A brake assembly and a vehicle thereof

Abstract

The present invention relates to a brake assembly (100). The brake assembly (100) has one or more lining members (110) and a brake housing (120). The one or more lining members (110) have an annular shape. The one or more lining members (110) are configured to be in selective contact with one or more brake shoes (132) of the brake assembly (110). The one or more lining members (110) are made of a first material. The brake housing (120) is configured to be connected to a rotary shaft (134) that is operably connected to a power unit. The brake housing (120) is configured to accommodate the one or more lining members (110). The brake housing (120) is made of a second material.

Description

[0001] TITLE OF INVENTION

[0002] A BRAKE ASSEMBLY AND A VEHICLE THEREOF

[0003] FIELD OF THE INVENTION

[0004]

[0001] The present invention relates to a brake assembly. More particularly, the present invention relates to a brake assembly for a vehicle.

[0005] BACKGROUND OF THE INVENTION

[0006]

[0002] In all vehicles, a brake assembly is one of the most important components of the vehicle since it is used to stop and control the motion of the vehicle. The safety of the vehicle is directly dependent on the operation of the brake assembly. In drum brake assemblies, one or more brake shoes are provided that come in contact with a friction lining material to provide a braking action for the vehicle.

[0007]

[0003] The drum brake assemblies, thus in general, work by allowing frictional forces to act on the friction lining material that is attached to the drum brake housing, which in turn is connected to the wheel. During braking, friction lining material and the component housing the friction lining material are subjected to extremely high temperatures during braking. This repeated exposure of the friction lining material and the housing to high temperatures thus create the risk of excessive thermal stress in the friction lining material and the housing which may lead to cracking. Moreover, for proper functioning of the brake assembly, it is important that the friction lining material and the housing to have good thermal conductivity to sufficiently and quickly dissipate the heat generated during the braking.

[0008]

[0004] In conventional drum brake assemblies, the housing and the friction lining material are made of a single material. While this single material may have good thermal conductivity and heat dissipation properties, cast iron is a heavy material. Thus usage of cast iron to make the housing as well as the friction lining material leads to an overall increase in the weight of the drum brake assembly and the vehicle, which affectsthe fuel efficiency of the vehicle as well as the handling. On the other hand, if to reduce weight, the housing and the friction lining material are made of a lightweight material, then this material may not have the sufficient frictional characteristics and sufficient thermal conductivity to meet the requirements of the drum braking assembly.

[0009]

[0005] Thus, there is a need in the art for a brake assembly and a vehicle thereof which addresses the aforementioned problems.

[0010] SUMMARY OF THE INVENTION

[0011]

[0006] In an aspect, the present invention is directed towards a brake assembly. The brake assembly has one or more lining members and a brake housing. The one or more lining members have an annular shape. The one or more lining members are configured to be in selective contact with one or more brake shoes of the brake assembly. The one or more lining members are made of a first material. The brake housing is configured to be connected to a rotary shaft that is operably connected to a power unit. The brake housing is configured to accommodate the one or more lining members. The brake housing is made of a second material.

[0012]

[0007] In an embodiment of the invention, each of the one or more lining member has one or more protrusions. The one or more protrusions are provided on a radially outward face of the lining member.

[0013]

[0008] In a further embodiment of the invention, the one or more protrusions extend along an axial direction of the lining member.

[0014]

[0009] In a further embodiment of the invention, the brake housing has one or more recesses. The one or more recesses are configured to engage with the one or more protrusions on the lining member.

[0015]

[0010] In a further embodiment of the invention, the brake assembly has a sleeve and a base plate. The sleeve is provided to house the rotary shaft and and the base plate is connected to the sleeve. The base plate is configured to support the one or more brakeshoes. The brake housing is disposed adjacent to the base plate for allowing the one or more brake shoes to come in contact with the one or more lining members.

[0016] [Oil] In a further embodiment of the invention, the second material has a lower mass density than the first material. In a further embodiment, the second material has a higher thermal conductivity than the first material.

[0017]

[0012] In a further embodiment of the invention, the brake housing has one or more ventilation apertures. The one or more ventilation apertures are configured to facilitate heat dissipation from the lining member during braking operation.

