Disc brake device

Abstract

This disc brake device has a gap adjustment mechanism, and is configured such that a surface of a cam holder, which faces an anchor plate, is in contact with the anchor plate when not braking, and separates from the anchor plate when braking. The gap adjustment mechanism comprises: a ring member having a first lever; a second lever for holding the first lever to rotate the ring member; and a ratchet for rotating a ratchet gear in only one direction in response to the rotation of the ring member. A spindle of the gap adjustment mechanism moves outward in an axial direction as an adjuster nut rotates together with the ratchet gear before the spindle presses a brake pad against a rotor surface during braking. A rotation restriction part that abuts the anchor plate to restrict rotation of the second lever when not braking is provided at an end portion of the second lever on a rotation center side.

Description

Disk Brake Device

[0001] The present disclosure relates to a disk brake device.

[0002] Conventionally, disk brake devices have been widely used to brake vehicles such as automobiles and trains. In this type of disk brake device, during braking, a pair of brake pads arranged on both axial sides of a disk rotor that rotates with the wheel is configured to be pressed against both axial side surfaces (hereinafter also referred to as "rotor surfaces") of the disk rotor by a pad pressing mechanism. The unit brake (disk brake device) disclosed in Patent Document 1 is provided with a gap adjuster (gap adjusting mechanism) that automatically adjusts the gap between the disk rotor and the brake pad.

[0003] Also, among general conventional gap adjusting mechanisms, many adopt the so-called screw method, and during braking of the disk brake device, the screw (or piston) is configured to automatically operate so as to bring the brake pad closer to the brake disk according to the wear of the brake pad.

[0004] Japanese Patent Application Laid-Open No. 2020-097954

[0005] However, in the conventional gap adjusting mechanism as described above, gap adjustment is performed in a state where a force is generated that presses the brake pad against the rotor surface by the pad pressing mechanism during braking of the disk brake device, and so-called over-adjustment may be caused due to excessive rotation of the screw or the like. Therefore, in the conventional gap adjusting mechanism, there is room for improvement from the viewpoint of the accuracy of gap adjustment.

[0006] [[ID=]18] The present disclosure has been made in view of the above-described situation, and an object thereof is to provide a disk brake device capable of accurately adjusting the gap between a disk rotor and a brake pad.

[0007] In order to achieve the above-described object, the disk brake device of the present disclosure is characterized by the following [1] to [8].

[0008] [1] A disc brake device comprising: a disc rotor that rotates with a wheel; a brake pad provided facing the rotor surface of the disc rotor; a pad pressing means for pressing the brake pad against the rotor surface; and a cylinder body housing the pad pressing means, wherein the disc brake device brakes the disc rotor by pressing the brake pad against the rotor surface with the pad pressing means, wherein the pad pressing means includes: a cam holder that moves axially outward on the disc rotor during braking; an anchor plate attached to the cylinder body axially inward on the disc rotor from the cam holder and guiding the axial movement of the cam holder; and a gap adjustment mechanism for adjusting the size of the gap between the disc rotor and the brake pad, wherein the surface of the cam holder facing the anchor plate is configured to contact the anchor plate when not braking and to move away from the anchor plate when braking, and the gap adjustment mechanism includes: an adjuster nut located axially outward on the disc rotor from the cam holder and having a fitting portion fitted into the cam holder, The cam holder comprises: a spindle that screws onto the adjuster nut and presses the brake pad against the rotor surface; a ratchet gear fitted onto the adjuster nut; a ring member that is rotatably fitted onto the adjuster nut such that its central axis substantially coincides with the central axis of the adjuster nut and is provided with a first lever that protrudes radially; a second lever that is rotatably supported on the outer circumferential surface of the cam holder and holds the first lever in order to rotate the ring member; and a ratchet that meshes with the ratchet gear and rotates the ratchet gear in only one direction in response to the rotation of the ring member, wherein the spindle moves axially outward when braking and before the spindle presses the brake pad against the rotor surface as the adjuster nut rotates together with the ratchet gear, and the end of the second lever on the rotation center side is provided with a rotation restricting portion that contacts the anchor plate so as to restrict the rotation of the second lever when not braking.Disc brake system.

[0009] [2] The disc brake device described in [1] above, wherein the ratchet is fixed to the ring member so as to be rotatable together with the ring member.

[0010] [3] The disc brake device described in [1] above, wherein the gap adjustment mechanism further comprises a spring that biases the second lever to rotate.

[0011] [4] The disc brake device described in [1] above, wherein the gap adjustment mechanism further includes a regulating spring that biases the adjuster nut axially inward to restrict the rotation of the adjuster nut when not braking, and the rotation of the adjuster nut is restricted by the frictional resistance between the adjuster nut and the cam holder caused by the biasing of the adjuster nut by the regulating spring.

[0012] [5] The disc brake device described in [1] above, wherein the ratchet is located in the radial direction of the adjuster nut, substantially opposite to the first lever, with respect to the central axis of the adjuster nut.

[0013] [6] The disc brake device described in [1] above, wherein the pad pressing means further comprises a cam lever unit having an eccentric camshaft, the camshaft is pivotally supported on the cam holder such that the cam lever unit can rotate around the camshaft, and during braking, the force transmitted by the rotation of the cam lever unit is amplified to move the cam holder outward in the axial direction, the disc brake device.

[0014] [7] The disc brake device described in [6] above, wherein the camshaft is composed of a cylindrical cam body and a pair of eccentric portions provided at both ends of the cam body in the extending direction and eccentric to the cam body, and the eccentric portions are provided with bearings that are in contact with the anchor plate.

[0015] [8] A disc brake device comprising: a disc rotor that rotates with a wheel; a brake pad provided facing the rotor surface of the disc rotor; a pad pressing means for pressing the brake pad against the rotor surface; and a cylinder body housing the pad pressing means, wherein the disc brake device brakes the disc rotor by pressing the brake pad against the rotor surface with the pad pressing means, wherein the pad pressing means includes: a cam holder that moves axially outward on the disc rotor during braking; an anchor plate attached to the cylinder body axially inward on the disc rotor from the cam holder and guiding the axial movement of the cam holder; and a gap adjustment mechanism for adjusting the size of the gap between the disc rotor and the brake pad, wherein the surface of the cam holder facing the anchor plate is configured to contact the anchor plate when not braking and to move away from the anchor plate when braking, and the gap adjustment mechanism includes: an adjuster nut located axially outward on the disc rotor from the cam holder and having a fitting portion fitted into the cam holder, A disc brake device comprising: a spindle that screws onto the adjuster nut and presses the brake pad against the rotor surface; a ratchet gear fitted onto the adjuster nut; a lever rotatably supported on the outer circumference of the cam holder; a slide plate having a projection held by the lever and sliding as the lever rotates; and a ratchet fixed to the slide plate, meshing with the ratchet gear and rotating the ratchet gear in response to the sliding movement of the slide plate, wherein, during braking, before the spindle presses the brake pad against the rotor surface, the spindle moves axially outward as the adjuster nut rotates together with the ratchet gear; and a rotation restricting portion is provided on the rotation center side of the lever, which contacts the anchor plate to restrict the rotation of the lever when not braking.

