Brake disk and assembling method for same

Abstract

Provided are: a brake disk which can achieve reduction in the number of part items and improve workability in assembling; and an assembling method for the same.　A brake disk 1 is provided with: a bracket part 2 that is composed of a circular member having a circular outer circumferential shape and is mounted on an axle of a vehicle; a disk part 3 that is composed of an annular member formed along the outer circumferential shape of the bracket part 2 and is for braking the vehicle as a result of pressing of a brake pad; a plurality of projection parts 4 that are formed along the inner circumferential surface of the disk part 3 and are formed projectingly toward the bracket part 2; and a plurality of insertion recess parts 5 that are formed in the bracket part 2 and respectively allow the projection parts 4 to be inserted thereinto. The peripheral edge areas of the insertion recess parts 5 including the projection parts 4 are plastically deformed in a state of being twisted in the circumferential direction to form twisted areas (A, B). Further, due to the twisted areas (A, B), the projection parts 4 are engaged with the insertion recess parts 5, and the bracket part 2 and the disk part 3 are coupled.

Description

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[0001] The present invention relates to a brake disk attached to an axle of a vehicle and a method for assembling the same, which is braked by pressing a brake pad.

[0002] As a brake device disposed in a vehicle such as a passenger car or a motorcycle and capable of braking the vehicle, a disk brake device including a brake disk and a brake pad can be mentioned. Such a disk brake device is configured to obtain a braking force by attaching a brake disk to a wheel of a vehicle so as to be rotatable integrally and pressing a brake pad against the brake disk.

[0003] As such a brake disk, for example, as disclosed in Patent Document 1, a floating type brake disk configured by connecting a bracket portion and a disk portion can be mentioned. Such a floating type brake disk is assembled with a disk portion and a bracket portion by inserting a tip portion of a protruding piece protruding from a rotor (disk portion) into a receiving recess formed in a hub (bracket portion) and connecting them with a connecting pin.

[0004] Japanese Patent Application Laid-Open No. 2018-31406

[0005] However, the conventional brake disk requires a connecting pin for assembling the disk portion and the bracket portion, so there is a problem that the number of parts increases and the workability during assembly deteriorates. Therefore, the applicant has come to consider eliminating or reducing separate parts such as connecting pins by connecting the bracket portion and the disk portion by plastic deformation.

[0006] The present invention has been made in view of such circumstances, and an object thereof is to provide a brake disk and an assembly method thereof that can reduce the number of parts and improve the workability during assembly.

[0007] The invention described in claim 1 is a brake disc comprising: a bracket portion made of a circular member having a circular outer circumference and attached to the axle of a vehicle; a disc portion made of an annular member formed along the outer circumference of the bracket portion and for which a brake pad is pressed to brake the vehicle; a plurality of protrusions formed along the inner circumferential surface of the disc portion and projecting toward the bracket portion; and a plurality of insertion recesses formed in the bracket portion through which each of the protrusions is inserted, wherein the protrusions are inserted into the insertion recesses and the bracket portion and the disc portion are connected, characterized in that the peripheral region of the insertion recess, including the protrusions, is plastically deformed in a twisted state in the circumferential direction to form a twisted region, and the protrusions engage with the insertion recesses by the twisted region and the bracket portion and the disc portion are connected.

[0008] The invention described in claim 2 is characterized in that, in the brake disc described in claim 1, the torsion regions adjacent to each other in the circumferential direction are twisted in different directions and undergo plastic deformation.

[0009] The invention described in claim 3 is characterized in that, in the brake disc described in claim 1, the protruding portion of the torsion region has a groove shape extending in the torsional direction.

[0010] The invention described in claim 4 is a method for assembling a brake disc comprising: a bracket portion made of a circular member having a circular outer circumference and attached to the axle of a vehicle; a disc portion made of an annular member formed along the outer circumference of the bracket portion and for which a brake pad is pressed to brake the vehicle; a plurality of protrusions formed along the inner circumferential surface of the disc portion and projecting toward the bracket portion; and a plurality of insertion recesses formed in the bracket portion through which each of the protrusions is inserted, wherein the bracket portion and the disc portion are connected by inserting the protrusions into the insertion recesses, characterized in that, after inserting the protrusions into the insertion recesses, a twisted region is formed by twisting and plastically deforming the peripheral region of the insertion recess including the protrusions in the circumferential direction, and the protrusions are engaged with the insertion recesses by the twisted region to connect the bracket portion and the disc portion.

[0011] The invention described in claim 5 is characterized in that, in the method for assembling a brake disc according to claim 4, the torsion regions adjacent to each other in the circumferential direction are twisted and plastically deformed in different directions.

