DE102019128440B4 - Brake caliper, disc brake and a method of manufacturing the brake caliper - Google Patents

Abstract

Brake caliper (4) of a disc brake (1) made of a cast material comprising an application segment (6) as a cavity for arranging an application device (20) and comprising a first bearing segment (5) as a cavity for arranging a fixed bearing (3) and/or floating bearing, with a Partition (25) between the clamping segment (6) and the bearing segment (5) is made of cast material and has an opening (30), characterized in that the walls of the bearing segment (5) and/or the clamping segment (6) have an anti-corrosion layer have, with a layer thickness of 200-1000 µm in all areas of the bearing segment (5) and/or clamping segment (6), in particular also in the area of undercuts (19) and/or projections (119).

Description

The present invention relates to a brake caliper according to the preamble of claim 1, as well as a disc brake and a method for producing a brake caliper.

A generic example is from WO 2016/034377 A1 known. It includes a brake caliper made from a cast material and a cavity for accommodating an application device. Two further cavities for arranging a fixed bearing and a loose bearing are arranged to the side of this brake caliper. With regard to the structural design variants of a brake caliper, reference is also made to this publication within the scope of the present invention.

Other relevant documents in the context of the present invention are those DE 31 21 893 A1 , the U.S. 5,540,311A , the DE 10 2010 009 262 A1 , the DE 10 2009 058 604 A1 , DE 20 2009 003 262 U1 and the DE 197 55 061 A1 .

The DE 20 2009 003 262 U1 discloses a brake caliper of a disc brake, which has a cylindrical fixed bearing, the fixed bearing having a ventilation hole for pressure equalization at the end, ie not on the lateral surface but on the so-called base surface or in the cover of the fixed bearing. The ventilation hole is provided as a bore or, in the case of the cover, is worked into a sheet metal wall.

In the solution of DE 20 2009 003 262 U1 It is primarily about solving a ventilation problem in the fixed bearing.

Due to the increased temperature development within a brake, condensation water can settle on the inner walls of the brake caliper. This can lead to signs of corrosion over many years of use. It therefore makes sense to also apply a corrosion layer to the inner walls of a brake caliper in addition to the outer walls.

However, when coating the inside of brake caliper walls, it has been shown that the coating cannot be applied continuously with a uniform coating thickness and that some wall sections may even remain uncoated due to the formation of bubbles, for example in dipping processes. This applies in particular to the areas of projections and undercuts within the brake caliper. The one in the DE 20 2009 003 262 U1 The solution presented does not address this issue.

Proceeding from the aforementioned prior art, the object of the present invention is now to provide a brake caliper, a disc brake and a method for producing a brake caliper which, on the one hand, reliably solves the aforementioned ventilation problem, but at the same time offers a possibility for more optimal coating of the inner wall of a brake caliper.

The present invention solves the problem with a brake caliper having the features of claim 1.

The brake caliper of a disk brake according to the invention consists of a cast material, in particular a cast metal. It includes an application segment as a cavity for arranging an application device.
The caliper also includes a first bearing segment as a cavity for arranging a fixed bearing and/or a floating bearing. The bearing segment is preferably provided for the fixed bearing.

The brake caliper has a partition between the application segment and the bearing segment. This is formed from the cast material. An opening is provided in the partition.

On the one hand, this advantageously enables pressure equalization and it also enables coating liquid and other media, e.g. for reworking the brake caliper, to be better distributed in the interior of the brake caliper and then also to be able to drain off optimally.

In contrast to DE 20 2009 003 262 U1 no pressure equalization is attempted between the fixed bearing and the environment. This would necessitate an additional filter element in the ventilation opening to prevent dirt and possibly also humidity from entering the bearing segment of the fixed bearing.

The present invention follows a different constructive path here, which surprisingly results in additional advantages, e.g. in the production or when applying the inner coating.

Advantageous configurations of the invention are the subject matter of the dependent claims.

The bearing segment can be essentially cylindrical and have a uniform cross-section over at least 30% of its length. Cross-section-enlarging depressions or cross-section-reducing projections are only provided over a small part of the length, preferably over less than 20% of the length.

