CN113039373A - Stepped piston with oversized foot for a disc brake - Google Patents

Stepped piston with oversized foot for a disc brake Download PDF

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Publication number
CN113039373A
CN113039373A CN201980075308.3A CN201980075308A CN113039373A CN 113039373 A CN113039373 A CN 113039373A CN 201980075308 A CN201980075308 A CN 201980075308A CN 113039373 A CN113039373 A CN 113039373A
Authority
CN
China
Prior art keywords
piston
foot
ball
ramp
end wall
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CN201980075308.3A
Other languages
Chinese (zh)
Other versions
CN113039373B (en
Inventor
D·史密斯
G·切莱蒂特
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
HL Mando Corp
Original Assignee
Mando Corp
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Filing date
Publication date
Application filed by Mando Corp filed Critical Mando Corp
Priority claimed from PCT/KR2019/015578 external-priority patent/WO2020101404A1/en
Publication of CN113039373A publication Critical patent/CN113039373A/en
Application granted granted Critical
Publication of CN113039373B publication Critical patent/CN113039373B/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60TVEHICLE BRAKE CONTROL SYSTEMS OR PARTS THEREOF; BRAKE CONTROL SYSTEMS OR PARTS THEREOF, IN GENERAL; ARRANGEMENT OF BRAKING ELEMENTS ON VEHICLES IN GENERAL; PORTABLE DEVICES FOR PREVENTING UNWANTED MOVEMENT OF VEHICLES; VEHICLE MODIFICATIONS TO FACILITATE COOLING OF BRAKES
    • B60T13/00Transmitting braking action from initiating means to ultimate brake actuator with power assistance or drive; Brake systems incorporating such transmitting means, e.g. air-pressure brake systems
    • B60T13/74Transmitting braking action from initiating means to ultimate brake actuator with power assistance or drive; Brake systems incorporating such transmitting means, e.g. air-pressure brake systems with electrical assistance or drive
    • B60T13/741Transmitting braking action from initiating means to ultimate brake actuator with power assistance or drive; Brake systems incorporating such transmitting means, e.g. air-pressure brake systems with electrical assistance or drive acting on an ultimate actuator
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K7/00Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/14Structural association with mechanical loads, e.g. with hand-held machine tools or fans
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60TVEHICLE BRAKE CONTROL SYSTEMS OR PARTS THEREOF; BRAKE CONTROL SYSTEMS OR PARTS THEREOF, IN GENERAL; ARRANGEMENT OF BRAKING ELEMENTS ON VEHICLES IN GENERAL; PORTABLE DEVICES FOR PREVENTING UNWANTED MOVEMENT OF VEHICLES; VEHICLE MODIFICATIONS TO FACILITATE COOLING OF BRAKES
    • B60T1/00Arrangements of braking elements, i.e. of those parts where braking effect occurs specially for vehicles
    • B60T1/02Arrangements of braking elements, i.e. of those parts where braking effect occurs specially for vehicles acting by retarding wheels
    • B60T1/06Arrangements of braking elements, i.e. of those parts where braking effect occurs specially for vehicles acting by retarding wheels acting otherwise than on tread, e.g. employing rim, drum, disc, or transmission or on double wheels
    • B60T1/065Arrangements of braking elements, i.e. of those parts where braking effect occurs specially for vehicles acting by retarding wheels acting otherwise than on tread, e.g. employing rim, drum, disc, or transmission or on double wheels employing disc
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60TVEHICLE BRAKE CONTROL SYSTEMS OR PARTS THEREOF; BRAKE CONTROL SYSTEMS OR PARTS THEREOF, IN GENERAL; ARRANGEMENT OF BRAKING ELEMENTS ON VEHICLES IN GENERAL; PORTABLE DEVICES FOR PREVENTING UNWANTED MOVEMENT OF VEHICLES; VEHICLE MODIFICATIONS TO FACILITATE COOLING OF BRAKES
    • B60T13/00Transmitting braking action from initiating means to ultimate brake actuator with power assistance or drive; Brake systems incorporating such transmitting means, e.g. air-pressure brake systems
    • B60T13/74Transmitting braking action from initiating means to ultimate brake actuator with power assistance or drive; Brake systems incorporating such transmitting means, e.g. air-pressure brake systems with electrical assistance or drive
    • B60T13/746Transmitting braking action from initiating means to ultimate brake actuator with power assistance or drive; Brake systems incorporating such transmitting means, e.g. air-pressure brake systems with electrical assistance or drive and mechanical transmission of the braking action
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60TVEHICLE BRAKE CONTROL SYSTEMS OR PARTS THEREOF; BRAKE CONTROL SYSTEMS OR PARTS THEREOF, IN GENERAL; ARRANGEMENT OF BRAKING ELEMENTS ON VEHICLES IN GENERAL; PORTABLE DEVICES FOR PREVENTING UNWANTED MOVEMENT OF VEHICLES; VEHICLE MODIFICATIONS TO FACILITATE COOLING OF BRAKES
    • B60T8/00Arrangements for adjusting wheel-braking force to meet varying vehicular or ground-surface conditions, e.g. limiting or varying distribution of braking force
    • B60T8/26Arrangements for adjusting wheel-braking force to meet varying vehicular or ground-surface conditions, e.g. limiting or varying distribution of braking force characterised by producing differential braking between front and rear wheels
    • B60T8/28Arrangements for adjusting wheel-braking force to meet varying vehicular or ground-surface conditions, e.g. limiting or varying distribution of braking force characterised by producing differential braking between front and rear wheels responsive to deceleration
    • B60T8/282Arrangements for adjusting wheel-braking force to meet varying vehicular or ground-surface conditions, e.g. limiting or varying distribution of braking force characterised by producing differential braking between front and rear wheels responsive to deceleration using ball and ramp
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B62LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62DMOTOR VEHICLES; TRAILERS
    • B62D15/00Steering not otherwise provided for
    • B62D15/02Steering position indicators ; Steering position determination; Steering aids
    • B62D15/021Determination of steering angle
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B62LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62DMOTOR VEHICLES; TRAILERS
    • B62D5/00Power-assisted or power-driven steering
    • B62D5/04Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear
    • B62D5/0442Conversion of rotational into longitudinal movement
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B62LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62DMOTOR VEHICLES; TRAILERS
    • B62D5/00Power-assisted or power-driven steering
    • B62D5/04Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear
    • B62D5/0457Power-assisted or power-driven steering electrical, e.g. using an electric servo-motor connected to, or forming part of, the steering gear characterised by control features of the drive means as such
    • B62D5/046Controlling the motor
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D55/00Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes
    • F16D55/02Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members
    • F16D55/22Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members by clamping an axially-located rotating disc between movable braking members, e.g. movable brake discs or brake pads
    • F16D55/224Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members by clamping an axially-located rotating disc between movable braking members, e.g. movable brake discs or brake pads with a common actuating member for the braking members
    • F16D55/225Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members by clamping an axially-located rotating disc between movable braking members, e.g. movable brake discs or brake pads with a common actuating member for the braking members the braking members being brake pads
    • F16D55/226Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members by clamping an axially-located rotating disc between movable braking members, e.g. movable brake discs or brake pads with a common actuating member for the braking members the braking members being brake pads in which the common actuating member is moved axially, e.g. floating caliper disc brakes
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00Parts or details
    • F16D65/02Braking members; Mounting thereof
    • F16D65/04Bands, shoes or pads; Pivots or supporting members therefor
    • F16D65/092Bands, shoes or pads; Pivots or supporting members therefor for axially-engaging brakes, e.g. disc brakes
    • F16D65/095Pivots or supporting members therefor
    • F16D65/097Resilient means interposed between pads and supporting members or other brake parts
    • F16D65/0973Resilient means interposed between pads and supporting members or other brake parts not subjected to brake forces
    • F16D65/0979Resilient means interposed between pads and supporting members or other brake parts not subjected to brake forces acting on the rear side of the pad or an element affixed thereto, e.g. spring clips securing the pad to the brake piston or caliper
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00Parts or details
    • F16D65/14Actuating mechanisms for brakes; Means for initiating operation at a predetermined position
    • F16D65/16Actuating mechanisms for brakes; Means for initiating operation at a predetermined position arranged in or on the brake