[0016] According to the configuration described in [1] above, during braking, before the spindle constituting the gap adjustment mechanism presses the brake pad against the rotor surface, the adjuster nut constituting the gap adjustment mechanism rotates together with the ratchet gear constituting the gap adjustment mechanism, causing the spindle to move axially outward, thereby adjusting the size of the gap between the disc rotor and the brake pad. In addition, the gap adjustment mechanism includes a ring member on which a first lever is provided, a second lever that holds the first lever in order to rotate the ring member, and a ratchet that rotates the ratchet gear in only one direction in response to the rotation of the ring member. Furthermore, the surface of the cam holder facing the anchor plate is configured to contact the anchor plate when not braking and to move away from the anchor plate when braking, and the end of the second lever on the rotation center side is provided with a rotation restricting part that contacts the anchor plate so as to restrict the rotation of the second lever when not braking. In other words, according to this configuration, when gap adjustment is required during braking, when the cam holder moves axially outward, the second lever rotates, and the ring member rotates in conjunction with this. As a result, the ratchet rotates in response to the rotation of the ring member, and the ratchet gear rotates due to the ratchet. Then, as described above, the spindle moves axially outward as the adjuster nut rotates together with the ratchet gear, thereby completing the gap adjustment. In addition, frictional resistance is generated between the adjuster nut and the spindle due to the pressing force generated during braking, and this frictional resistance restricts the rotation of the adjuster nut, so that gap adjustment due to pad wear and deformation of the cylinder body does not occur during braking. Thus, with this configuration, the gap adjustment is performed before the spindle presses the brake pad against the rotor surface, so over-adjustment can be prevented. Furthermore, with this configuration, the amount of axial outward movement of the cam holder, and consequently the amount of rotation of the second lever, is determined according to the gap between the disc rotor and the brake pad during braking. In other words, the amount of rotation of the adjuster nut, which is linked to the rotation of the second lever, is also determined according to the above gap. Therefore, with this configuration, the spindle moves axially outward according to the above gap, so the size of the above gap can be adjusted with high precision.As explained above, this configuration allows for highly precise adjustment of the gap between the disc rotor and the brake pad.

[0017] According to the configuration described in [2] above, the ratchet is fixed to the ring member so as to be rotatable together with the ring member, allowing the ratchet to rotate the ratchet gear with high precision in accordance with the amount of rotation of the second lever.

[0018] According to the configuration described in [3] above, the gap adjustment mechanism further includes a spring that biases the second lever to rotate, so that when braking and gap adjustment is necessary, the second lever can be rotated more appropriately.

[0019] According to the configuration described in [4] above, the gap adjustment mechanism further includes a regulating spring that biases the adjuster nut axially inward to restrict the rotation of the adjuster nut when not braking. The rotation of the adjuster nut can be restricted by the frictional resistance between the adjuster nut and the cam holder caused by the biasing force of the regulating spring on the adjuster nut.

[0020] According to the configuration described in [5] above, the ratchet is located approximately opposite the first lever in the radial direction of the adjuster nut, with the central axis of the adjuster nut in between. This makes it possible to miniaturize the gap adjustment mechanism compared to the case where the ratchet is located at the same position as the first lever.

[0021] According to the configuration of [6] above, the pad pressing means further comprises a cam lever unit having an eccentric camshaft, and the camshaft is configured to amplified the force transmitted by the rotation of the cam lever unit during braking, thereby moving the cam holder axially outward. As a result, the pad pressing means can brake the disc rotor.

[0022] According to the configuration described in [7] above, a bearing is provided in contact with the anchor plate at the eccentric portion of the camshaft, thereby reducing friction between the eccentric portion and the anchor plate, and suppressing the loss of energy related to the power assist described above.

[0023] According to the configuration described in [8] above, during braking, before the spindle constituting the gap adjustment mechanism presses the brake pad against the rotor surface, the adjuster nut constituting the gap adjustment mechanism rotates together with the ratchet gear constituting the gap adjustment mechanism, causing the spindle to move axially outward, thereby adjusting the size of the gap between the disc rotor and the brake pad. In addition, the gap adjustment mechanism includes a lever with a rotation restricting portion that contacts the anchor plate so as to restrict rotation when not braking, a slide plate with a projection held by the lever that slides when the lever rotates, and a ratchet fixed to the slide plate that rotates the ratchet gear in response to the sliding movement of the slide plate. Furthermore, the surface of the cam holder facing the anchor plate is configured to contact the anchor plate when not braking and to move away from the anchor plate when braking. In other words, according to this configuration, when gap adjustment is necessary during braking, when the cam holder moves axially outward, the lever rotates, and the slide plate slides in conjunction with this. Then, the ratchet moves in response to the sliding of the slide plate, and the ratchet gear rotates as a result. As described above, the adjuster nut rotates together with the ratchet gear, causing the spindle to move axially outward, thereby completing the clearance adjustment. In addition, frictional resistance is generated between the adjuster nut and the spindle due to the pressing force generated during braking, and this frictional resistance restricts the rotation of the adjuster nut, so that clearance adjustment due to pad wear and deformation of the cylinder body does not occur during braking. Thus, with this configuration, clearance adjustment is performed before the spindle presses the brake pad against the rotor surface, thus preventing over-adjustment, etc. Furthermore, with this configuration, the amount of axial outward movement of the cam holder, and consequently the amount of rotation of the second lever, is determined according to the clearance between the disc rotor and the brake pad during braking. In other words, the amount of rotation of the adjuster nut, which is linked to the rotation of the second lever, is also determined according to the above clearance. Therefore, with this configuration, the spindle moves axially outward according to the above clearance, so the size of the above clearance can be adjusted with high precision.As explained above, this configuration allows for highly precise adjustment of the gap between the disc rotor and the brake pad.

[0024] Figure 1 is a perspective view of a disc brake device according to one embodiment of the present disclosure (however, the disc rotor is not shown). Figure 2 is a cross-sectional view taken along line A-A of Figure 1, showing the state when not braking. Figure 3 is a cross-sectional view taken along line A-A of Figure 1, showing the state when braking. Figure 4 is a cross-sectional view taken along line B-B of Figure 1, showing the state when not braking (however, the disc rotor is not shown). Figure 5 is a perspective view for explaining the cam lever unit. Figure 6 is a cross-sectional view of the main part showing how the anchor plate is fixed to the cylinder body. Figure 7 is a perspective view for explaining the gap adjustment mechanism. Figure 8 is a view of Figure 7 from the right side of the paper. Figure 9 is a view of Figure 7 from the top side of the paper. Figure 10 is a view of Figure 7 from the bottom side of the paper. Figure 11 is a diagram for explaining the operation of the gap adjustment mechanism, where (a) shows the state when not braking and no gap adjustment is required, (b) shows the state when braking and no gap adjustment is required, (c) shows the state when braking and gap adjustment is required, and (d) shows the state after gap adjustment. Figure 12 shows a first modified example of the disc brake device, and corresponds to Figure 8. Figure 13 shows a second modified example of the disc brake device, and corresponds to Figure 4.