The opening has a mean cross-sectional area that is smaller, preferably at least twice as small, as the cross-sectional area of the uniform cross-section of the bearing segment. In the case of rounded edges, it is clear that the cross-section expands from the center outwards. The mean cross-sectional area therefore corresponds to the mean value of the cross-sections over the length of the opening in its longitudinal extension perpendicular to the partition.

The small opening size prevents extensive material exchange of high-viscosity liquids such as lubricants, but at the same time enables exchange of low-viscosity liquids such as coating liquids or machining liquids and also enables pressure equalization.

The caliper can have at least one projection and/or an undercut. The brake caliper can also have an application device comprising at least one pressure piece acting on a brake pad and a bridge connected to the pressure piece, the aforementioned projection being provided for guiding the bridge.

The projection can form an undercut with the wall, in particular the aforementioned partition, of the brake caliper, with the opening being arranged within this undercut. This prevents an air bubble from forming in the area of the undercut.

The opening can preferably have a length of 8 to 18 mm.

To avoid mechanical damage, e.g. to the material of the bellows, the opening can have rounded edge areas, preferably with a rounding radius of 1 to 7.

The brake caliper can also have a second bearing segment, the first bearing segment being part of a fixed bearing and the second bearing segment being part of a floating bearing and the application segment being arranged between the bearing segments. Such an arrangement is used in a variety of known brakes, for example in the WO 2016/034377 A1 used and has proven to be particularly advantageous.

In a special embodiment of the invention, the second bearing segment has no opening to the application segment, so that the movable bearing is spatially separated from the application segment.

The walls of the bearing segment and/or the clamping segment, preferably the walls in both segments, have an anti-corrosion layer. According to the invention, this has a layer thickness of 200-1000 μm in all areas of the bearing segment and/or application segment, in particular also in the area of the undercuts and/or projections. Coating-free areas within the segments are not intended.

The fixed bearing can preferably and in a manner known per se be designed as a slide bearing of the brake caliper, in which a bearing bush is guided in a guide sleeve that is fixedly connected to the brake caliper so that it can move in particular axially to the axis of rotation of the brake disc. This enables an axial displacement of the brake caliper, based on the brake disc, relative to the stationary brake carrier.

The bearing bush can be connected, in particular screwed, to the brake carrier via a fixing means with a head, in particular via a screw.

Also according to the invention is a disc brake comprising a brake disc and the aforementioned brake caliper according to the invention, the brake caliper having, in a manner known per se, a brake caliper back which extends radially over the brake disc in some areas, and the aforementioned bearing segment and the application segment, in relation to the axis of rotation of the brake disc, at least is arranged in some areas next to the brake disc.

The brake caliper comprises a brake caliper back with an opening for mounting and/or removing brake pads, the opening being spanned by a securing bracket for securing the position of the brake pads.

1. a) Bereitstellen einer Gießform zur Begrenzung der Außenwandung des Bremssattels;
2. b) Bereitstellen eines Gusskerns zur Ausbildung von Hohlräumen innerhalb des Bremssattels, wobei ein erster Gusskernabschnitt zur Ausbildung des Lagersegments im Wesentlichen zylindrisch ausgebildet ist und wobei ein zweiter Gusskernabschnitt zur Ausbildung des Zuspannsegments vorgesehen ist;
3. c) Einleiten von Metall unter Ausbildung eines Gießlings; und
4. d) Abkühlung des Gießlings und vorzugsweise Nachbearbeitung des Gießlings.

Also according to the invention is a method for producing a brake caliper according to the invention, the method comprising the following steps:

1. a) providing a mold for delimiting the outer wall of the brake caliper;
2. b) providing a casting core for forming cavities within the brake caliper, a first casting core section for forming the bearing segment being essentially cylindrical and a second casting core section being provided for forming the application segment;
3. c) introducing metal to form a casting; and
4. d) cooling of the casting and preferably post-processing of the casting.

According to the invention, the casting core mentioned in step b) has a bridge between the first casting core section and the second casting core section, which extends from the lateral surface and not from the base surface of the first casting core section.

In addition, after step c) or d), mechanical post-processing can take place.

Furthermore, the outer and inner surfaces of the casting can be coated with an anti-corrosion layer.

The coating can take place in particular as a dip coating, in particular as a galvanic deposition.