[0012] The invention described in claim 6 is characterized in that, in the method for assembling a brake disc according to claim 4, the protruding portion of the torsion region has a groove shape extending in the torsional direction.

[0013] According to the inventions of claims 1 and 4, the peripheral region of the insertion recess including the protruding portion is plastically deformed in a twisted state in the circumferential direction to form a twisted region, and the protruding portion engages with the insertion recess due to the twisted region, thereby connecting the bracket portion and the disc portion. This reduces the number of parts and improves workability during assembly.

[0014] According to the inventions of claims 2 and 5, since adjacent torsional regions in the circumferential direction are twisted and plastically deformed in different directions, when the brake disc rotates after the bracket and disc portions are connected, it is possible to prevent the locking of the protruding portion into the insertion recess from being released, thereby suppressing the disc portion from unintentionally coming off the bracket portion.

[0015] According to the inventions of claims 3 and 6, since the protrusions in the twisted region have a groove shape extending in the twisting direction, the peripheral region of the insertion recess including the protrusions can be easily twisted, and the twisted region can be easily formed.

[0016] A perspective view showing a brake disc according to an embodiment of the present invention. A plan view and a side view showing the same brake disc. A cross-sectional view along line III-III in Figure 2. A cross-sectional view along line IV-IV in Figure 2. An exploded perspective view showing the same brake disc (before the formation of the twisted region). A perspective view showing the same brake disc (before the formation of the twisted region). A plan view and a side view showing the same brake disc (before the formation of the twisted region). An enlarged view showing the peripheral region of the protruding portion and insertion recess of the same brake disc (before the formation of the twisted region A). An enlarged view showing the twisted region A of the same brake disc. Enlarged view showing the protruding portion of the skewer (before the formation of twisted region B) and the peripheral region of the insertion recess of the brake disc. Enlarged view showing twisted region B of the brake disc. Enlarged view showing adjacent twisted regions (twisted region A and twisted region B) of the brake disc. Cross-sectional view showing twisted region A and its periphery in a brake disc according to another embodiment of the present invention. Cross-sectional view showing twisted region B and its periphery in a brake disc according to another embodiment of the present invention. Cross-sectional view showing twisted regions A and B and their periphery in a brake disc according to another embodiment of the present invention.

[0017] Embodiments of the present invention will now be described in detail with reference to the drawings. The brake disc 1 according to this embodiment is a component that is attached to the wheel of a vehicle such as an automobile or motorcycle and is rotatable integrally with the wheel, and is used to obtain braking force when a brake pad is pressed against it. As shown in Figures 1 and 2, it is configured to have a bracket portion 2, a disc portion 3, a protruding portion 4, an insertion recess 5, and twisted regions (A, B).

[0018] The bracket portion 2 is obtained by press-forming a metal plate material, such as an aluminum alloy, and consists of a circular member with a circular outer circumference. Multiple mounting holes 2a are formed at predetermined positions. These mounting holes 2a are used to insert fastening means such as bolts, and the bracket portion 2 (brake disc 1) is attached to the wheel (not shown) of the vehicle. Furthermore, a disc portion 3 is connected to the outer edge of the bracket portion 2, forming a brake disc 1 that is disc-shaped in plan view.

[0019] The disc portion 3 is obtained by press-forming a metal plate material such as stainless steel, and has multiple drainage holes 3a formed at multiple locations in a predetermined area (the brake pad pressing area) in the circumferential direction. The disc portion 3 consists of an annular member formed along the outer circumference shape of the bracket portion 2, and is pressed against the vehicle's brake pad (not shown) to enable braking of the vehicle.

[0020] As shown in Figure 5, the protrusions 4 are formed in multiple locations along the inner circumferential surface of the disc portion 3 and protrude toward the bracket portion 2. Specifically, the protrusions 4 are convex shapes integrally formed with the disc portion 3 at the inner edge of the disc portion 3, and are formed in multiple locations along the circumferential direction of the disc portion 3, each protruding by a predetermined distance toward the inner bracket portion 2.

[0021] As shown in Figure 5, the insertion recess 5 consists of multiple recessed shapes formed on the bracket portion 2, and as shown in Figures 6 and 7, the protruding portions 4 can be inserted through each of them. That is, the insertion recess 5 consists of a recessed shape formed slightly smaller than the outer ring dimensions of the protruding portion 4, and multiple recesses are formed along the outer edge of the bracket portion 2 in the circumferential direction. The protruding portions 4 can be inserted (fitted) into each of these recesses, forming twisted regions (A, B), thereby enabling the bracket portion 2 and the disc portion 3 to be connected.