[0018]

[0013] In another aspect, the present invention relates to a vehicle. The vehicle has a power unit and a plurality of wheels. A brake assembly is provided on one or more of the plurality of wheels. The brake assembly has one or more lining members having an annular shape. The one or more lining members are configured to be in selective contact with one or more brake shoes of the brake assembly. The one or more lining members are made of a first material. A brake housing is connected to one or more of the plurality of wheels. The brake housing is configured to be connected to a rotary shaft that is operably connected to the power unit. The brake housing is configured to accommodate the one or more lining members, and the brake housing is made of a second material that is dissimilar from the first material.

[0019]

[0014] In an embodiment of the invention, the rotary shaft has a mounting bracket attached thereto. The mounting bracket has a plurality of projections that engage with a plurality of through holes on the brake housing for attaching the brake housing to the rotary shaft.

[0020] BRIEF DESCRIPTION OF THE DRAWINGS

[0021]

[0015] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context ofthese embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.

[0022] Figure 1 illustrates an exploded view of a brake assembly, in accordance with an embodiment of the present invention.

[0023] Figure 2A illustrates a side view of the brake assembly, in accordance with an embodiment of the present invention.

[0024] Figure 2B illustrates a sectional view of the brake assembly along Section A-A illustrated in Figure 2A, in accordance with an embodiment of the present invention.

[0025] Figure 3 illustrates a perspective view of a brake housing and a lining member of the brake assembly, in accordance with an embodiment of the present invention.

[0026] Figure 4 A illustrate a perspective view of the brake housing, in accordance with an embodiment of the present invention.

[0027] Figure 4B illustrates a perspective view of the lining member, in accordance with an embodiment of the present invention.

[0028] DETAILED DESCRIPTION OF THE INVENTION

[0029]

[0016] The present invention relates to a brake assembly. More particularly, the present invention relates to a brake assembly for a vehicle. The brake assembly of the present invention is typically used in a vehicle such as a three wheeled vehicle, or a four wheeled vehicle, or a multi-wheeled vehicle as required. However, it should be understood that the brake assembly as illustrated may find its application in any nonautomotive application using a brake assembly. The present invention provides for usage of dissimilar materials for a lining member and a brake housing, which achieves reduction in weight while ensuring sufficient heat dissipation and frictional characteristics. The present invention also provides for prevention of slippage between the lining member and the brake housing.

[0030]

[0017] Figure 1 illustrates an exploded view of a brake assembly 100, in accordance with an embodiment of the invention. In an embodiment, the brake assembly 100comprises a drum brake assembly. As illustrated in Figure 1 read with Figure 3, the brake assembly 100 comprises one or more lining members 110. The one or more lining members 110 have an annular shape and the one or more lining members 110 are configured to be in selective contact with one or more brake shoes 132 of the brake assembly 100. Hereinafter, the present invention has been explained in the context of a single lining member 110 in accordance with an embodiment of the invention. However, it should be understood that the present invention is capable of having more than one identical lining members 110. Herein, for example, the one or more brake shoes 132 are crescent shaped with a rough friction material provided at least on one side. When a brake pedal (not shown) or a brake lever (not shown) is pressed, the one or more brake shoes 132 are forced radially outward by means of a cam, thus pushing against a radially inward face HOB (shown in Figure 4B) of the lining member 110, thus providing the friction force for braking action. In an embodiment, the lining member 110 is made of a first material. In an embodiment of the present disclosure, the radially inward face HOB of the lining member 110 is made of a high-strength material such as steel or the like and the radially outward face 110A of the lining member 110 is made up of a friction-optimized composite such as ceramic matrix composite or the like. This allows the lining member 110 to have sufficient strength, while also ensuring that the radially inward face 110B is configured to have adequate frictional characteristics so as to provide sufficient braking performance. In an alternate embodiment, the radially outward face 110A and the radially inward face HOB of the lining member 110 are made up of same material.

[0031]

[0018] The brake assembly 100 further comprises a brake housing 120. As illustrated in Figure 1, the brake housing 120 is configured to be connected to a rotary shaft 134 that operably connected to a power unit (not shown). In an embodiment, the rotary shaft 134 has a mounting bracket 140 attached thereto. The mounting bracket 140 has a plurality of projections 142 that engage with a plurality of through holes 124 on the brake housing 120 for attaching the brake housing 120 to the rotary shaft 134. Thus,power from the power unit is transmitted to the brake housing 134 by means of the rotary shaft 134 and the brake housing is further connected to a component, such as a wheel that rotates by the power transmitted by the rotary shaft 134.