• 1 Teilausschnitt einer ersten perspektivischen Schnittansicht einer erfindungsgemäßen Scheibenbremse;
• 2 Teilausschnitt einer zweiten Schnittansicht einer erfindungsgemäßen Scheibenbremse;
• 3 Perspektivansicht auf einen Gusskern zur Herstellung eines erfindungsgemäßen Bremssattels;
• 4 Seitenansicht auf einen Gusskern zur Herstellung eines erfindungsgemäßen Bremssattels;
• 5 erste perspektivische Schnittansicht auf einen Teilbereich eines erfindungsgemäßen Bremssattels;
• 6 zweite Schnittansicht auf den Teilbereich der 5; und
• 7 Schnittansicht des erfindungsgemäßen Bremssattels.

The invention is explained in more detail below using an exemplary embodiment for a disc brake with a displaceable brake caliper with the aid of the accompanying figures. Show it:

• 1 Partial detail of a first perspective sectional view of a disc brake according to the invention;
• 2 Partial detail of a second sectional view of a disc brake according to the invention;
• 3 Perspective view of a casting core for producing a brake caliper according to the invention;
• 4 Side view of a casting core for producing a brake caliper according to the invention;
• 5 first perspective sectional view of a portion of a brake caliper according to the invention;
• 6 second sectional view of the portion of 5 ; and
• 7 Sectional view of the brake caliper according to the invention.

In the following description of the figures, terms such as top, bottom, left, right, front, rear, etc. refer exclusively to the exemplary representation and position of the brake disc, the brake caliper, the support horns, the brake pads, the locking element and the like selected in the respective figures. These terms are not to be understood as limiting, so these references can change due to different working positions or the mirror-symmetrical design or the like. In the 1 and 2 an embodiment variant of a disc brake 1 according to the invention of a motor vehicle, in particular a commercial vehicle, is shown.

A generic disc brake is, inter alia, in the WO 2016/034377 A1 presented. In the 1 and 2 The disc brake 1 shown in the present invention has a brake caliper 4 that engages over a brake disc, and a brake carrier 2 that can be fixed in place on the vehicle side and has carrier horns arranged on the inlet and outlet sides. At least one brake pad is arranged in the brake carrier 2, preferably in brake pad shafts provided for this purpose, but mostly two brake pads with respective pad carrier plates and friction linings attached thereto are arranged inside the brake carrier for contact with the brake disc on both sides.

There is preferably a direct connection between the brake caliper 4 and the brake carrier 2 via a fixed bearing 3. Only one fixed bearing 3 can be provided as the only direct connection between the aforementioned components. The fixed bearing 3 is preferably designed as a plain bearing of the brake caliper 4, in which a bearing bushing 13 is guided, in particular movable axially to the axis of rotation of the brake disc 200, in a guide sleeve 11 that is firmly connected to the brake caliper 4, so that an axial displacement of the brake caliper 4, based on the brake disc 200, relative to the stationary brake carrier 3 is possible. The bearing bushing 13 is connected, in particular screwed, to the brake carrier 3 via a fixing means with a head, in particular a screw 12 . In the direction of the brake lining 5 on the action side, the guide sleeve 11 is shielded from the inside of the disc brake by bellows 15 . The bellows 15 is attached to the bearing bushing 13 at one end and to the brake caliper 4 at a remote end. A cover 14 prevents dirt from entering the bore of the bearing bush 13 in which the bearing pin 12 rests. When screwed into the brake carrier 3, a screw head 17 of the screw 12 presses against a step 16 in the bore of the bearing bushing 13.

The fixed bearing 3 essentially assumes the function of a main guide for the brake caliper 4 to ensure smooth displacement when the brake is actuated and to adjust for wear. Such a plain bearing designed as a fixed bearing 3 is, as in FIG 1 and 2 shown, provided between the brake caliper 4 and the brake carrier 3, whereby the brake caliper 4 can be displaced axially to the axis of rotation A of the brake disc 200 relative to the brake carrier ger 3 out and about an axis of rotation A of the brake disc 200 parallel axis of rotation is pivotable. The fixed bearing has a fixed bearing axis B.