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00Parts or details
    • F16D65/14Actuating mechanisms for brakes; Means for initiating operation at a predetermined position
    • F16D65/16Actuating mechanisms for brakes; Means for initiating operation at a predetermined position arranged in or on the brake
    • F16D65/18Actuating mechanisms for brakes; Means for initiating operation at a predetermined position arranged in or on the brake adapted for drawing members together, e.g. for disc brakes
    • F16D65/183Actuating mechanisms for brakes; Means for initiating operation at a predetermined position arranged in or on the brake adapted for drawing members together, e.g. for disc brakes with force-transmitting members arranged side by side acting on a spot type force-applying member
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16HGEARING
    • F16H48/00Differential gearings
    • F16H48/06Differential gearings with gears having orbital motion
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16HGEARING
    • F16H48/00Differential gearings
    • F16H48/20Arrangements for suppressing or influencing the differential action, e.g. locking devices
    • F16H48/30Arrangements for suppressing or influencing the differential action, e.g. locking devices using externally-actuatable means
    • F16H48/34Arrangements for suppressing or influencing the differential action, e.g. locking devices using externally-actuatable means using electromagnetic or electric actuators
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01BMEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B7/00Measuring arrangements characterised by the use of electric or magnetic techniques
    • G01B7/30Measuring arrangements characterised by the use of electric or magnetic techniques for measuring angles or tapers; for testing the alignment of axes
    • G01B7/315Measuring arrangements characterised by the use of electric or magnetic techniques for measuring angles or tapers; for testing the alignment of axes for testing wheel alignment
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K1/00Details of the magnetic circuit
    • H02K1/06Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/12Stationary parts of the magnetic circuit
    • H02K1/14Stator cores with salient poles
    • H02K1/146Stator cores with salient poles consisting of a generally annular yoke with salient poles
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K1/00Details of the magnetic circuit
    • H02K1/06Details of the magnetic circuit characterised by the shape, form or construction
    • H02K1/22Rotating parts of the magnetic circuit
    • H02K1/27Rotor cores with permanent magnets
    • H02K1/2706Inner rotors
    • H02K1/272Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis
    • H02K1/274Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets
    • H02K1/2753Inner rotors the magnetisation axis of the magnets being perpendicular to the rotor axis the rotor consisting of two or more circumferentially positioned magnets the rotor consisting of magnets or groups of magnets arranged with alternating polarity
    • H02K1/276Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM]
    • H02K1/2766Magnets embedded in the magnetic core, e.g. interior permanent magnets [IPM] having a flux concentration effect
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K21/00Synchronous motors having permanent magnets; Synchronous generators having permanent magnets
    • H02K21/12Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets
    • H02K21/14Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets rotating within the armatures
    • H02K21/16Synchronous motors having permanent magnets; Synchronous generators having permanent magnets with stationary armatures and rotating magnets with magnets rotating within the armatures having annular armature cores with salient poles
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K29/00Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices
    • H02K29/03Motors or generators having non-mechanical commutating devices, e.g. discharge tubes or semiconductor devices with a magnetic circuit specially adapted for avoiding torque ripples or self-starting problems
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02KDYNAMO-ELECTRIC MACHINES
    • H02K7/00Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
    • H02K7/06Means for converting reciprocating motion into rotary motion or vice versa
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60YINDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY
    • B60Y2400/00Special features of vehicle units
    • B60Y2400/81Braking systems
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2121/00Type of actuator operation force
    • F16D2121/02Fluid pressure
    • F16D2121/04Fluid pressure acting on a piston-type actuator, e.g. for liquid pressure
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2121/00Type of actuator operation force
    • F16D2121/18Electric or magnetic
    • F16D2121/24Electric or magnetic using motors
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2125/00Components of actuators
    • F16D2125/18Mechanical mechanisms
    • F16D2125/44Mechanical mechanisms transmitting rotation
    • F16D2125/46Rotating members in mutual engagement
    • F16D2125/50Rotating members in mutual engagement with parallel non-stationary axes, e.g. planetary gearing
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2127/00Auxiliary mechanisms
    • F16D2127/06Locking mechanisms, e.g. acting on actuators, on release mechanisms or on force transmission mechanisms
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16DCOUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D55/00Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes
    • F16D55/02Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members
    • F16D55/04Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members by moving discs or pads away from one another against radial walls of drums or cylinders
    • F16D55/14Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members by moving discs or pads away from one another against radial walls of drums or cylinders with self-tightening action, e.g. by means of coacting helical surfaces or balls and inclined surfaces

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Transportation (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Braking Arrangements (AREA)
  • Power Steering Mechanism (AREA)
  • Iron Core Of Rotating Electric Machines (AREA)
  • Retarders (AREA)
  • Permanent Magnet Type Synchronous Machine (AREA)
  • Steering Control In Accordance With Driving Conditions (AREA)
  • Permanent Field Magnets Of Synchronous Machinery (AREA)

Abstract

A piston configured for use in a braking system is disclosed. The piston includes: a body; and a foot positioned adjacent an end of the body and having a recess receiving a central portion of the end, the foot extending along a brake pad during operation of the braking system and configured to apply a force to the brake pad during actuation of the disc brake system; and the foot has a surface configured to contact the brake pad, the surface having a length and a width, wherein the length is longer than an outer width of the body and the length is greater than the width, and/or the surface has a cross-sectional area orthogonal to a direction of travel of the piston that is greater than a cross-sectional area of the piston body orthogonal to the direction of travel of the piston.

Description

Stepped piston with oversized foot for a disc brake
Technical Field
The present disclosure relates to brake systems (e.g., vehicle brake systems) including pistons for brake system operation.
Background
A brake system (e.g., a disc brake system on a vehicle such as an automobile or truck) may include a caliper housing and one or more pistons within the caliper housing. In operation, a disc brake system may press brake pads against opposing contact surfaces of a brake rotor to generate tangential friction forces, thereby inducing a braking effect. Disc brake systems may include a piston that moves against a brake pad in response to a signal to cause a braking effect.
The present disclosure relates to disc brake caliper pistons and piston systems, such as for use in various vehicles including automobiles, trucks, airplanes and the like. Embodiments of the present disclosure include: a piston providing an oversized bearing surface for contacting a brake pad; a retraction system for retracting a portion of the piston; and/or a sealing system inside the piston. Embodiments of the present disclosure include a piston utilizing a ball ramp actuator. Embodiments of the present invention include a piston having a stepped surface.
As the vehicle is made larger and heavier, a larger braking force may help bring the vehicle to a stop. The increase in braking force may be achieved in a variety of ways, such as, for example, depressing the brake pedal harder, increasing the hydraulic advantage within the brake system to achieve greater pressure at the brake piston, increasing the torque delivered to a linear motion converter in the brake system (e.g., by increasing the torque of a motor or adding a gearbox or other torque multiplier), reducing frictional (e.g., viscous, mechanical, etc.) losses in the brake system, increasing the number of brake pistons to increase the braking force achieved at a given hydraulic pressure, or increasing the diameter of the pistons to increase the braking force achieved at a given hydraulic pressure.