[0032]

[0019] As illustrated in Figure 3, the brake housing 120 is configured to accommodate the lining member 110. In the embodiment depicted in Figure 2A and Figure 2B read with Figure 1, there is provided a sleeve 136 and a base plate 138. The sleeve 136 is provided to house the rotary shaft 134. The base plate 138 is connected to the sleeve 136 and extends orthogonally to the axis of the sleeve 136 or the rotary shaft 134. The base plate 138 is configured to support the one or more brake shoes 132. As particularly illustrated in Figure 2B, the brake housing 120 is disposed adjacent to the base plate 138 for allowing the one or more brake shoes 132 to come in contact with the lining member 110.

[0033]

[0020] Herein, in an embodiment, the brake housing 120 is made of a second material that is dissimilar from the first material. Accordingly, the frictional interaction between the one or more brake shoes 132 and the lining member 110 slows down the rotation of the lining member 110, and thus the brake housing 120 and thus, eventually the component such as the wheel that the brake housing 120 is connected to. The provision of the lining member 110 and the brake housing 120 having dissimilar material thus allow for the lining member 110 to be made of the first material that has good frictional characteristics to ensure sufficient braking action, while the brake housing 120, which is the larger component, to be made of the second material that is lightweight and has good thermal conductivity, thus allowing for quicker heat dissipation. In an embodiment, the first material that the lining member 110 is made of is, for example, but not limited to iron-based sintered alloys with additives like graphite, copper, and friction modifiers or ceramic-based composite. The second material that the brake housing 120 is made of is for example, but not limited to aluminium alloy or magnesium alloy. Thus, the present invention allows reduction in overall weight of thebrake assembly 100 without hampering the required braking and heat dissipation characteristics.

[0034]

[0021] In an embodiment, the brake assembly 100 comprises one or more sensors (not shown) that are configured to determine the level of deterioration or wear in the lining member 110. The sensors are configured to be in communication with a control unit or a remote server, whereby information relating to the wear and tear in the lining member 110 is transmitted to the control unit or the remote server, based on which it can be determined as to whether the brake assembly 100 requires a service. In another embodiment, the brake assembly 100 has a visual indicator (not shown) or marker which the user can visually inspect. As the lining member 110 faces wear and tear, once the lining member 110 is lined up or in line with the visual indicator, it can be an indication to the user that the brake assembly 100 requires servicing. In an embodiment, the lining member 110 is detachably mounted within the brake housing 120, , thus when it is determined that the lining member 110 needs replacement, the same can be easily replaced, without requiring any modification to the brake housing 120, thus reducing cost and complexity and servicing.

[0035]

[0022] In an embodiment of the present disclosure, the brake housing 120 includes one or more ventilation apertures (not shown) or channels configured to facilitate heat dissipation from the lining member 110 during braking operation. Further, the ventilation apertures or channels are helically oriented to induce an airflow path when the brake housing 120 rotates, thus enhancing cooling efficiency. This allows the brake housing 120 and the lining member 110 to have sufficient cooling so as to be able to operate within safe operable limits. In addition, in an embodiment, the brake assembly 100 comprises one or more temperature sensors (not shown) that are configured to detect the temperature of the lining member 110. This information on temperature of the lining member 110 may then be communicated to the control unit, whereby the opening of the ventilation apertures or channels may be suitably controlled to enhance cooling and regulate the temperature of the lining member 110.

[0023] In an aspect, the brake assembly 100 is provided on a vehicle. For example, the brake assembly 100 is provided on a cargo vehicle (not shown) having the power unit comprising an Internal combustion engine (not shown) or an electric powertrain (not shown) or a hybrid for driving the cargo vehicle. The cargo vehicle has one or more wheels, wherein at least one of the one or more wheels are driven by means of the traction provided by the power unit. A frame assembly (not shown) of the cargo vehicle includes long members that extend in a vehicle front-rear direction substantially parallelly to each other, and cross members that extend transversely between the pair of long members.