[0022] In this embodiment, the brake disc 1 is constructed such that the peripheral region A' (see Figures 8 and 10) of the insertion recess 5 including the protruding portion 4 undergoes plastic deformation in a twisted state in the circumferential direction to form a twisted region (A, B) (see Figures 9 and 11). The protruding portion 4 engages with the insertion recess 5 through the twisted region (A, B), connecting the bracket portion 2 and the disc portion 3. The twisted region (A, B) consists of adjacent regions in the circumferential direction on the brake disc 1.

[0023] However, as shown in Figures 2 and 3, the twisted region A is a region in which one of the adjacent protrusions 4 is inserted into the insertion recess 5 and twisted in the circumferential direction, causing plastic deformation. Around this region, stepped shapes A1 and A2 and a twisted shape A3 are formed due to the twisting. Furthermore, the protrusion 4 located in the twisted region A has a groove shape 4a extending in the twisting direction (circumferential direction), and the groove shape 4a is twisted in the same direction as the twisted shape A3.

[0024] On the other hand, as shown in Figures 2 and 4, the twisted region B is a region in which the other of two adjacent protrusions 4 is inserted into the insertion recess 5 and twisted in the circumferential direction, causing plastic deformation. Around this region, stepped shapes B1 and B2 and a twisted shape B3 are formed due to the twisting. Furthermore, the protrusion 4 located in the twisted region B has a groove shape 4a that extends in the twisting direction (circumferential direction), and the groove shape 4a is twisted in the same direction as the twisted shape B3.

[0025] Instead of having stepped shapes A1 and A2 formed on both sides of the twisted region A, it may be formed with gently sloping slope shapes C1 and C2, as shown in Figure 13. Similarly, instead of having stepped shapes B1 and B2 formed on both sides of the twisted region B, it may be formed with gently sloping slope shapes D1 and D2, as shown in Figure 14. By forming slope shapes C1, C2, D1 and D2 in this way, the connection surface between the bracket portion 2 and the disc portion 3 can be made gently sloping, as shown in Figure 15, and wind noise and the like that generated when the brake disc 1 rotates can be suppressed.

[0026] Next, the assembly method of the brake disc 1 according to this embodiment will be described. First, as shown in Figures 6 and 7, the bracket portion 2 is placed on the inside of the disc portion 3 on a press mold or the like, and the multiple protrusions 4 are inserted into the multiple insertion recesses 5. Then, as shown in Figures 8 and 10, the peripheral regions A' and B' of the insertion recesses 5 including the protrusions 4 are twisted to form twisted regions A and B.

[0027] Specifically, as shown in Figure 8, the peripheral region A' (the area with dot hatching in Figure 8) of the insertion recess 5 including the protruding portion 4 is clamped with a movable mold, and the movable mold is plastically deformed by twisting it in the circumferential direction (torsion direction α) about the axis L (a virtual radial line of the bracket portion 2 and the disc portion 3, passing through the center line of the protruding portion 4). As a result, as shown in Figure 9, the peripheral region A' is twisted to form a twisted region A, and by forming this twisted region A, the protruding portion 4 can be engaged with the insertion recess 5 and the bracket portion 2 and the disc portion 3 can be connected.

[0028] Similarly, as shown in Figure 10, the peripheral region B' (the area with dot hatching in Figure 10) of the insertion recess 5 including the protrusion 4 is clamped with a movable mold, and the movable mold is plastically deformed by twisting it in the circumferential direction (torsion direction β) about the axis L (a virtual radial line of the bracket portion 2 and the disc portion 3, passing through the center line of the protrusion 4). As a result, as shown in Figure 11, the peripheral region B' is twisted to form a twisted region B, and by forming this twisted region B, the protrusion 4 can be engaged with the insertion recess 5 and the bracket portion 2 and the disc portion 3 can be connected.

[0029] In this way, by forming torsion regions (A, B) from peripheral regions (A', B') using a press die, a brake disc 1 can be obtained in which the bracket portion 2 and the disc portion 3 are connected, as shown in Figures 1 and 2. In such a brake disc 1, the circumferentially adjacent torsion regions A and B are formed by being twisted in different directions (torsion directions α and β) and undergoing plastic deformation, as shown in Figure 12.

[0030] The twisting direction α and the twisting direction β are in different directions (opposite directions), and in this embodiment, the twisted regions (A and B) are formed by twisting them in opposite directions by the same angle. Note that the twisting angles of twisting direction α and twisting direction β are not limited to the same angle as in this embodiment, but may be different angles, in which case the twisting angles can be arbitrarily set according to the rotation direction of the brake disc 1.