Increasing the number of pistons may lead to problems in implementing a parking brake system integrated with the brake piston. The reasons for this may include: a spindle/nut arrangement (such as that shown in fig. 1) which should be implemented on both pistons associated with the wheel; or there is a risk of uneven wear and/or uneven brake application which may lead to other operational problems, such as piston binding.
However, simply increasing the diameter of the piston may be limited by the width of the brake pad and other system dimensions.
Furthermore, increasing the pressure at which the piston operates to increase the force also risks deforming the brake pads due to the presence of highly localized forces (at the piston), which also can lead to uneven wear and other operational problems.
Disclosure of Invention
Technical problem
Various embodiments of the present disclosure provide a disc brake caliper piston and piston system for various vehicles.
Means for solving the problems
In a first aspect disclosed herein, a piston configured for use in a disc brake system is provided. The piston includes: a body; and a footing; the body has: a sidewall surrounding an interior space within the piston; and an end wall at an end of the piston, the end wall having a central portion extending outwardly from the end wall; the footing being positioned adjacent the end wall distally of the interior space and having a recess receiving the central portion, wherein the footing is located between a portion of the end wall and a brake pad during operation of the disc brake system and the footing extends along the brake pad and is configured to apply a force to the brake pad during actuation of the disc brake system; and the foot has a surface configured to contact the brake pad, the surface having a length and a width, wherein the length is longer than an outer width of the body and the length is greater than the width, and/or the surface has a cross-sectional area orthogonal to a direction of travel of the piston that is greater than a cross-sectional area of a piston body orthogonal to the direction of travel of the piston.
In a first embodiment of the first aspect, the width is wider than a width of the body.
In a second embodiment of the first aspect, the piston further comprises: a main shaft; a spindle nut; and a ball ramp actuator; wherein the spindle, spindle nut, and ball ramp actuator are each located at least partially within the interior space with the spindle nut threadedly connected with the spindle, and the ball ramp actuator is located between the end wall and the spindle nut and is configured to push against the end wall and the spindle nut during operation of the disc brake system; and at least one of the spindle and the spindle nut extends into an internal piston recess defined by the central portion.
In a third embodiment of the first aspect, the foot distributes the braking force from the piston over a brake pad area that is larger than the cross-sectional area of the piston.
In a fourth embodiment of the first aspect, the foot has: first and second ends located at respective first and second ends of the length; and a midpoint corresponding to a central axis of the piston body, and the first and second ends deflect less than 0.3 millimeters, or less than 0.2 millimeters, or less than 0.1 millimeters from the midpoint during operation of the piston against a flat surface at a pressure of 100 bar.
In a fifth embodiment of the first aspect, the piston further comprises a ring forming a seal against debris between the foot and the body.
In a sixth embodiment of the first aspect, the foot is pressed onto the body.
In a seventh embodiment of the first aspect, the footing is glued to the body.
In an eighth embodiment of the first aspect, the foot is integral with the body.
In a ninth embodiment of the first aspect, the piston further comprises: a main shaft; a spindle nut; and a ball ramp actuator; wherein the spindle, spindle nut, and ball ramp actuator are each located at least partially within the interior space with the spindle nut threadedly connected with the spindle, and the ball ramp actuator is located between the end wall and the spindle nut and is configured to push against the end wall and the spindle nut during operation of the disc brake system; and at least one of the spindle and the spindle nut extending into an interior piston recess defined by the central portion, wherein the ball ramp actuator includes two balls, each ball located in a respective one of an upper race and a lower race, and when the upper and lower races rotate relative to each other, the balls move upwardly in the respective one of the upper and lower races causing the upper and lower races to move apart from each other and apply a linear force between the spindle nut and the end wall.
In a tenth embodiment of the first aspect, the piston further comprises: a main shaft; a spindle nut; and a ball ramp actuator; wherein the spindle, spindle nut, and ball ramp actuator are each located at least partially within the interior space with the spindle nut threadedly connected with the spindle, and the ball ramp actuator is located between the end wall and the spindle nut and is configured to push against the end wall and the spindle nut during operation of the disc brake system; and at least one of the spindle and the spindle nut extends into an internal piston recess defined by the central portion, wherein the ball ramp actuator comprises two balls, each ball being located in a respective one of the upper and lower races, and when the upper and lower races rotate relative to each other, the balls move upwardly in respective ones of the upper and lower races causing the upper and lower races to move apart from each other and apply a linear force between the spindle nut and the end wall, and the ball ramp actuator further includes a spring acting on the upper raceway and the side wall to preload the ball ramp actuator, such that upon actuation of the disc brake system via rotation of the spindle, the piston is moved by the lead screw prior to being moved by the ball ramp actuator.
In an eleventh embodiment of the first aspect, the piston further comprises: a main shaft; a spindle nut; and a ball ramp actuator; wherein the spindle, spindle nut, and ball ramp actuator are each located at least partially within the interior space with the spindle nut threadedly connected with the spindle, and the ball ramp actuator is located between the end wall and the spindle nut and is configured to push against the end wall and the spindle nut during operation of the disc brake system; and at least one of the spindle and the spindle nut extending into an internal piston recess defined by the central portion, wherein the ball ramp actuator includes two balls, each ball being located in a respective one of an upper race and a lower race and moving upwardly in the respective one of the upper race and the lower race as the upper race and the lower race rotate relative to each other causing the upper race and the lower race to move apart from each other and apply a linear force between the spindle nut and the end wall, and a second ramp race extending from each respective ramp race to form a separate continuous track for each ball including one ramp race and one second ramp, and each ball moving upwardly on the respective ramp as the upper race and the lower race rotate relative to each other in a first direction, causing the upper and lower races to move apart from each other and apply a linear force between the spindle nut and the end wall, and upon rotation of the upper and lower races in a second direction, each of the balls moves up the second ramp causing the upper and lower races to move apart from each other and apply a linear force between the spindle nut and the end wall.
In a twelfth embodiment of the first aspect, the piston further comprises: a main shaft; a spindle nut; and a ball ramp actuator; wherein the spindle, spindle nut, and ball ramp actuator are each located at least partially within the interior space with the spindle nut threadedly connected with the spindle, and the ball ramp actuator is located between the end wall and the spindle nut and is configured to push against the end wall and the spindle nut during operation of the disc brake system; and at least one of the spindle and the spindle nut extending into an internal piston recess defined by the central portion, wherein the ball ramp actuator comprises two balls, each ball being located in a respective one of an upper race and a lower race and moving upwardly in a respective one of the upper race and the lower race as the upper race and the lower race rotate relative to each other, causing the upper race and the lower race to move apart from each other and apply a linear force between the spindle nut and the end wall, and each of the or each second ramp is a service braking ramp on which the balls move upwardly during operation of the brake system as a service brake and each of the other of the or each second ramp is a parking braking ramp, during operation of the brake system as a parking brake, the ball moves upward on the parking brake ramp, and the parking brake ramp includes a stepped surface along which the ball travels.
In a thirteenth embodiment of the first aspect, the piston further comprises: a main shaft; a spindle nut; and a ball ramp actuator; wherein the spindle, spindle nut, and ball ramp actuator are each located at least partially within the interior space with the spindle nut threadedly connected with the spindle, and the ball ramp actuator is located between the end wall and the spindle nut and is configured to push against the end wall and the spindle nut during operation of the disc brake system; and at least one of the spindle and the spindle nut extends into an internal piston recess defined by the central portion, wherein the ball ramp actuator includes two balls, each ball located in a respective one of an upper race and a lower race, and when the upper race and the lower race rotate relative to each other, the balls move upwardly in the respective one of the upper race and the lower race causing the upper race and the lower race to move apart from each other and apply a linear force between the spindle nut and the end wall, and the ball ramp actuator includes three balls.