[0025] <Embodiment> A disc brake device according to one embodiment of the present disclosure will be described below with reference to the drawings.

[0026] [Overall Configuration] The disc brake device in this example is of the floating caliper type and, as shown in Figure 1, etc., comprises a disc rotor 1 (see Figures 2-3) that rotates together with the wheel (not shown) and a brake caliper 2 that straddles the disc rotor 1 so as to sandwich it from both sides. As shown in Figures 2-3, the brake caliper 2 supports two brake pads 3 (3a, 3b) that are arranged to face the rotor surface 1a of the disc rotor 1, so as to be displaceable in the axial direction of the disc rotor 1 (hereinafter also simply referred to as "axial direction"; see Figure 2, etc.).

[0027] Furthermore, as shown in Figure 1, the disc brake device includes a pad pressing mechanism 4 for pressing the brake pad 3 against the rotor surface 1a, and a cylinder body 5 that houses the pad pressing mechanism 4. The brake pad 3 is supported by a pad pressing plate 8, and the pad pressing mechanism 4 presses the brake pad 3 against the rotor surface 1a via this pad pressing plate 8. In this example, an air cylinder 6 is used as an actuator incorporated into the disc brake device, and the air cylinder 6 has a push rod 7 inside that moves forward by air pressure and transmits its thrust to the pad pressing mechanism 4.

[0028] In other words, when the disc brake system is braking, the air cylinder 6 receives pressure (pneumatic pressure), causing the push rod 7 to move forward. This thrust is transmitted to the pad pressing mechanism 4, which then amplifies (multiplies) the thrust transmitted by the push rod 7 to press the brake pad 3 against the rotor surface 1a, thereby generating braking force.

[0029] In this example, since the disc brake system is of the floating caliper type, first the brake pad 3a on the operating side is pressed against the rotor surface 1a by the pad pressing mechanism 4, and then the brake pad 3b on the reaction side is pressed against the rotor surface 1a by the movement of the brake caliper 2, which moves based on the reaction force.

[0030] [Pad Pressing Mechanism] As shown in Figure 2, the pad pressing mechanism 4 includes a cam lever unit 11 having an eccentric camshaft 12, and a cam holder 13 that pivotally supports the camshaft 12 so that the cam lever unit 11 can rotate around the camshaft 12, and is also movable in the axial direction. The cam lever unit 11 and the cam holder 13 primarily play the role of amplifying the thrust transmitted from the push rod 7.

[0031] As shown in Figure 5 and other figures, the cam lever unit 11 integrally comprises a pair of cam levers 111 that hold the camshaft 12 and a roller 112 positioned between one end 111a of the pair of cam levers 111, and is formed in a bifurcated shape with an external appearance that is roughly rectangular U-shaped. The other end 111b of each cam lever 111 is provided with a holding portion 111c that holds the camshaft 12 in a position where it is inserted. The roller 112 is supported by a guide groove 7a at the tip of the push rod 7, and thrust from the air cylinder 6 is transmitted to it (see Figure 3).

[0032] The camshaft 12 has the function of amplifying the force transmitted by the rotation of the cam lever unit 11 during braking, thereby moving the cam holder 13 axially outward. The camshaft 12 consists of a cylindrical cam body 121 and a pair of eccentric portions 122 provided at both ends of the cam body 121 in the extending direction (corresponding to the width direction above) and eccentric to the cam body 121. The cam body 121 is pivotally supported by the cam holder 13, and each eccentric portion 122 is located outside the cam holder 13 (see Figure 4).

[0033] Each eccentric portion 122 is formed eccentrically with respect to the rotation center of the cam body 121, and the rotation centers of each eccentric portion 122 are also formed to be different from each other. Furthermore, each eccentric portion 122 is formed to be smaller in diameter than the cam body 121, and each eccentric portion 122 is provided with a bearing 21 that is larger in diameter than the eccentric portion 122. This bearing 21 is provided to reduce the rotational resistance of the camshaft 12 and is positioned in contact with the anchor plate 14, which will be described later (see Figures 2 to 4).

[0034] As shown in Figure 2, the cam holder 13 is integrally constructed with a holder body portion 132 and a boss portion 133, arranged in order from the axial outer side. A flange portion 131 extending in the width direction is formed at the axial outer end of the holder body portion 132 (see Figure 4, etc.). A pair of holes 131a are formed in this flange portion 131a, through which a pair of bolts 22 for fixing the guide plate 16 (described later) to the cylinder body 5 are inserted.

[0035] Furthermore, the holder body portion 132 is provided with a fitting groove portion 134 at its axial outer end, which is recessed in the axial direction and into which an adjuster nut 31, described later, is fitted. In addition, the holder body portion 132 is provided with a through hole (reference numeral omitted) that extends through in the width direction and pivotally supports the camshaft 12. The boss portion 133 is formed to protrude axially inward from the axial inner end of the holder body portion 132 and is slidably inserted into a guide hole 142 provided in the anchor plate 14 and a guide hole 5a provided in the cylinder body 5. Note that the guide hole 142 of the anchor plate 14 and the guide hole 5a of the cylinder body 5 are formed to communicate in the axial direction.

[0036] Furthermore, as shown in Figure 2 and other figures, the pad pressing mechanism 4 is attached to the cylinder body 5 axially inward from the cam holder 13 and includes an anchor plate 14 that guides the axial movement of the cam holder 13. As shown in Figure 6, the anchor plate 14 is fixed to the cylinder body 5 by being fitted into a fitting groove 5b provided in the cylinder body 5.

[0037] The anchor plate 14 is formed in a roughly rectangular shape that is long in the width direction, and a horizontal guide surface 141 is provided at the center of its lower end, extending in the axial direction to guide the axial movement of the cam holder 13. The cam holder 13 is slidably mounted on this horizontal guide surface 141. The anchor plate 14 is also provided with a contact portion 143 (see Figure 9, etc.) that protrudes axially outward at a position corresponding to the bearing 21, and whose protruding end surface contacts the bearing 21.

[0038] Furthermore, as shown in Figure 2 and other figures, the pad pressing mechanism 4 includes a gap adjustment mechanism 15 for adjusting the size of the gap between the disc rotor 1 and the brake pad 3. The gap adjustment mechanism 15 includes an adjuster nut 31 located axially outward on the disc rotor 1 from the cam holder 13 and having a fitting portion 311 that fits inside the cam holder 13, and a spindle 32 that screws into the adjuster nut 31 and presses the brake pad 3 against the rotor surface 1a. Details of the gap adjustment mechanism 15 will be described later.

[0039] Furthermore, as shown in Figure 2 and other figures, the pad pressing mechanism 4 has a hole 161 into which the adjuster nut 31 is inserted, and is equipped with a guide plate 16 that guides the axial movement of the adjuster nut 31. The guide plate 16 is fixed to the axially outer end of the cylinder body 5 by a pair of bolts 22.

[0040] Furthermore, as shown in Figure 4, the pad pressing mechanism 4 includes a cam holder return spring 17 that biases the cam holder 13 to return to its initial position when not braking. The cam holder return spring 17 is positioned between the flange portion 131 of the cam holder 13 and the guide plate 16, and is set to its set length when not braking, and is configured to store energy by deforming to contract as the cam holder 13 moves axially outward when braking.