[0036]

[0024] In an embodiment, the one or more wheels comprise rear wheels and the rear wheels rotate by the driving force of the power unit transmitted through the rotary shaft 134. The cargo vehicle has a cargo deck that is mounted on the frame assembly. In an embodiment, the cargo deck of the cargo vehicle is hingedly mounted on the frame assembly and the cargo deck is configured to be operable between a lowered position and a raised position so as to allow loading and unloading of goods and cargo on the cargo deck.

[0037]

[0025] When the brake assembly 100 is provided on the vehicle, the brake assembly 100 is provided on one or more of the plurality of wheels. More particularly, the brake housing 120 is connected to one or more of the plurality of wheels. As explained hereinbefore, the brake housing 120 is configured to be connected to the rotary shaft 134 that is operably connected to the power unit. Thus, power from the power unit drives the rotary shaft 134, which drives the brake housing 120, which results in rotation of the wheel that the brake housing 120 is connected to. Similarly, as explained hereinbefore, frictional interaction between the one or more brake shoes 132 and the lining member 110 causes slowing of the rotational of the brake housing 120, and thus of the wheel that the brake housing 120 is connected to.

[0038]

[0026] In an embodiment, the second material that the brake housing 120 is made of has a lower mass density than the first material that the lining member 110 is made of.Further, the second material that the brake housing 120 is made of, has a higher thermal conductivity than the first material that the lining member 110 is made of. Since the brake housing is a bulkier component as well as has a larger surface area, the use of second material for the brake housing 120 not only achieves weight reduction but also achieves improved and quicker heat dissipation owing to the lower mass density and higher thermal conductivity of the second material.

[0039]

[0027] In an exemplary embodiment, the first material that the lining member 110 is made of is for example, but not limited to cast iron, and the second material that the brake housing member 120 is made of is for example, but not limited to aluminium. Herein, aluminium has both a lower mass density and higher thermal conductivity than cast iron, while cast iron has the required frictional characteristics to meet the braking performance requirements.

[0040]

[0028] With the usage of dissimilar materials for making of the lining member 110 and the brake housing 120, there remains a risk of axial or rotational slippage between the lining member 110 and the brake housing 120. To address this, in an embodiment, as illustrated in Figure 4B, the lining member 110 comprises one or more protrusions 112. The one or more protrusions 112 are provided on a radially outward face 110A of the lining member 110. In that, the one or more protrusions 112 project radially outward from the radially outward face 110A. Further the one or more protrusions 112 extend along an axial direction of the lining member 110. In an embodiment, each of the one or more protrusions 112 are provided in an equidistant manner to each other. In an embodiment, each of the one or more protrusions 112 are made of similar material as that of the lining member 110. In an alternate embodiment, each of the one or more protrusions 112 are made of different material from that of the lining material 110.

[0041]

[0029] Correspondingly, the brake housing 120 comprises one or more recesses 122. The one or more recesses 122 are configured to engage with the one or more protrusions 112 on the lining member 110. The engagement of the one or more protrusions 112 on the lining member 110 with the one or more recesses 122 on thebrake housing 120 provides for restricting relative rotational and axial movement between the lining member 110 and the brake housing 120 when the brake housing 120 and the lining member 110 are rotating or during the application of the brakes. In an embodiment, each of the one or more recesses 122 are made of similar material as that of the brake housing 120. In an alternate embodiment, each of the one or more recesses 122 is made of different material from that the brake housing 120.

[0042]

[0030] In an embodiment, to allow for the manufacturing of the brake assembly 100 whereby the lining member 110 has the one or more protrusions 112 and the brake housing 120 has the one or more recesses 122, a two stage casting process is adopted. At the first stage, the lining member 110 is cast with first material, say cast iron, wherein the lining member 110 has the annular shape. The one or more protrusions 112 are provided on the radially outward face of the lining member 110 during the casting itself by means of an appropriate mould. Thereafter at the second stage, the brake housing 120, having the second material, say aluminium, is cast around the lining member 110 wherein the lining member 110 is inserted into an appropriate mould and the brake housing 120 is cast in that mould. As a result of the one or more protrusions 112 provided on the lining member 110, when the brake housing 120 is cast, the one or more recesses 122 are created on a radially inner side of the brake housing 120 corresponding to the one or more protrusions 112 on the lining member 110.