In a fourteenth embodiment of the first aspect, the piston further comprises: a main shaft; a spindle nut; and a ball ramp actuator; wherein the spindle, spindle nut, and ball ramp actuator are each located at least partially within the interior space with the spindle nut threadedly connected with the spindle, and the ball ramp actuator is located between the end wall and the spindle nut and is configured to push against the end wall and the spindle nut during operation of the disc brake system; and at least one of the spindle and the spindle nut extending into an interior piston recess defined by the central portion, wherein the ball ramp actuator includes two balls, each ball being located in a respective one of an upper race and a lower race, and when the upper race and the lower race rotate relative to each other, the balls move upwardly in the respective one of the upper race and the lower race causing the upper race and the lower race to move apart from each other and apply a linear force between the spindle nut and the end wall, and the ball ramp actuator includes only two balls.
In a fifteenth embodiment of the first aspect, the piston is actuatable by means of a hydraulic force acting on the piston.
In a sixteenth embodiment of the first aspect, the piston further comprises: a main shaft; a spindle nut; and a ball ramp actuator; wherein the spindle, spindle nut, and ball ramp actuator are each located at least partially within the interior space with the spindle nut threadedly connected with the spindle, and the ball ramp actuator is located between the end wall and the spindle nut and is configured to push against the end wall and the spindle nut during operation of the disc brake system; and at least one of the spindle and the spindle nut extends into an internal piston recess defined by the central portion, and the piston is actuatable by hydraulic pressure acting on the piston.
In a second aspect, a method of applying a brake is provided. The method includes applying a linear force to an inner surface of an end wall of a piston configured for use in a disc brake system, wherein the piston includes: a body; and a footing; the body has: a sidewall surrounding an interior space within the piston; and an end wall at an end of the piston, the end wall having a central portion extending outwardly from the end wall; the footing being positioned adjacent the end wall distally of the interior space and having a recess receiving the central portion, wherein the footing is located between a portion of the end wall and a brake pad during operation of the disc brake system and the footing extends along the brake pad and is configured to apply a force to the brake pad during actuation of the disc brake system; and the footing has a surface configured to contact the brake pad, the surface having a length and a width, wherein the length is longer than the outer width of the body and the length is greater than the width, whereupon the shoulder of the end wall moves the footing against the brake pad.
In a third aspect, a method of applying a brake is provided. The method includes rotating a spindle configured for a piston used in a disc brake system, wherein the piston includes: a body; and a footing; the body has: a sidewall surrounding an interior space within the piston; and an end wall at an end of the piston, the end wall having a central portion extending outwardly from the end wall; the footing being positioned adjacent the end wall distally of the interior space and having a recess receiving the central portion, wherein the footing is located between a portion of the end wall and a brake pad during operation of the disc brake system and the footing extends along the brake pad and is configured to apply a force to the brake pad during actuation of the disc brake system; and the foot has a surface configured to contact the brake pad, the surface having a length and a width, wherein the length is longer than an outer width of the body and the length is greater than the width, wherein the piston further comprises: a main shaft; a spindle nut; and a ball ramp actuator; wherein the spindle, spindle nut, and ball ramp actuator are each located at least partially within the interior space with the spindle nut threadedly connected with the spindle, and the ball ramp actuator is located between the end wall and the spindle nut and is configured to push against the end wall and the spindle nut during operation of the disc brake system; and at least one of the spindle and the spindle nut extends into an interior piston recess defined by the central portion, wherein rotation of the spindle causes relative rotation of upper and lower races of the ball ramp and movement of a ball bearing along a ball ramp of the ball ramp actuator causing the upper and lower races to move apart, the lower ramp applying a linear force to an inner surface of the end wall of the piston, the shoulder of the end wall moving the foot against the brake pad.
Advantageous effects
Pistons and piston systems according to various embodiments of the present disclosure may be used in braking systems, such as vehicle braking systems.
Drawings
FIG. 1 illustrates one embodiment of a braking system.
FIG. 2 illustrates an exploded view of one embodiment of a brake piston.
Fig. 3 to 6 show an embodiment of a stepped brake piston.
Fig. 7 shows one embodiment of a stepped brake piston body.
FIG. 8 illustrates one embodiment of a brake piston foot.
FIG. 9 illustrates a cross-sectional view of an embodiment of the foot illustrated in FIG. 8.
Fig. 10-12 illustrate an embodiment of a ball ramp in a braking system.
Detailed Description
In the following description, numerous specific details are set forth in order to provide a thorough description of various embodiments disclosed herein. However, it will be understood by those skilled in the art that the presently claimed invention may be practiced without all of the specific details discussed below. In other instances, well-known features have not been described in order to avoid obscuring the present invention.
Fig. 1 shows an embodiment of a brake system in which a piston with a foot 5 is positioned in a caliper 6, the foot 5 being pressable against a brake pad 7, the brake pad 7 being pressable against a rotor in a rotor space 8 during a braking operation.
Fig. 2 shows an exploded view of the brake piston with foot 5, where foot 5 is separated from the piston body 12 of piston 4, and shows an optional malleable ring 14, which malleable ring 14 may be located between the piston body 12 and foot 5.
As shown in fig. 3, the body 12 of the piston 4 may include a side wall 15, the side wall 15 surrounding a piston cavity 32 (fig. 1, 5) and being closed at one end by an end wall 16. As shown in fig. 7, the end wall 16 may have a stepped shape, wherein the step 17 is formed by a central portion 18 extending from a shoulder 19.
As shown in fig. 2, the surface of the foot in contact with the back side of the brake pad 7 (or an intervening material such as a shim by which movement of the piston 4 including the foot 5 is transferred to the brake pad 7) may have a length 20 and a width 21. In various embodiments, the length 20 of the foot 5 may be longer than the width 21 of the foot 5. In some embodiments, the width 21 of the foot 5 may be longer than the width 22 of the piston body 12. The extension of the foot size (e.g. the surface area of the foot 5 is larger than the cross-sectional area of the piston 4) enables the force delivered to the brake pad 7 to be distributed over a larger area.
In some embodiments, it may be desirable to increase the strength of the foot 5 to reduce/prevent/eliminate deformation of the foot 5 during braking operations, which may result in uneven braking and brake wear. In some embodiments, the foot 5 may have a recess 23 which, in the presence of the central portion 18 extending from the end wall 16 of the piston body 12, corresponds to the central portion 18 and may receive the central portion 18. In some embodiments, the foot 5 may be configured not to contact the distal face of the central portion, but only the shoulder 19 of the end face of the piston body 12 or the shoulder 19 and the side of the central portion 18.
In various embodiments, the foot 5 may be assembled to the other portions of the piston 4 by any suitable method. In some embodiments, the foot 5 may be disposed adjacent the piston body 12. In some embodiments, the foot 5 may be slid onto the central portion 18 of the piston body 12, for example, with a friction fit. In some embodiments, the slip fit may allow removal of a subsequent foot and allow the foot to be optionally reattached to the piston body. In some embodiments, the foot 5 may be affixed by an adhesive material. In some embodiments, the foot 5 may be permanently attached. In some embodiments, the foot 5 may be integral with the piston body 12, e.g., the two parts are made integral or the two parts of material are fused (e.g., by welding) together.
In some embodiments, an intervening material may be located between the foot and the piston body. In some embodiments, the intervening material may be a malleable material such as malleable ring 14 placed between the foot 5 and the piston body 12. In some embodiments of an intervening material, such as the malleable ring 14, the intervening material may exclude or limit the intrusion of foreign material (e.g., dust, dirt, road debris, grease, water, asphalt, brake fluid, or other foreign material that may be present near the brake caliper) from entering between the foot and the piston body. In some embodiments, the intervening material may fill a gap that exists between the foot 5 and the piston body 12. In some embodiments, the intervening material may adhere to one or more of the foot 5 and the piston body 12. In some embodiments, the intervening material may be compatible with one or more of the foot 5 and the piston body 12.