[0041] Here, the pad pressing mechanism 4, configured as described above, operates as follows: When the disc brake device is braking, the air cylinder 6 receives pressure (pneumatic pressure) and the push rod 7 moves forward. The end of the cam lever unit 11 on the roller 112 side is pressed axially outward by the push rod 7, causing it to rotate around the camshaft 12 (counterclockwise in Figures 2-3).

[0042] Next, as the cam lever unit 11 rotates, the camshaft 12 rotates around the central axis of the cam body 121 as its center of rotation (counterclockwise in Figures 2-3). As a result, a force (action) is applied to the contact portion 143 of the anchor plate 14 from the eccentric portion 122 inwards via the bearing 21. The cam holder 13, whose eccentric portion 122 is in contact with the anchor plate 14 via the bearing 21 described later, receives a reaction force (reaction force) from the anchor plate 14 to the above action and is moved outwards in the axial direction. In other words, the camshaft 12 multiplies the force transmitted by the rotation of the cam lever unit 11, moving the cam holder 13 outwards in the axial direction.

[0043] As a result, the adjusting nut 31 with the fitting portion 311 fitted into the fitting groove portion 134 of the cam holder 13 and the spindle 32 screwed with the adjusting nut 31 also move axially outward. The spindle 32 presses the brake pad 3a on the operating side against the rotor surface 1a via the pad pressing plate 8. Thereafter, as described above, the brake pad 3b on the reaction force side is pressed against the rotor surface 1a, and braking force is generated.

[0044] Although details will be described later, in the disk brake device of this example, gap adjustment is performed by the gap adjustment mechanism 15 before the spindle 32 presses the brake pad 3 against the rotor surface 1a.

[0045] Thereafter, when the braking is released, the push rod 7 retracts, and the cam holder 13 is urged by the cam holder return spring 17 and returned to the initial position, so that the adjusting nut 31 and the spindle 32 move axially inward. As a result, a gap exists between the rotor surface 1a and the brake pad 3.

[0046] Incidentally, regarding the axial movement of the pad pressing mechanism 4 during braking and when the braking is released as described above, the horizontal guide surface 141 of the anchor plate 14 on which the cam holder 13 is placed, the guide hole 142 of the anchor plate 14 through which the boss portion 133 of the cam holder 13 is inserted, the guide hole 5a of the cylinder body 5, the pair of bolts 22 respectively inserted through the pair of hole portions 131a of the flange portion 131, and the hole portion 161 of the guide plate 16 into which the adjusting nut 31 is inserted position the pad pressing mechanism 4 and guide it so that it can move smoothly along the axial direction.

[0047] That is, in the disk brake device, the pad pressing mechanism 4 is guided by the anchor plate 14 in the axially inner region and by the guide plate 16 in the axially outer region so that the pad pressing mechanism 4 can move smoothly along the axial direction.

[0048] [Clearance Adjustment Mechanism] The clearance adjustment mechanism 15 includes an adjuster nut 31 and a spindle 32 as described above. As shown in FIG. 2 and the like, the adjuster nut 31 is integrally formed of the above-described fitting portion 311 and a substantially cylindrical nut body portion 312 in this order from the axial inner side. The inner end portion in the axial direction of the spindle 32 is screwed into the inside of the nut body portion 312. The spindle 32 is fixed to the pad pressing plate 8 so as not to rotate via a rotation prevention member 23, and the spindle 32 is prevented from rotating with the rotation of the adjuster nut 31.

[0049] Further, as shown in FIG. 8 and the like, the clearance adjustment mechanism 15 includes a ratchet gear 33 and a ring member 34 that are externally fitted to the nut body portion 312 of the adjuster nut 31. The ratchet gear 33 and the ring member 34 are arranged in this order from the axial inner side. The ratchet gear 33 is externally fitted so as to rotate together with the adjuster nut 31, and the ring member 34 is externally fitted to the outer peripheral surface of the nut body portion 312 so that the central axis O substantially coincides with the nut body portion 312 and is rotatable (so as not to rotate together with the adjuster nut 31).

[0050] The ratchet gear 33 is formed in a substantially short cylinder, and a plurality of teeth 331 (see FIG. 11) are arranged along the circumferential direction over the entire outer peripheral surface thereof. The ring member 34 is provided with a first lever 35 that projects in the radial direction of the nut body portion 312 (the upper side in FIG. 8). The first lever 35 is formed in a substantially L-shaped plate, one of which is screwed and fastened to the ring member 34 and the other of which projects in the radial direction. In this specification, mainly the other side (the portion projecting in the radial direction) will be described as the first lever 35.

[0051] Furthermore, the ratchet gear 33 is detachably fixed to the adjuster nut 31 by a fixing means such as a spring pin. As will be described in detail later, in this disc brake device, the ratchet gear 33 is rotated by a ratchet 37, which will be described later. At this time, the adjuster nut 31 also rotates together with the ratchet gear 33 to adjust the gap. For this reason, the amount of rotation of the adjuster nut 31, i.e., the fineness of the gap adjustment, changes depending on the number of teeth on the ratchet gear 33. In other words, in this disc brake device, ratchet gears 33 with different numbers of teeth are appropriately replaced according to changes in the vehicle model and the specifications of the adjuster, etc. Therefore, because the ratchet gear 33 is detachably fixed to the adjuster nut 31, it is possible to easily respond to the above-mentioned changes in specifications.

[0052] Furthermore, the ring member 34 is fixed to the adjuster nut 31 so as to be rotatable, and its axial displacement is restricted by a snap ring 61, which is a fixing member fixed to the adjuster nut 31 (see Figure 2, etc.). A spacer (not shown) may be provided between the ring member 34 and the snap ring 61. In this case, the ring member 34 is fixed to the snap ring 61 via the spacer as described above.

[0053] Furthermore, as shown in Figure 9 and other figures, the gap adjustment mechanism 15 includes a second lever 36 that is rotatably supported on the outer circumferential surface of the cam holder 13 and holds the first lever 35 in order to rotate the ring member 34, and a spring 38 that biases the second lever 36 to rotate. The second lever 36 is formed to be long in the axial direction, and the axially inner portion of the second lever 36 is rotatably supported on the outer circumferential surface of the cam holder 13. The portion of the second lever 36 that is rotatably supported on the cam holder 13 becomes the pivot center 361 of the second lever 36.

[0054] A retaining portion 362 for holding the first lever 35 is provided at the axially outer end of the second lever 36. In this example, the retaining portion 362 is formed in a bifurcated shape to clamp the first lever 35, but its shape is not particularly limited. Furthermore, a rotation restricting portion 363 for restricting the rotation of the second lever 36 when not braking is provided at the axially inner end (towards the rotation center 361). That is, when not braking, the rotation of the second lever 36 is restricted by the rotation restricting portion 363 contacting the anchor plate 14, and when braking, the cam holder 13 moves axially outward and away from the anchor plate 14, allowing the rotation restricting portion 363 to rotate by the spring 38 while still in contact with the anchor plate 14.