[0043]

[0031] Advantageously, the present invention provides a brake assembly whereby the lining member that comes in contact with the brake shoes, and the brake housing that houses the lining member are made of dissimilar materials. This allows for the lining member to have good frictional characteristics to ensure sufficient braking action, while the brake housing is lightweight and has good thermal conductivity, thus allowing for quicker heat dissipation. Thus, the present invention allows reduction in overall weight of the brake assembly without hampering the required braking and heat dissipation characteristics.

[0032] Since the brake housing is a bulkier component as well as has a larger surface area, the use of second material having lower density and higher thermal conductivity, for the brake housing not only achieves weight reduction but also achieves improved and quicker heat dissipation. Further, the provision of the protrusions on the lining member and recesses on the brake housing also ensures that there is no relative axial movement or rotational movement or slippage between the lining member and the brake housing, even when the brake housing the lining member are made of dissimilar materials.

[0044]

[0033] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the scope of the invention as defined in the following claims.

[0045] List of Reference Numerals

[0046] 100: Brake Assembly

[0047] 110: Lining Member

[0048] 110A: Radially Outward Face of the Lining Member

[0049] 110B: Radially Inward Face of the Lining Member

[0050] 112: One or More Protrusions

[0051] 120: Brake Housing

[0052] 122: One or More Recesses

[0053] 124: Plurality of Through Holes

[0054] 132: One or More Brake Shoes

[0055] 134: Rotary Shaft

[0056] 136: Sleeve

[0057] 138: Base Plate

[0058] 140: Mounting Bracket

[0059] 142: Plurality of Projections

Claims

WE CLAIM:

1. A brake assembly (100), the brake assembly (100) comprising:one or more lining members (110), the one or more lining members (110) having an annular shape, the one or more lining members (110) being configured to be in selective contact with one or more brake shoes (132) of the brake assembly (100), the one or more lining members (110) being made of a first material; and a brake housing (120), the brake housing (120) being configured to be connected to a rotary shaft (134) operably connected to a power unit, the brake housing (120) being configured to accommodate the one or more lining members (110), and the brake housing (120) being made of a second material.

2. The brake assembly (100) as claimed in claim 1, wherein each of the one or more lining members (110) comprises one or more protrusions (112), the one or more protrusions (112) provided on a radially outward face (110A) of the lining member (HO).

3. The brake assembly (100) as claimed in claim 2, wherein the one or more protrusions (112) extend along an axial direction of the lining member (110).

4. The brake assembly (100) as claimed in claim 2, wherein the brake housing (120) comprises one or more recesses (122), the one or more recesses (122) being configured to engage with the one or more protrusions (112) on the lining member (HO).

5. The brake assembly (100) as claimed in claim 1, comprising a sleeve (136) and a base plate (138), the sleeve (136) provided to house the rotary shaft (134), and the base plate (138) being connected to the sleeve (136) and being configured to support the one or more brake shoes (132), wherein the brake housing (120) isdisposed adjacent to the base plate (138) for allowing the one or more brake shoes (132) to come in contact with the one or more lining members (110).

6. The brake assembly (100) as claimed in claim 1, wherein the second material has a lower mass density than the first material.

7. The brake assembly (100) as claimed in claim 1, wherein the second material has a higher thermal conductivity than the first material.

8. The brake assembly (100) as claimed in claim 1, wherein the brake housing (120) comprises one or more ventilation apertures, the one or more ventilation apertures being configured to facilitate heat dissipation from the lining member (110) during braking operation.

9. A vehicle, comprising:a power unit;a plurality of wheels;a brake assembly (100), the brake assembly (100) being provided on one or more of the plurality of wheels, the brake assembly (100) comprising:one or more lining members (110), the one or more lining members (110) having an annular shape, the one or more lining members (110) being configured to be in selective contact with one or more brake shoes (132) of the brake assembly (100), the one or more lining members (110) being made of a first material; and a brake housing (120), the brake housing (120) being connected to one or more of the plurality of wheels, the brake housing being configured to be connected to a rotary shaft (134) operably connected to the power unit, the brake housing (120) being configured to accommodate the one or more lining members (110), and thebrake housing (120) being made of a second material that is dissimilar from the first material.

10. The vehicle (10) as claimed in claim 9, wherein the rotary shaft (134) having a mounting bracket (140) attached thereto, the mounting bracket (140) having a plurality of projections (142) that engage with a plurality of through holes (124) on the brake housing (120) for attaching the brake housing (120) to the rotary shaft

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