In some embodiments, there may be a shield contact surface 24 on the outer surface of the side wall 15 and/or foot 5, which shield contact surface 24 may act as a shield contact surface 24 extending between the piston 4 and another portion of the brake caliper 6, wherein the shield may exclude or limit the ingress of foreign material (e.g. dust, dirt, road debris, grease, water, bitumen, brake fluid or other foreign material that may be present in the vicinity of the brake caliper 6) between the piston 4 and the brake caliper 6. In one embodiment, the shield contact surface 24 is shown in fig. 3, wherein the shield contact surface 24 is present on the outer surface of both the foot 5 and the sidewall 15. Fig. 6 shows one embodiment of a detail of the shield contact surface 24 bridging the foot 5 and the side wall 15. Also shown in fig. 3 and 6 is an optional groove 25 for interfacing with the shield to stabilize and/or improve the seal of the shield. In some embodiments, the shield contact surface 24 may be present only on the outer wall of the foot 5 or on the outer surface of the side wall 15.
In some embodiments, there may be a seal along the exterior of the side wall 15 of the piston body 12, or the seal may be located on or in the outer surface of the foot that extends into the cylinder to act as a hydraulic seal for the hydraulic piston operation. In various embodiments, the seal may be an O-ring, such as a square cut, circular or other profile O-ring, and in some embodiments, a seal such as an O-ring may be located in a groove on the outer surface of the foot or outside of the sidewall that extends into the cylinder, or may be located in a groove within the cylinder of the caliper 6 where the piston 4 is located.
In some embodiments of the piston body 12, the distal end of the central portion may include a relief edge 26 (e.g., a chamfered edge), or a relief edge having another shape, which may assist in aligning the foot with the piston body (see fig. 3 and 5). Furthermore, the foot may have a relief edge 27 at the end of the recess close to the end wall of the piston body (see fig. 4).
Bottom foot
Foot 5 may be any suitable material that provides sufficient dimensional stability and chemical resistance to the environment and conditions to which the foot will be exposed, including temperature. In some embodiments, the foot 5 may be or comprise a metal, such as a steel or iron alloy or aluminum alloy. In some embodiments, the foot may be or include a ceramic material, such as an oxide, nitride, carbide, or other sufficiently strong and durable material. In some embodiments, the foot may be or include a plastic material, such as a phenolic plastic or other sufficiently strong and durable material. In some embodiments, the foot 5 may be or comprise a carbon material, such as carbon fiber or glass, plastic, or a combination thereof. In some embodiments, the footing can be or include a composite of more than one material (e.g., one or more metal, ceramic, and/or carbon materials) and optionally a binder and/or adhesive material.
The foot may be configured and sized to reduce deflection of the foot and/or brake pad to an acceptable level, for example, a first end 55 and a second end 56 of the foot (located at respective first and second ends of the length 20 of the foot) deflect less than a particular distance relative to a midpoint 57 corresponding to a central axis 58 of the piston body 12 during operation of the brake piston. (in some embodiments, the midpoint 57 may be located within the notch 23). In some embodiments, where the braking operation includes application of a force (e.g., hydraulic, mechanical, or electromechanical, etc.) of 100 bar (force/piston body cross-sectional area) at the piston body, the deflection may be less than 0.3 millimeters, or less than 0.2 millimeters, or less than 0.1 millimeters, or less than 0.5 millimeters. In some embodiments, the deflection may be described as a percentage of the braking stroke where the braking operation includes application of a force of 100 bar (force/piston body cross-sectional area) (e.g., hydraulic, mechanical, or electromechanical, etc. application), e.g., less than 5% or 10% or 15% or 25% or 30% of the distance the brake pad moves at the piston central axis. In some embodiments, the foot may contact the brake pad backing plate 9 (or intervening material between the backing plate 9 and the foot) along the entire surface of the foot or in discrete areas of the foot (such as surface features 30, 31) to assess the amount of deflection.
In some embodiments, the footing may be configured and sized to improve the uniformity of the force applied at the brake pad-brake rotor interface, for example by increasing the thickness of the footing (or changing the section modulus of the footing) or the flexural properties (e.g., increasing the young's modulus) or by providing surface features 30, 31 on the surface of the footing to distribute the force applied to the brake pad backing plate 9. Improving the uniformity of the force applied at the brake pad-brake rotor interface may result in more uniform wear of the brake pads and may improve the noise-vibration-harshness (NVH) characteristics of the brake system. In some embodiments, the footing may be configured and sized to have surface features 30 positioned toward one or both ends of the footing to apply force to the brake pad backing plate 9 (or intervening material) proximate one or both ends of the footing. In some embodiments, the foot may be configured and sized to have surface features 31 located at one or more locations between an end of the base 28 of the foot 5 and the recess 23 of the foot 5 (or at the recess, e.g., where the recess 23 has foot material covering at least a portion of the recess). In some embodiments, one or more surface features 30 may be used with one or more surface features 31. In some embodiments, the surface features 30, 31 may be sized and positioned to simulate a dual piston caliper. In some embodiments, the surface features 30, 31 may be present on the brake pad back plate 9 (or intervening material), extend toward and contact the footing (extending from the brake pad back plate 9 and contacting the intervening material), and are shaped in the same manner as the surface features extending from the footing.
In some embodiments, the amount of deflection may also be affected by the brake pad or brake pad backing plate 9, for example by increasing the stiffness of the backing plate 9 and/or the placement of contact points (e.g., surface features 30, 31) on the surface of the foot to reduce deflection of the foot. In some embodiments, a more rigid backing plate 9 may allow for a reduction in the stiffness of the foot while achieving the same degree of force uniformity at the brake pad-brake rotor interface. In some embodiments, the arrangement of the surface features 30, 31 may be used to distribute the force transferred from the foot to the backplate 9 to achieve a higher degree of force uniformity at the brake pad-brake rotor interface.
As shown in fig. 8, the footing may have an oval (or other shaped) base portion 28, which base portion 28 may be configured to push the brake pad 7 directly or with an intervening material such as a shim. The oval shaped base portion 28 may be flat or may have surface features on the side facing the brake pad 7, such as one or more of a rim lip 29, one or more surface features 30 located towards one or both ends of the foot, and/or surface features 31 located at one or more locations between the end of the base portion 28 of the foot 5 and the notch 23 of the foot 5 (or at the notch, e.g., where the notch 23 has foot material covering at least a portion of the notch), which in some embodiments may function to distribute forces and/or control or limit deflection of the foot and/or brake pad. In some embodiments, the rim lip 29 may be present to interface with the edge of the brake pad or intervening material between the brake pad 7 and the foot 5, for example, to provide alignment and/or prevent relative rotation of the foot 5 and the brake pad 7 or intervening material. In some embodiments, the surface features may include one or more spacers 30, 31 on the foot surface to assist in distributing the force applied to the brake pad to provide more uniform brake pad wear and more repeatable braking results. In some embodiments, spacers 30 may be located at or near both ends of base 28 of foot 5. (in some embodiments, the base 28 may be oval or have rounded or square or flat ends). In some embodiments, the spacer 31 may be located at a position between the end of the base 28 of the foot 5 and the notch 23 of the foot 5 (or at a notch, e.g., where the notch 23 has foot material covering at least a portion of the notch).