[0055] The spring 38 has hooks at both ends, with one end hooked onto a spring fixing part 135 (see Figure 7, etc.) provided on the cam holder 13, and the other end hooked onto a spring fixing part 364 (see Figure 7, etc.) provided on the second lever 36, thereby biasing the second lever 36 to rotate counterclockwise in Figure 9. As will be described in detail later, when braking and gap adjustment is performed, the adjuster nut 31 rotates in conjunction with the rotation of the second lever 36, moving the spindle 32 outward in the axial direction. Therefore, it is rotated in a direction that loosens the screw engagement with the spindle 32 (clockwise in this example, Figure 8). For this reason, the spring 38 biases the second lever 36 so that the adjuster nut 31 rotates in the above direction.

[0056] Furthermore, as shown in Figure 8 and other figures, the gap adjustment mechanism 15 includes a ratchet 37 that meshes with the ratchet gear 33 and rotates the ratchet gear 33 in only one direction in response to the rotation of the ring member 34, and a spring 39 that biases the ratchet 37 toward the ratchet gear 33.

[0057] The ratchet 37 is fixed to the ring member 34 so as to be rotatable together with the ring member 34, and is positioned approximately opposite the first lever 35 in the radial direction (vertical direction in Figure 8) of the adjuster nut 31, with the central axis O of the adjuster nut 31 in between (see Figures 7-10). The ratchet 37 has a pawl 371 (see Figure 11) that engages with the teeth 331 of the ratchet gear 33. Note that the pawl 371 of the ratchet 37 does not engage with the teeth 331 of the ratchet gear 33 when the disc brake device is not braking (see Figures 11(a) and 11(d)).

[0058] The spring 39 has hooks at both ends, with one end hooked onto a spring fixing part 341 (see Figure 8, etc.) provided on the ring member 34, and the other end hooked onto a spring fixing part 372 (see Figure 8, etc.) provided on the ratchet 37. When the disc brake device is braking, the spring 39 biases the pawl 371 of the ratchet 37 to engage with the teeth 331 of the ratchet gear 33 in response to the rotation of the ring member 34 (see Figures 11(b) and 11(c)).

[0059] Furthermore, as shown in Figure 9, the gap adjustment mechanism 15 includes a restricting spring 40 that biases the adjuster nut 31 axially inward, thereby restricting the rotation of the adjuster nut 31 when not braking. The restricting spring 40 is fitted into the nut body portion 312 of the adjuster nut 31 so as to be positioned between the guide plate 16 and the snap ring 61 fixed to the adjuster nut 31 (see Figure 2).

[0060] In a disc brake system, the rotation of the adjuster nut 31 is restricted when not braking by the frictional resistance between the adjuster nut 31 and the cam holder 13, which is generated by the biasing force of the restricting spring 40 on the adjuster nut 31. The restriction of the rotation of the adjuster nut 31 by the restricting spring 40 is intended to prevent unintended rotation of the adjuster nut 31. Therefore, the load of the restricting spring 40 is set to allow rotation of the adjuster nut 31 when the disc brake system is braking.

[0061] Furthermore, since the aforementioned restricting spring 40 biases the adjuster nut 31 axially inward, it assists in returning the cam holder 13 to its initial position when the brake of the disc brake device is released.

[0062] Here, the gap adjustment mechanism 15, configured as described above, operates as follows. In the following explanation, we will describe two cases as examples: when the gap between the disc rotor 1 and the brake pad 3 is less than a specified value, and when the gap is greater than or equal to a specified value. Also, as described above, the gap adjustment by the gap adjustment mechanism 15 is performed during braking, before the spindle 32 presses the brake pad 3 against the rotor surface 1a.

[0063] When the disc brake system is applied, as described above, the cam holder 13 moves axially outward, and the axially inward end face of the cam holder 13, which was in contact with the anchor plate 14 when not braking, separates from the anchor plate 14. Then, due to the biasing force of the spring 38, the second lever 36 rotates counterclockwise in Figure 9, even though the rotation restricting portion 363 of the second lever 36 is in contact with the anchor plate 14.

[0064] Next, since the first lever 35 of the ring member 34 is held by the holding portion 362 of the second lever 36, when the second lever 36 is rotated, the ring member 34 rotates clockwise in Figure 8 in conjunction with the rotation of the second lever 36. Then, the ratchet 37 also rotates in response to the rotation of the ring member 34, and consequently, the pawl 371 of the ratchet 37 engages with the teeth 331 of the ratchet gear 33 by the spring 39 (see Figure 10(b)).

[0065] Next, if the gap between the disc rotor 1 and the brake pad 3 is less than the specified value, the amount of rotation of the ratchet 37, i.e., the amount of rotation of the second lever 36, will not cause the ratchet gear 33 to rotate. Therefore, the adjuster nut 31 will not rotate, and the spindle 32 will not move axially outward relative to the adjuster nut 31, that is, the gap will not be adjusted, and the brake pad 3 will be pressed against the rotor surface 1a.

[0066] On the other hand, if the gap between the disc rotor 1 and the brake pad 3 is greater than or equal to a specified value, the rotation of the ratchet 37 causes the pawl 371 to push the teeth 331, causing the ratchet gear 33 to rotate clockwise in Figure 8 (see Figure 11(c)). Consequently, the adjuster nut 31 is also rotated clockwise in Figure 8, causing the spindle 32 to move axially outward relative to the adjuster nut 31, thus completing the gap adjustment. In other words, after the gap adjustment, the spindle 32 protrudes axially outward by the amount of the adjustment compared to before the gap adjustment. Then, after the gap adjustment is completed, the brake pad 3 is pressed against the rotor surface 1a by the spindle 32.

[0067] Subsequently, when the braking force of the disc brake device is released, the cam holder 13 returns to its initial position, and as a result, the second lever 36 also returns to its initial position (see Figure 9). Accordingly, the ring member 34 and the ratchet 37 also return to their initial positions (see Figure 11(a) if the gap is less than the specified value, and Figure 11(d) if the gap is greater than or equal to the specified value). Note that when the ratchet 37 returns to its initial position, the pawl 371 slides along the tooth tip without engaging with the tooth 331, so the ratchet gear 33 does not rotate.

[0068] As can be understood from the above explanation, in a disc brake system, the amount of axial outward movement of the cam holder 13, and consequently the amount of rotation of the second lever 36, is determined by the gap between the disc rotor 1 and the brake pad 3 during braking. In other words, the amount of rotation of the adjuster nut 31, which is linked to the rotation of the second lever 36, is also determined according to the above gap. Furthermore, frictional resistance is generated between the adjuster nut 31 and the spindle 32 due to the pressing force generated during braking, and this frictional resistance restricts the rotation of the adjuster nut 31, so that gap adjustment due to pad wear and deformation of the cylinder body is not performed during braking. Therefore, in a disc brake system, the spindle 32 is moved axially outward by the necessary amount relative to the adjuster nut 31 according to the above gap, so that the gap is adjusted appropriately and over-adjustment is prevented.