[0031] Furthermore, during the process of forming the twisted regions A and B, when the peripheral regions (A', B') of the insertion recess 5 including the protrusion 4 are twisted in the circumferential direction (twisting direction α, β), they are designed to twist smoothly along the groove shape 4a of the protrusion 4. In this embodiment, the groove shape 4a is formed on both the front and back surfaces of the protrusion 4, but it may also be formed on only one of the front or back surfaces of the protrusion 4.

[0032] According to the brake disc 1 of this embodiment, the peripheral regions (A', B') of the insertion recess 5 including the protruding portion 4 are plastically deformed in a twisted state in the circumferential direction (circumferential direction of the brake disc 1) to form twisted regions (A, B), and the protruding portion 4 engages with the insertion recess 5 due to the twisted regions (A, B), connecting the bracket portion 2 and the disc portion 3. As a result, a separate member for connecting the bracket portion 2 and the disc portion 3 is not required, reducing the number of parts and improving workability during assembly.

[0033] Furthermore, according to the brake disc 1 of this embodiment, the circumferentially adjacent torsional regions (A, B) are twisted and plastically deformed in different directions (torsion directions α, β). Therefore, when the brake disc 1 rotates after the bracket portion 2 and the disc portion 3 are connected, it is possible to avoid the locking of the protruding portion 4 into the insertion recess 5 being released, thereby suppressing the disc portion 3 from unintentionally detaching from the bracket portion 2.

[0034] Furthermore, according to the brake disc 1 of the embodiment, the protruding portion 4 of the torsion region (A, B) has a groove shape 4a that extends in the torsion direction (circumferential direction of the brake disc 1), so that the peripheral region (A', B') of the insertion recess 5 including the protruding portion 4 can be easily twisted, and the torsion region (A, B) can be easily formed.

[0035] Although this embodiment has been described above, the present invention is not limited thereto. For example, the twisted regions (A, B) may be formed only on a part of the brake disc 1, or the groove shape 4a may not be formed on the protruding portion 4. When the twisted regions (A, B) are formed only on a part of the brake disc 1, conventional connecting pins or connecting clips can be used for the other parts. In addition, the protruding portion 4 and the insertion recess 5 may have other shapes (for example, the width of the protruding portion 4 and the insertion recess 5 may change continuously in the extending direction, or they may have a stepped portion in the middle).

[0036] The invention may have other functions as long as they are in line with the spirit of the present invention.

[0037] 1 Brake disc 2 Bracket portion 2a Mounting hole 3 Disc portion 3a Drainage hole 4 Protruding portion 4a Groove shape 5 Insertion recess A, B Twisted region A', B' Peripheral region

Claims

1. A brake disc comprising: a bracket portion made of a circular member having a circular outer circumference and attached to the axle of a vehicle; a disc portion made of an annular member formed along the outer circumference of the bracket portion and for which a brake pad is pressed to brake the vehicle; a plurality of protrusions formed along the inner circumferential surface of the disc portion and projecting toward the bracket portion; and a plurality of insertion recesses formed in the bracket portion through which each of the protrusions is inserted, wherein the protrusions are inserted into the insertion recesses and the bracket portion and the disc portion are connected, characterized in that the peripheral region of the insertion recess, including the protrusions, is plastically deformed in a twisted state in the circumferential direction to form a twisted region, and the protrusions engage with the insertion recesses by the twisted region and the bracket portion and the disc portion are connected.

2. The brake disc according to claim 1, characterized in that the torsion regions adjacent to each other in the circumferential direction are twisted in different directions and undergo plastic deformation.

3. The brake disc according to claim 1, characterized in that the protruding portion of the torsion region has a groove shape extending in the torsional direction.

4. A method for assembling a brake disc comprising: a bracket portion made of a circular member having a circular outer circumference and attached to the axle of a vehicle; a disc portion made of an annular member formed along the outer circumference of the bracket portion and for which a brake pad is pressed to brake the vehicle; a plurality of protrusions formed along the inner circumferential surface of the disc portion and projecting toward the bracket portion; and a plurality of insertion recesses formed in the bracket portion through which each of the protrusions is inserted, wherein the bracket portion and the disc portion are connected by the protrusions being inserted into the insertion recesses, characterized in that, after inserting the protrusions into the insertion recesses, a twisted region is formed by twisting the peripheral region of the insertion recess including the protrusions in the circumferential direction to form a twisted region, and the protrusions are engaged with the insertion recesses by the twisted region to connect the bracket portion and the disc portion.

5. The method for assembling a brake disc according to claim 4, characterized in that adjacent torsional regions in the circumferential direction are plastically deformed by twisting them in different directions.

6. The method for assembling a brake disc according to claim 4, characterized in that the protruding portion of the torsion region has a groove shape extending in the torsional direction.

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