As can be seen in fig. 9, the foot 5 may be made of a sufficiently thick material to provide the desired resistance to deformation which may result in uneven brake wear and lack of repeatability of braking performance. The foot 5 may have a recess 23 for receiving the central portion 18 of the piston body 12, and the foot 5 may have a thickness profile, e.g. the thickness of the foot is thicker at the area acted on by the piston body 12 (e.g. the area around the recess 23) than at the end of the oval base 28 of the foot 5.
In some embodiments, the foot 5 may have a recess 23, the recess 23 configured to receive the central portion 18 of the piston body 12, while the surface of the foot 5 is in operative communication with the end wall 16 of the piston body 12, such that the end wall 16 of the piston body 12 pushes against the surface of the foot 5 during a braking operation. In some embodiments, the end wall 16 may be in contact with the surface. In some embodiments, the end wall 16 and the surface may have an intervening material therebetween, such as a malleable ring 14. In some embodiments, the force of the braking operation is transmitted directly from the end wall 16 to the surface. In some embodiments, the force of the braking operation is transferred from the end wall 16 to the surface via an intervening material (e.g., the malleable ring 14). In some embodiments, a portion of the braking force is transmitted directly between the end wall 16 and the surface, and a portion is transmitted via an intervening material (e.g., the malleable ring 14).
In some embodiments, the stiffness of the footing may be supplemented by the stiffness of the disc pad back plate 9, with a decrease in the stiffness of the footing 5 being accompanied by an increase in the stiffness of the brake pad 7 (e.g. by increasing the stiffness of the brake pad back plate 9).
Piston body
The piston body 12 may be any suitable material that provides sufficient dimensional stability and chemical resistance to the environment and conditions (including temperature) to which the foot 5 is exposed to allow for proper movement within the cylinder of the brake caliper, proper sealing, and interfacing with the foot 5, spindle 34, spindle nut 35, and ball ramp assembly 40. The piston body 12 may be or include a metal such as a steel or iron alloy or aluminum alloy or other metal or metal alloy or other suitable material. In some embodiments, the piston body 12 may be or include a plastic material, such as a phenolic plastic. In some embodiments, the piston body 12 may be or include a ceramic material, such as an oxide, nitride, carbide, or other sufficiently strong and durable material. In some embodiments, the piston body 12 may be or include a carbon material, such as carbon fiber, or glass or other material having suitable properties. In some embodiments, the piston body 12 may be or include a composite of more than one material (e.g., one or more metal, ceramic, and/or carbon materials) and optionally a binder and/or adhesive material.
As shown in fig. 7, the piston body 12 may include a sidewall 15 and may include a central portion 18 extending from a shoulder 19 of the piston 4. In some embodiments, there may be a shield contact surface 24 located at an end of the side wall 15 or elsewhere on the side wall 15 to contact the shield to exclude dust, debris, moisture or other undesirable material from between the piston body 12 and a cylinder in the brake caliper 6 within which the piston body 12 is at least partially located.
As shown in fig. 3, the piston body 12 may be hollow, the side wall 15 surrounding the piston cavity 32, and the central portion 18 may be hollow, with the piston cavity outer extension 33 extending into the central portion 18, and the central portion being closed by the central portion closed end 36. The central portion 18 extends from a shoulder 19 of the end wall 16. An inner surface 37 of the end wall resides within the piston cavity 32.
In some embodiments of the piston body 12, the piston cavity outer extension 33 may be sized to receive a portion of the spindle 34 and/or spindle nut 35. In the embodiment shown in fig. 1, spindle 34 and spindle nut 35 are shown extending into piston chamber extension 33, however, in some embodiments, only one of spindle 34 and spindle nut 35 or both spindle 34 and spindle nut 35 may be located within piston chamber 32 and not within piston chamber extension 33 during at least some steps of operation of braking system 3.
Ball ramp
Some embodiments of the brake caliper 6 may utilize a ball ramp assembly 40 (as shown in FIG. 1). In FIG. 1, a piston 4 is shown, the piston 4 including a piston body, a ball ramp assembly 40, a thrust bearing 50, a spring 44, and a retainer ring 46. The ball ramp assembly 40 includes an upper raceway 41, a lower raceway 42, and at least two (e.g., 2, 3, 4, or more) ball bearings 43 located between the upper raceway 41 and the lower raceway 42. In some preferred embodiments, the number of ball bearings 43 may be limited to two. The use of only two balls may provide more space for each ball ramp 47, 48 (see fig. 10-12) associated with each ball, which in turn may provide a more gradual slope and smoother operation and/or allow for a reduced size torque actuation system (e.g., a smaller motor, a lower torque motor, and/or a lower torque converter (e.g., a gear box)) and/or allow for lighter components to apply or resist forces associated with the piston 4. In the assembled order, the ball ramp assembly 40, thrust bearing 50, spring 44 may be positioned within the piston cavity 32. In some embodiments, clips may be positioned in slots located within piston bore 32, retaining spring 44, upper race 41, ball bearing 43, and/or lower race 42 within piston bore 32.
As noted above, the thrust bearing 50 may comprise a ball bearing, such as in some preferred embodiments a ball bearing comprising a double row of balls. In some embodiments, the upper race 41, lead screw, thrust bearing 50 may be located within the caliper housing 53, and the spindle 34 may be at least partially located within the caliper housing 53.
In some embodiments (including but not limited to embodiments including only two ball bearings 43), the ball ramp assembly may be stabilized (laterally and/or rotationally) by the inner surface of the sidewall 15, the inner surface of the shoulder 19, and/or the spindle nut 35.
Fig. 10-12 illustrate various features of one embodiment of the ball ramp assembly 40. In this discussion, both the service brake ramp 47 and the parking brake ramp 48 are discussed. In some embodiments of the brake system disclosed herein, there may be both a service brake ramp 47 and a parking brake ramp 48. However, in some embodiments, only the service brake ramp 47 or only the parking brake ramp 48 will be present.
Fig. 10 shows an embodiment in which two ball bearings 43 are diametrically opposed to each other in an upper raceway ball path 45 and a lower raceway ball path 46. As shown in fig. 10-12, each of the upper and lower raceway ball paths 45, 46 has a home position 49, the service brake ramp 47 extends in one direction from the home position 49, and the parking brake ramp 48 extends in the opposite direction around the upper/ lower raceway 41, 42 circle. Each ball bearing 43 has a home position 49. As can be seen from fig. 11, one of the ball bearings 43 is accommodated between the upper and lower raceway ball paths 45, 46. When the brake is released, each ball bearing 43 is located at a home position 49 between the service brake ramp 47 and the parking brake ramp 48 for each of the upper and lower raceway ball paths. In the home position, the service brake ramp 47 of the upper raceway ball path 45 is located above the parking brake ramp 48 of the lower raceway ball path 46, and the parking brake ramp 48 of the upper raceway ball path 45 is located above the service brake ramp 47 of the lower raceway ball path 46. (Note that the designations of upper, lower, left, right, front, etc. used in this disclosure are for how depicted in the specific drawings, and the actual orientation of a particular feature in a component in use will depend on the orientation of the component in the vehicle or elsewhere, and may vary.)
In various embodiments, the ball ramp assembly discussed herein may be combined with a lead screw formed by spindle 34 and spindle nut 35, as shown in fig. 1, formed by lead screw threads on spindle 34 and spindle nut 35.
Actuation of the service brake may occur by rotating the upper race 41 in a first direction from the home position 49, while actuation of the parking brake may occur by rotating the upper race 41 in a second direction from the home position 49, the second direction being opposite the first direction. As can be seen from fig. 12, rotation of the upper raceway 41 in a first direction causes movement of the upper raceway ball path 45 relative to the lower raceway ball path 46, causing the trapped ball bearing 43 therebetween to interact by rolling on the service braking ramp 47 of both the upper and lower raceway ball paths 45, 46. This interaction with the service braking ramp 47 causes the lower raceway 42 to move linearly away from the upper raceway 41. As can be seen from fig. 1, this linear movement will cause the lower raceway 42 to push against the piston body 12 and move the piston body 12 and the foot 5 towards or against the brake pad 7.