[0069] <Operation and Effects> According to this embodiment, when the cam holder 13, and consequently the adjuster nut 31 and spindle 32 move in the axial direction, the cam holder 13 is guided by the anchor plate 14 on the axially inward side, and the adjuster nut 31 is guided by the guide plate 16 on the axially outward side. As a result, the pad pressing mechanism 4 is properly positioned and can move smoothly in the axial direction.

[0070] According to this embodiment, the pair of bolts 22 can properly guide the axial movement of the cam holder 13.

[0071] According to this embodiment, when not braking, and especially when the brake is released, the cam holder return spring 17 can return the cam holder 13, and consequently the adjuster nut 31 and spindle 32, to their initial positions.

[0072] According to this embodiment, the roller 112 reduces friction between the push rod 7 and the cam lever unit 11, thereby suppressing energy loss related to thrust from the air cylinder 6.

[0073] According to this embodiment, the cam lever unit 11 is composed of multiple components (cam lever 111 and roller 112), which improves design flexibility and maintainability.

[0074] According to this embodiment, the bearing 21 reduces friction between the eccentric portion 122 and the anchor plate 14, thereby suppressing the energy loss related to the force amplification described above.

[0075] According to this embodiment, the guide holes 5a and 142 can properly guide the axial movement of the cam holder 13.

[0076] According to this embodiment, the horizontal guide surface 141 can properly guide the axial movement of the cam holder 13.

[0077] According to this embodiment, the anchor plate 14 is securely fixed to the cylinder body 5 by being fitted into the fitting groove 5b of the cylinder body 5, thereby enabling more appropriate and stable guidance of the axial movement of the cam holder 13.

[0078] According to this embodiment, during braking, the amount of axial outward movement of the cam holder 13, and consequently the amount of rotation of the second lever 36, is determined according to the gap between the disc rotor 1 and the brake pad 3. In other words, the amount of rotation of the adjuster nut 31, which is linked to the rotation of the second lever 36, is also determined according to the gap. Therefore, according to this embodiment, since the spindle 32 is moved axially outward according to the gap, the size of the gap can be adjusted with high precision.

[0079] According to this embodiment, by fixing the ratchet 37 to the ring member 34, the ratchet gear 33 can be rotated with high precision according to the amount of rotation of the second lever 36.

[0080] According to this embodiment, the gap adjustment mechanism 15 has a spring 38, which allows the second lever 36 to be rotated more appropriately when gap adjustment is necessary during braking.

[0081] According to this embodiment, the gap adjustment mechanism 15 has a regulating spring 40, and the frictional resistance between the adjuster nut 31 and the cam holder 13, which is generated by the biasing force of the regulating spring 40 on the adjuster nut 31, can restrict the rotation of the adjuster nut 31 when not braking.

[0082] According to this embodiment, the ratchet 37 is positioned approximately opposite the first lever 35 in the radial direction, straddling the central axis O of the adjuster nut 31. This allows for a miniaturization of the gap adjustment mechanism 15 compared to the case where the ratchet 37 is located at the same position as the first lever 35.

[0083] According to this embodiment, frictional resistance is generated between the adjuster nut 31 and the spindle 32 due to the pressing force generated during braking. This frictional resistance restricts the rotation of the adjuster nut 31, preventing gap adjustments caused by pad wear and deformation of the cylinder body during braking, thus preventing over-adjustment and the like.

[0084] [First Modified Example] The difference between the first modified example and the above embodiment lies in a part of the gap adjustment mechanism. In the following, only this difference will be explained, and identical components will be denoted by the same reference numerals, and explanations will be omitted as much as possible.

[0085] The gap adjustment mechanism of the first modified example, as shown in Figure 12, comprises an adjuster nut 31, a spindle 32, a ratchet gear 33, a second lever 36, a spring 38, and a regulating spring 40 (not shown). Since these components are the same as those of the gap adjustment mechanism 15 of the above embodiment, their description is omitted.

[0086] Furthermore, the gap adjustment mechanism of the first modified example includes a slide plate 51 on which a projection 52 held by the second lever 36 is provided, and a ratchet 53 fixed to the slide plate 51, which meshes with a ratchet gear 33 and rotates the ratchet gear 33 in response to the sliding of the slide plate 51.

[0087] The slide plate 51 is attached to the cam holder 13 so as to be slidable in the width direction. The projection 52 protrudes radially (upward in Figure 12) from the nut body 312 and is formed in a hollow shape, with the fitting portion 531 of the ratchet 53 fitted inside the hollow portion 521 of the projection 52.

[0088] The ratchet 53 has a fitting portion 531 that protrudes radially (upward in Figure 12) from the nut body portion 312, and the fitting portion 531 is fitted into the hollow portion 521 of the projection 52, thereby enabling it to slide together with the slide plate 51. The ratchet 53 has a pawl 532 that engages with the teeth 331 of the ratchet gear 33. The pawl 532 of the ratchet 53 is engaged with the teeth 331 of the ratchet gear 33 even when the disc brake device is not braking.

[0089] Here, the gap adjustment mechanism configured as described above operates as follows. In the following explanation, we will describe two cases as examples: when the gap between the disc rotor 1 and the brake pad 3 is less than a specified value, and when the gap is greater than or equal to a specified value. Also, as described above, the gap adjustment by the gap adjustment mechanism 15 is performed during braking and before the spindle 32 presses the brake pad 3 against the rotor surface 1a.

[0090] When the disc brake system is applied, as described above, the cam holder 13 moves axially outward, and the axially inward end face of the cam holder 13, which was in contact with the anchor plate 14 when not braking, separates from the anchor plate 14. Then, due to the biasing force of the spring 38, the second lever 36 rotates counterclockwise in Figure 9, even though the rotation restricting portion 363 of the second lever 36 is in contact with the anchor plate 14.

[0091] Next, since the projection 52 of the slide plate 51 is held by the holding portion 362 of the second lever 36, when the second lever 36 is rotated, the slide plate 51 slides to the right in Figure 12 in conjunction with the rotation of the second lever 36. At this time, the ratchet 53 fixed to the slide plate 51 also slides to the right in Figure 12 along with the slide plate 51.

[0092] Next, if the gap between the disc rotor 1 and the brake pad 3 is less than the specified value, the amount of sliding of the ratchet 53, that is, the amount of rotation of the second lever 36, will not cause the ratchet gear 33 to rotate. Therefore, the adjuster nut 31 will not rotate, and the spindle 32 will not move axially outward relative to the adjuster nut 31, that is, the gap will not be adjusted, and the brake pad 3 will be pressed against the rotor surface 1a.

[0093] On the other hand, if the gap between the disc rotor 1 and the brake pad 3 is greater than the specified value, the sliding of the ratchet 53 causes the pawl 532 to push the teeth 331, and the ratchet gear 33 rotates clockwise in Figure 12. Consequently, the adjuster nut 31 also rotates clockwise in Figure 12, and the spindle 32 moves axially outward relative to the adjuster nut 31, completing the gap adjustment. In other words, after the gap adjustment, the spindle 32 protrudes axially outward by the amount of the adjustment compared to before the gap adjustment. Then, after the gap adjustment is completed, the brake pad 3 is pressed against the rotor surface 1a by the spindle 32.

