based20240273410 on automatic form locking interaction between cooperating interfaces of cover(20.200) and housing (10,100).

5. Cover (20,200) mounting process for automotive disk brake caliper assembly according to one or more of the preceding claims 1 - 4, wherein the automatic prepositioning cooperation between housing (10,100) and cover (20,200) is based on adhesive interaction between housing (10,100) and cover (20,200).

6. Cover (20,200) mounting process for automotive disk brake caliper assembly according to preceding claim 5, wherein a glue substance, that can be applied in form of a tape, is deposited on at least one or on both components (10, 10;20;200) or components interfaces.

7. Cover (20,200) mounting process for automotive disk brake caliper assembly according to at least one of preceding claims, wherein when finally mounted and locked to each other pretensioning force clamps cover (20,200) and housing (10,100) together.

8. Cover (20,200) with automotive disk brake caliper assembly, comprising a fist type disk brake caliper housing with actuator section, bridge section and fist section, the fist section comprising abutment for carrying the cover (20,200), the caliper housing (10,100) comprising an axial actuator axis 03 that is in parallel with an axis of wheel rotation, the assembly comprising releasable fastening means in cooperation with abutment for the cover (20,200), the fastening means is at least a bolt comprising an axis that is essentially radially, the cover (20,200) comprising a visible frontside face with invisible back face behind the frontside face, the backface serving for locking contact with the caliper housing (10,100) together with the bolt as releasable fastening means and the bolt hidden behind the frontside of the cover(20.200), wherein the fist section comprises interface orifice for reception of an interface protrusion that erects from the cover backside and cooperates with the interface orifice of the fist.

9. Cover (20,200) with automotive disk brake caliper assembly according to at least one of the preceding claims, wherein the cooperating interfaces comprise form locking means for their interaction and wherein the form locking means are preferably configured as snaplock means.2024027341110. Cover (20,200) with automotive disk brake caliper assembly according to claim 8, wherein the bolt is configured in shape of a screw and more preferably in form of a countersunk head screw.11 . Cover (20,200) with automotive disk brake caliper assembly according to at least one of the preceding claims, wherein the bolts counterpart thread means are integrated either preferably in a through bore of the fist portion or alternatively in a blind hole of the fist portion of the housing (10, 100).

12. Cover (20,200) with automotive disk brake caliper assembly according to at least one of the preceding claims, wherein fastening means include a radial directed through bore, that is preferably without threat in the housing (10,100), wherein the through bore is preferably situated hidden in between a window orifice of the housing bridge portion (Fig. 7a, b).

13. Cover (20,200) with automotive disk brake caliper assembly according to at least one of the preceding claims, wherein the bolts counterpart threat means is integrated in, manufactured with, and / or assembled in, connection with the cover (20,200).

14. Cover (20,200) with automotive disk brake caliper assembly according to at least one of the preceding claims, wherein the counterpart threat means is integrated in an extra component that is preferably configured in shape of a special inlay or a nut.

15. Cover (20,200) with automotive disk brake caliper assembly according to at least one of the preceding claims, wherein the housings axial contact surface (housing front) (12,22) for the cover (20,200) is essentially flat leveled (Fig. 5 b, 8b) or alternatively configured as stepped surface for integration of the cover (20,200; Fig. 5a, 7b).

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