As can also be seen in fig. 12, rotation of the upper raceway 41 in the second direction causes the upper raceway ball path 45 to move relative to the lower raceway ball path 46 such that the ball bearing 43 trapped therebetween interacts by rolling with the parking brake ramp 48 of the upper and lower raceway ball paths 45, 46. This interaction with the parking brake ramp 48 causes the lower race 42 to move linearly away from the upper race 41. As can be seen from fig. 1, this linear movement will cause the lower raceway 42 to push against the piston body 12 and move the piston body 12 and the foot 5 towards or against the brake pad 7.
In some embodiments, the service and/or braking ramps 47, 48 in the upper and/or lower raceway ball paths 45, 46 may include one or more slope variations to impart different resistance to movement of the ball bearings 43 along the ramp, e.g., movement along portions of the ramp having a greater slope may require more force than movement along portions of the ramp having a lesser slope. In some embodiments, the change in slope may be gradual. In some embodiments, the change in slope may occur in steps, or the change in slope may approximate a step. In some embodiments, a portion of the ramp may have a flat portion (with zero or approximately zero slope) and/or may be negative (resulting in a reduction in the force required to move along the corresponding portion of the ramp). In some embodiments, the use of a change in slope on the brake ramp may leave the position of the service or parking brake ramp in the upper raceway ball path unchanged relative to the position of the service or parking brake ramp in the lower raceway ball path and thus maintain a corresponding clamping force on the brake disc 34 while reducing or eliminating the torque applied via the main shaft.
In some preferred embodiments, the service brake ramp 47 in the upper raceway ball path 45 and the service brake ramp 47 in the lower raceway ball path 46 may have a constant slope or a continuously increasing slope for the entire length of the service brake ramp 47, while the parking brake ramp 48 in the upper raceway ball path 45 and the parking brake ramp 48 in the lower raceway ball path 46 may have a stepped form with a series of positive slope regions interrupted by flat portions. In some embodiments, when the ball bearing 43 is positioned on the flat portion of the parking brake ramp 48 of the upper raceway ball path 45, the ball bearing 43 is also positioned on the flat portion of the parking brake ramp 48 of the lower raceway ball path 46. Such a flat configuration may maintain a clamping force between the inner and outer brake pads on the disc without maintaining a torque on the spindle, and thus may prevent the parking brake from releasing itself (unless there is a counter torque applied by the spindle).
During operation of the service brake, the spindle 34 is rotated in a first direction, for example by means of a motor. Initially, the spindle 34 will move relative to the spindle nut 35, the spindle 34 and spindle nut 35 acting as a lead screw, causing the upper and lower raceways 41, 42 to move against the piston body 12 at the inner surface of the shoulder 19. Ball ramp movement is now prevented because the spring 44 acting between the upper raceway 41 and the piston body 12 or between the upper raceway 41 and the retainer ring 46 applies a preload to increase the friction force within the ball ramp actuator 40. When the piston 4 closes the gap between the piston 4 and the respective brake pad 7, the brake pad 7 will push against the piston 4, which results in an increase of the friction torque at the lead screw. When the frictional torque in the screw is sufficiently large and overcomes the preload torque provided by the spring 44, the upper raceway 41 of the ball ramp assembly 40 will move relative to the lower raceway 42 to further move the piston body 12 and further apply a braking force to the brake pad via the piston body 12, the foot 5 and the brake pad 7.
During the process of releasing the service brake, the sequence of events is essentially reversed, the spindle 34 is moved in a second direction opposite to the first direction, the ball ramp actuator 40 is moved back to the home position 49, and then the spindle 34 is moved relative to the spindle nut 35 at the lead screw due to the reduction of the force applied by the brake pad 7 to the piston 4. During rotation of the spindle (and return of the ball bearing 43 to the home position 49), the spring 44 retracts the piston 4 into the caliper housing 53. After the spindle 34 is appropriately additionally rotated, the rotation is stopped.
During operation of the parking brake, when there is only a parking brake ramp in the ball ramp assembly 40, operation of the parking brake is substantially the same as operation of the service brake discussed above.
During operation of the parking brake, with both the parking brake ramp and the service brake ramp present within the ball ramp assembly 40, the spindle first moves in a first direction, which causes the piston body 12 and the foot 5 to move in a linear direction toward the respective brake pad 7 via the lead screw. When the piston body 12 and the foot 5 contact the brake pad 7, the reaction force exerted by the brake pad 7 on the piston 4 increases. When brake pad 7 exerts a sufficient reaction force on piston 4, the preload force from spring 44 will be overcome due to the increased friction in the screw, and upper raceway 41 of ball ramp assembly 40 will begin to rotate relative to lower raceway 42 of the ball ramp assembly, with ball bearing 43 moving along the ball ramp (e.g., service brake ramp 47 or parking brake ramp 48). The piston 4 is constrained within the caliper housing 53 against rotational and/or linear movement relative to the caliper housing 53, which allows for reversal of the direction of rotation of the spindle (rotation in a second direction) and operation of the ball ramp assembly 40 in the opposite direction. Such reversal of direction may be utilized in various embodiments, including but not limited to embodiments having both a service ramp 47 and a parking ramp, wherein the utilization of either the service ramp 47 or the parking ramp 48 may be selected for braking operations. In some embodiments, the reversal of direction may allow the ball bearing 43 to move on a different ramp than when the direction is not reversed. In one embodiment, rotation of the ball ramp assembly in the opposite direction may be facilitated by placing the screw under sufficient load to limit movement (sideways or rotation) of the piston 4 within the caliper housing 53 by relaxing the torque of the screw (rotation in the second direction that will move the piston 4 away from the brake pad 7) greater than the torque that rotates the ball ramp on the parking brake ramp 48. In some embodiments, limiting the movement (laterally and/or rotationally) of the piston 4 may be accomplished by features such as including one or more solenoid and/or voice coil actuators.
During a brake release with a ball ramp engaged in reverse rotation, the sequence of events is essentially reversed, with spindle 34 moving in a first direction, causing upper raceway ball path 45 to move back to home position 49 relative to lower raceway ball path 46. At this point, the force applied by the brake pad backing plate 9 to the piston 4 and from the piston 4 to the screw via the ball ramp actuator 42 is reduced, thereby reducing friction at the screw. Spindle 34 then continues to rotate in the second direction, allowing upper race 41 to retract under the action of spring 44, retracting piston 4 into caliper housing 53 and pulling piston 4 away from brake pad backing plate 9. After the main shaft 34 is sufficiently rotated, the rotation is stopped.
In some embodiments, a full retraction stop for the piston may be provided by stopping spindle nut 35 against spindle 34 or against retaining ring 46 (as shown in fig. 1). In various embodiments, a full retraction stop may be provided within the brake piston assembly to facilitate activities (e.g., removing or installing caliper 6 into a vehicle or installing, removing or replacing one or more brake pads in the caliper housing) by retracting piston 4 into caliper housing 53. Using the full retraction stop may include a braking operation to retract the piston body 12 into the caliper housing 53 until the full retraction stop is utilized, such as by the proximal portion of the spindle nut 35 contacting the spindle 34 or retaining ring 46, or by a stop extending from the inner surface of the sidewall 15.
Having now described the invention in accordance with the requirements of the patent statutes, those skilled in the art will understand how to make changes and modifications to the invention to meet their specific requirements or conditions. Such changes and modifications can be made without departing from the scope and spirit of the present invention as disclosed herein.