[0094] Subsequently, when the braking force of the disc brake device is released, the cam holder 13 returns to its initial position, and as a result, the second lever 36 also returns to its initial position, and accordingly, the slide plate 51 and the ratchet 53 also return to their initial positions. Note that when the ratchet 53 returns to its initial position, the pawl 532 slides along the tooth tips without engaging with the teeth 331, so the ratchet gear 33 does not rotate.

[0095] As can be understood from the above explanation, in the disc brake device of this example, during braking, the amount of axial outward movement of the cam holder 13, and consequently the amount of rotation of the second lever 36, is determined according to the gap between the disc rotor 1 and the brake pad 3. In other words, the amount of rotation of the adjuster nut 31, which is linked to the rotation of the second lever 36, is also determined according to the gap. Therefore, according to the first modified example, since the spindle 32 is moved axially outward according to the gap, the size of the gap can be adjusted with high precision.

[0096] [Second Modification] As shown in Figure 13, the disc brake device may have the cam holder return spring 17 arranged coaxially with the pair of bolts 22. This reduces the number of parts and allows for miniaturization of the disc brake device.

[0097] <Other Embodiments> The present invention is not limited to the embodiments described above, and can be modified, improved, etc. as appropriate. Furthermore, the material, shape, dimensions, number, placement, etc. of each component in the embodiments described above are arbitrary and not limited as long as they can achieve the present invention.

[0098] In the above embodiment, the anchor plate 14 is provided with a horizontal guide surface 141, but for example, the anchor plate 14 does not necessarily have to be provided with a horizontal guide surface 141.

[0099] In the above embodiment, the ratchet 37 is positioned approximately opposite the first lever 35 in the radial direction (vertical direction in Figure 8) of the adjuster nut 31, with the central axis O of the adjuster nut 31 in between. However, for example, it may be positioned at the same position in the circumferential direction of the adjuster nut 31, or it may simply be positioned offset.

[0100] <Note> The features of the embodiments of the disc brake device described above are briefly summarized below. [1] A disc brake device comprising: a disc rotor (1) that rotates with the wheel; a brake pad (3) provided opposite to the rotor surface (1a) of the disc rotor (1); a pad pressing means (pad pressing mechanism 4) for pressing the brake pad (3) against the rotor surface (1a); and a cylinder body (5) housing the pad pressing means (pad pressing mechanism 4), wherein the disc brake device brakes the disc rotor (1) by pressing the brake pad (3) against the rotor surface (1a) with the pad pressing means (pad pressing mechanism 4), wherein the pad pressing means (pad pressing mechanism 4) includes: a cam holder (13) that moves axially outward on the disc rotor (1) during braking; and an anchor plate (14) attached to the cylinder body (5) axially inward on the disc rotor (1) from the cam holder (13) and guiding the axial movement of the cam holder (13), The disc rotor (1) and the brake pad (3) have a gap adjustment mechanism (15) for adjusting the size of the gap between them, the surface of the cam holder (13) facing the anchor plate (14) is configured to contact the anchor plate (14) when not braking and to be separated from the anchor plate (14) when braking, the gap adjustment mechanism (15) has an adjuster nut (31) located axially outward on the disc rotor (1) from the cam holder (13) and having a fitting portion (311) fitted into the cam holder (13), a spindle (32) that screws into the adjuster nut (31) and presses the brake pad (3) against the rotor surface (1a), and a ratchet gear (33) fitted onto the adjuster nut (31). A ring member (34) is rotatably fitted onto the adjuster nut (31) such that its central axis substantially coincides with the central axis (O) of the adjuster nut (31), and is provided with a first lever (35) that protrudes radially,A disc brake device comprising: a second lever (36) rotatably supported on the outer circumferential surface of the cam holder (13) and holding the first lever (35) to rotate the ring member (34); a ratchet (37) that meshes with the ratchet gear (33) and rotates the ratchet gear (33) in only one direction in response to the rotation of the ring member (34); the spindle (32) moves axially outward when braking, before the spindle (32) presses the brake pad (3) against the rotor surface (1a), by the rotation of the adjuster nut (31) together with the ratchet gear (33); and a rotation restricting portion (363) that contacts the anchor plate (14) to restrict the rotation of the second lever (36) when not braking. [2] The disc brake device according to [1] above, wherein the ratchet (37) is fixed to the ring member (34) so ​​as to be rotatable together with the ring member (34). [3] The disc brake device according to [1] or [2] above, wherein the gap adjustment mechanism (15) further comprises a spring (38) that biases the second lever (36) to rotate. [4] A disc brake device according to any one of [1] to [3] above, wherein the gap adjustment mechanism (15) further comprises a regulating spring (40) that biases the adjuster nut (31) axially inward to restrict the rotation of the adjuster nut (31) when not braking, and the rotation of the adjuster nut (31) is restricted by the frictional resistance between the adjuster nut (31) and the cam holder (13) caused by the biasing of the adjuster nut (31) by the regulating spring (40). [5] A disc brake device according to any one of [1] to [4] above, wherein the ratchet (37) is located in the radial direction of the adjuster nut (31) on substantially the opposite side from the first lever (35) with respect to the central axis (O) of the adjuster nut (31). [6]A disc brake device according to any one of [1] to [5] above, wherein the pad pressing means (pad pressing mechanism 4) further comprises a cam lever unit (11) having an eccentric cam shaft (12), the cam shaft (12) is pivotally supported on the cam holder (13) such that the cam lever unit (11) is rotatable around the cam shaft (12), and during braking, the force transmitted by the rotation of the cam lever unit (11) is amplified to move the cam holder (13) outward in the axial direction, a disc brake device. [7] The disc brake device described in [6] above, wherein the camshaft (12) is composed of a cylindrical cam body (121) and a pair of eccentric portions (122) provided at both ends of the cam body (121) in the extending direction and eccentric to the cam body (121), and the eccentric portions (122) are provided with bearings (21) that are in contact with the anchor plate (14), the disc brake device. [8] A disc brake device comprising: a disc rotor (1) that rotates with the wheel; a brake pad (3) provided opposite to the rotor surface (1a) of the disc rotor (1); a pad pressing means (pad pressing mechanism 4) for pressing the brake pad (3) against the rotor surface (1a); and a cylinder body (5) housing the pad pressing means (pad pressing mechanism 4), wherein the disc brake device brakes the disc rotor (1) by pressing the brake pad (3) against the rotor surface (1a) with the pad pressing means (pad pressing mechanism 4), wherein the pad pressing means (pad pressing mechanism 4) includes: a cam holder (13) that moves axially outward on the disc rotor (1) during braking; and an anchor plate (14) attached to the cylinder body (5) axially inward on the disc rotor (1) from the cam holder (13) and guiding the axial movement of the cam holder (13), The cam holder (13) has a gap adjustment mechanism (15) for adjusting the size of the gap between the disc rotor (1) and the brake pad (3), and the surface of the cam holder (13) facing the anchor plate (14) isThe gap adjustment mechanism (15) is configured to contact the anchor plate (14) when not braking and to move away from the anchor plate (14) when braking, and the gap adjustment mechanism (15) is configured to be located axially outward on the disc rotor (1) from the cam holder (13) and to have a fitting portion (311) that fits inside the cam holder (13), an adjuster nut (31) having a fitting portion (311) that fits inside the cam holder (13), a spindle (32) that screws into the adjuster nut (31) and presses the brake pad (3) against the rotor surface (a), a ratchet gear (33) that fits outside the adjuster nut (31), a lever (second lever 36) that is rotatably supported on the outer circumferential surface of the cam holder (13), and a slide plate (51) that has a projection (52) that is held by the lever (second lever 36) and slides when the lever (second lever 36) rotates, A disc brake device comprising: a ratchet (53) fixed to the slide plate (51) and meshing with the ratchet gear (33), which rotates the ratchet gear (33) in response to the sliding movement of the slide plate (51); the spindle (32) moves axially outward when braking, before the spindle (32) presses the brake pad (3) against the rotor surface (1a), as the adjuster nut (31) rotates together with the ratchet gear (33); and a rotation restricting portion (363) is provided on the rotation center (361) side of the lever (second lever 36) which contacts the anchor plate (14) to restrict the rotation of the lever (second lever 36) when not braking.

[0101] This application is based on a Japanese patent application (Patent Application No. 2024-184063) filed on October 18, 2024, the contents of which are incorporated by reference within this application.

[0102] The technology disclosed herein is useful as a disc brake system capable of precisely adjusting the gap between the disc rotor and the brake pad.

[0103] 1 Disc rotor 1a Rotor surface 3 Brake pad 4 Pad pressing mechanism 5 Cylinder body 5a Guide hole 6 Air cylinder 7 Push rod 7a Guide groove 11 Cam lever unit 12 Camshaft 13 Cam holder 14 Anchor plate 15 Gap adjustment mechanism 16 Guide plate 17 Cam holder return spring 21 Bearing 22 Bolt 31 Adjuster nut 32 Spindle 33 Ratchet gear 34 Ring member 35 First lever 36 Second lever 37, 53 Ratchet 38 Spring 40 Restricting spring 51 Slide plate 52 Protrusion 111 Cam lever 112 Roller 121 Cam body 122 Eccentric part 131 Flange part 131a Hole part 133 Boss part 141 Horizontal guide surface 142 Guide hole 161 Hole 311 Fitting part 361 Rotation center 363 Rotation restricting part

Claims

1. A disc brake device comprising: a disc rotor that rotates with a wheel; a brake pad provided facing the rotor surface of the disc rotor; a pad pressing means for pressing the brake pad against the rotor surface; and a cylinder body housing the pad pressing means, wherein the disc brake device brakes the disc rotor by pressing the brake pad against the rotor surface with the pad pressing means, wherein the pad pressing means includes: a cam holder that moves axially outward on the disc rotor during braking; an anchor plate attached to the cylinder body axially inward on the disc rotor from the cam holder and guiding the axial movement of the cam holder; and a gap adjustment mechanism for adjusting the size of the gap between the disc rotor and the brake pad, wherein the surface of the cam holder facing the anchor plate is configured to contact the anchor plate when not braking and to move away from the anchor plate when braking, and the gap adjustment mechanism includes: an adjuster nut located axially outward on the disc rotor from the cam holder and having a fitting portion fitted into the cam holder, A disc brake device comprising: a spindle that screws onto the adjuster nut and presses the brake pad against the rotor surface; a ratchet gear fitted onto the adjuster nut; a ring member that is rotatably fitted onto the adjuster nut such that its central axis substantially coincides with the central axis of the adjuster nut and is provided with a first lever that protrudes radially; a second lever that is rotatably supported on the outer circumferential surface of the cam holder and holds the first lever in order to rotate the ring member; and a ratchet that meshes with the ratchet gear and rotates the ratchet gear in only one direction in response to the rotation of the ring member, wherein, during braking, before the spindle presses the brake pad against the rotor surface, the spindle moves axially outward as the adjuster nut rotates together with the ratchet gear, and the end of the second lever on the rotation center side is provided with a rotation restricting portion that contacts the anchor plate so as to restrict the rotation of the second lever when not braking.

2. A disc brake device according to claim 1, wherein the ratchet is fixed to the ring member so as to be rotatable together with the ring member.

3. A disc brake device according to claim 1, wherein the gap adjustment mechanism further comprises a spring that biases the second lever to rotate.

4. A disc brake device according to claim 1, wherein the gap adjustment mechanism further comprises a regulating spring that biases the adjuster nut axially inward to restrict the rotation of the adjuster nut when not braking, and the rotation of the adjuster nut is restricted by the frictional resistance between the adjuster nut and the cam holder caused by the biasing of the adjuster nut by the regulating spring.

5. A disc brake device according to claim 1, wherein the ratchet is located in the radial direction of the adjuster nut, substantially opposite to the first lever, with respect to the central axis of the adjuster nut.

6. A disc brake device according to claim 1, wherein the pad pressing means further comprises a cam lever unit having an eccentric camshaft, the camshaft is pivotally supported on the cam holder such that the cam lever unit is rotatable around the camshaft, and during braking, the force transmitted by the rotation of the cam lever unit is amplified to move the cam holder outward in the axial direction.

7. A disc brake device according to claim 6, wherein the camshaft is composed of a cylindrical cam body and a pair of eccentric portions provided at both ends of the cam body in the extending direction and eccentric to the cam body, and the eccentric portions are provided with bearings that are in contact with the anchor plate.

8. A disc brake device comprising: a disc rotor that rotates with a wheel; a brake pad provided facing the rotor surface of the disc rotor; a pad pressing means for pressing the brake pad against the rotor surface; and a cylinder body housing the pad pressing means, wherein the disc brake device brakes the disc rotor by pressing the brake pad against the rotor surface using the pad pressing means, wherein the pad pressing means includes: a cam holder that moves axially outward on the disc rotor during braking; an anchor plate attached to the cylinder body axially inward on the disc rotor from the cam holder and guiding the axial movement of the cam holder; and a gap adjustment mechanism for adjusting the size of the gap between the disc rotor and the brake pad, wherein the surface of the cam holder facing the anchor plate is configured to contact the anchor plate when not braking and to move away from the anchor plate when braking, and the gap adjustment mechanism includes: an adjuster nut located axially outward on the disc rotor from the cam holder and having a fitting portion fitted into the cam holder, A disc brake device comprising: a spindle that screws onto the adjuster nut and presses the brake pad against the rotor surface; a ratchet gear fitted onto the adjuster nut; a lever rotatably supported on the outer circumference of the cam holder; a slide plate having a projection held by the lever and sliding as the lever rotates; and a ratchet fixed to the slide plate, meshing with the ratchet gear and rotating the ratchet gear in response to the sliding movement of the slide plate, wherein, during braking, before the spindle presses the brake pad against the rotor surface, the spindle moves axially outward as the adjuster nut rotates together with the ratchet gear; and a rotation restricting portion is provided on the rotation center side of the lever, which contacts the anchor plate to restrict the rotation of the lever when not braking.

Images