The foregoing detailed description of exemplary and preferred embodiments has been presented for purposes of illustration and disclosure in accordance with the requirements of the law. It is not intended to be exhaustive or to limit the invention to the precise form described, but only to enable others skilled in the art to understand how the invention may be adapted for particular uses or implementations. The possibilities for modifications and alterations will be apparent to those skilled in the art. The description of the exemplary embodiments is not intended to be limiting, and these embodiments may include tolerances, feature sizes, specific operating conditions, engineering specifications, etc., and may vary from one embodiment to another or as the state of the art changes, and no limitation should thereby be implied. The applicant has made this disclosure in the light of the state of the art, but has also considered advancements which future adjustments may take into account (i.e. in light of the state of the art at the time). It is intended that the scope of the invention be defined by the written claims and the applicable equivalents. Reference to claim elements in the singular does not mean "one and only one" unless explicitly so stated. Furthermore, no element, component, method, or process step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or step is explicitly recited in the claims. The use of terms such as "substantially," "somewhat," "about," "approximately," and other terms of degree that appear in this disclosure are intended to be interpreted as those skilled in the art would understand these words from the context and further understand that a 20% tolerance should apply if the context provides insufficient guidance.

Claims (20)

1. A piston configured for use in a disc brake system, the piston comprising:
a body; and
footing;
the body has:
a sidewall surrounding an interior space within the piston; and
an end wall at an end of the piston, the end wall having a central portion extending outwardly from the end wall;
the foot is positioned adjacent the end wall distal of the interior space and has a recess receiving the central portion,
wherein, during operation of the disc brake system, the footing is located between a portion of the end wall and a brake pad, and the footing extends along the brake pad and is configured to apply a force to the brake pad during actuation of the disc brake system; and is
The foot has a surface configured to contact the brake pad, the surface having a length and a width, wherein the length is longer than an outer width of the body and the length is greater than the width, and/or the surface has a cross-sectional area orthogonal to a direction of travel of the piston that is greater than a cross-sectional area of a piston body orthogonal to the direction of travel of the piston.
2. The piston of claim 1, wherein the width is wider than a width of the body.
3. The piston of claim 1, further comprising:
a main shaft;
a spindle nut; and
a ball ramp actuator;
the spindle, spindle nut, and ball ramp actuator are each located at least partially within the interior space with the spindle nut threadedly connected with the spindle, and the ball ramp actuator is located between the end wall and the spindle nut and is configured to push against the end wall and the spindle nut during operation of the disc brake system; and is
At least one of the spindle and the spindle nut extends into an interior piston recess defined by the central portion.
4. The piston of claim 1, wherein the foot distributes braking force from the piston over a brake pad area that is larger than a cross-sectional area of the piston.
5. The piston of claim 1, wherein the foot has: first and second ends located at respective first and second ends of the length; and a midpoint corresponding to a central axis of the piston body, and a deflection of the first end and the second end relative to the midpoint during operation of the piston against a flat surface at a pressure of 100 bar is less than 0.3 millimeters.
6. The piston of claim 5, wherein the deflection of the first and second ends relative to the midpoint is less than 0.1 millimeters.
7. The piston of claim 1, further comprising a ring that forms a seal against debris between the foot and the body.
8. The piston of claim 1, wherein the foot presses onto the body.
9. The piston of claim 1, wherein the foot is glued to the body.
10. The piston of claim 1, wherein the foot is integral with the body.
11. The piston of claim 3, wherein said ball ramp actuator includes two balls, each ball being located in a respective one of an upper and lower race, and when said upper and lower races rotate relative to each other, said balls move upwardly in said respective one of said upper and lower races causing said upper and lower races to move apart from each other and apply a linear force between said spindle nut and said end wall.
12. The piston of claim 11, wherein the ball ramp actuator further includes a spring acting on the upper raceway and the side wall to preload the ball ramp actuator such that, upon actuation of the disc brake system via rotation of the spindle, the piston moves with a lead screw prior to movement with the ball ramp actuator.
13. The piston of claim 11, wherein a second ramp raceway extends from each respective ramp raceway to form a separate continuous track including one ramp raceway and one second ramp for each ball, and upon relative rotation of the upper and lower raceways in a first direction, each ball moves upwardly on the respective ramp causing the upper and lower raceways to move apart from each other and apply a linear force between the spindle nut and the end wall, and upon rotation of the upper and lower raceways in a second direction, each ball moves upwardly on the second ramp causing the upper and lower raceways to move apart from each other and apply a linear force between the spindle nut and the end wall.
14. The piston of claim 13, wherein each of the raceway ramps or each of the second ramps is a service brake ramp on which the balls move upward during operation of the brake system as a service brake and each of the other of the raceway ramps and the second ramps is a parking brake ramp on which the balls move upward during operation of the brake system as a parking brake and which includes a stepped surface along which the balls travel.
15. The piston of claim 11, wherein the ball ramp actuator includes three balls.
16. The piston of claim 11, wherein the ball ramp actuator includes only two balls.
17. The piston of claim 1, wherein the piston is actuatable by hydraulic pressure acting on the piston.
18. The piston of claim 3, wherein the piston is actuatable by hydraulic pressure acting on the piston.
19. A method of applying braking, the method comprising applying a linear force to an inner surface of the end wall of the piston of claim 1, whereupon a shoulder of the end wall moves the foot against the brake pad.
20. A method of applying a brake, the method comprising rotating the spindle of the piston of claim 3, wherein rotation of the spindle causes relative rotation of upper and lower races of the ball ramp and movement of a ball bearing along a ball ramp of the ball ramp actuator, thereby causing the upper and lower races to move apart, the lower ramp applying a linear force to an inner surface of the end wall of the piston, the shoulder of the end wall moving the foot against the brake pad.
CN201980075308.3A 2018-11-15 2019-11-14 Stepped piston with oversized foot for disc brake Active CN113039373B (en)

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US201862768035P 2018-11-15 2018-11-15
US62/768,035 2018-11-15
PCT/KR2019/015578 WO2020101404A1 (en) 2018-11-15 2019-11-14 Stepped piston for disk brake with oversized footing

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CN201980075308.3A Active CN113039373B (en) 2018-11-15 2019-11-14 Stepped piston with oversized foot for disc brake
CN201980075447.6A Active CN113039115B (en) 2018-11-15 2019-11-14 Apparatus and method for calculating absolute angular position for controlling steering system of vehicle
CN201980075338.4A Active CN113039374B (en) 2018-11-15 2019-11-15 Brake system having spindle/nut assembly providing soft braking
CN201980075328.0A Active CN113056403B (en) 2018-11-15 2019-11-15 Electromechanical actuator kit for actuating a brake assembly
CN201980075786.4A Pending CN113056860A (en) 2018-11-15 2019-11-15 Variable motor lamination

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CN201980075338.4A Active CN113039374B (en) 2018-11-15 2019-11-15 Brake system having spindle/nut assembly providing soft braking
CN201980075328.0A Active CN113056403B (en) 2018-11-15 2019-11-15 Electromechanical actuator kit for actuating a brake assembly
CN201980075786.4A Pending CN113056860A (en) 2018-11-15 2019-11-15 Variable motor lamination

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CN113056403A (en) 2021-06-29
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DE112019005763T5 (en) 2021-08-05
CN113039115A (en) 2021-06-25
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KR20210077002A (en) 2021-06-24
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DE112019005759T5 (en) 2021-08-19
DE112019005764T5 (en) 2021-07-29
KR20210077001A (en) 2021-06-24
CN113056860A (en) 2021-06-29
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CN113039374A (en) 2021-06-25
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KR20210076991A (en) 2021-06-24
CN113039374B (en) 2023-04-11

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