In an optional further embodiment variant, the brake can have a further direct connection between the brake caliper 4 and the brake carrier 2 by means of a further sliding bearing of the brake caliper 4, referred to as a loose bearing. In this, a bearing bushing is also movably guided axially to the axis of rotation of the brake disc 200 in an oval-shaped sliding sleeve, which serves in particular to compensate for manufacturing tolerances. For the further connection of the brake caliper 4 to the brake carrier 2, locking means can be provided. With these locking means, the brake caliper 4 is coupled to at least one of the brake pads 50 , which in turn is coupled to the brake carrier 2 .

A first cavity section provided for accommodating the fixed bearing 3 or optionally a floating bearing in a brake caliper 4 is referred to below as the bearing segment 5 .

Furthermore, the brake caliper 4 has a second cavity section in which, in particular, an application device 20 of the brake is arranged. This second cavity section is therefore referred to below as the clamping segment 6 .

In the second cavity, in particular, one or more pressure pieces 7 for actuating a brake pad to overcome the clearance between the brake pad 50 and a brake disc 200 can be arranged. The configuration of the pressure pieces and the mechanical parts connected therewith can be different. For example, the respective pressure piece 7 can be connected to an adjustment device and it can each have a bellows 18 . Furthermore, a compression spring 9, a bridge 10 and/or a brake lever (not shown) can be arranged within the application segment 6.

The caliper 4 has several openings. First of all, the brake caliper 4 has a lower first opening 100 with which a brake disc 200 can be guided into the brake caliper in certain areas. Radially spaced from the brake disc 200 is analogous to the variants of 1 and 8th the WO 2016/034377 A1 arranged the back of the caliper, which engages over the brake disc 200. A second opening can be arranged in the back of the brake caliper, through which the brake pads can be inserted into or removed from the brake. A safety bracket spans this second opening and secures the position of the brake pads.

The clamping segment 6 is arranged at least in regions adjacent to the braking surface of the brake disk, so that it is spaced apart from the axis of rotation of the brake disk in the axial direction. At this point, at least one or more third openings 104 can be provided, via which mechanical elements of the application direction, such as the pressure pieces 7 or the compression spring 9, can act on the brake pads. At the same time, this third opening 104 can be designed as an assembly opening in order to position individual components of the application device individually or possibly also as a structural unit within the application segment 6 of the brake caliper 4 .

Finally, the brake caliper 4 also has a fourth opening, not shown, through which the brake lever and/or another actuating element acting on the brake lever, such as a plunger of a brake cylinder, can be inserted into the brake caliper 4 and can act on the application device 20.

The brake cylinder also has a fifth opening 106, which is arranged at the end of the bearing segment 5 and via which the fixed bearing 3 is connected to the brake carrier 2 and can also be replaced if necessary. Furthermore, the brake cylinder has an opening 107 at the second end, which is closed by the cover 14 and protects the bearing segment 5 and the components of the fixed or floating bearing arranged therein from dirt.

The brake caliper 4 is formed from a cast metal. The bearing segment 5 is preferably of cylindrical design. It may have an annular indentation 23 along the cylindrical wall.

The clamping segment 6 can preferably be pot-shaped with the third opening 104 as the pot rim and the fourth opening (not shown) along the bottom of the pot. The inner wall of the application segment 6 can have rounded portions 117 and possibly one or more undercuts 19 or one or more projections 119 protruding into the application segment 6, which in 1 serves as a bridge guide 8.

The wall between the bearing segment 5 and the clamping segment 6 is also referred to as a partition wall 25 within the scope of the present invention. The partition wall 25 and the projection 119 form an undercut 19 within the clamping segment 6 .

Typically, the bearing segment 5 and the application segment 6 of the brake is closed against dirt, so that the third, Fourth and fifth opening 104-106 no dust or the like can get to the components of the fixed bearing 3, the floating bearing or the clamping device 20.

The brake caliper 4 is cast in a manufacturing method that is also according to the invention.

The brake caliper 4 according to the invention has an anti-corrosion layer on the external points, which come into contact with dust but also increasingly with liquid or atmospheric moisture.

However, it has been shown that the inner wall, here in particular the wall of the application segment 6 and the bearing segment 5, should also be protected from corrosive damage. Temperature changes in these areas can lead to the accumulation of condensation water, which means that the surface of the inner wall is also exposed to corrosive influences.

In a large number of coating processes, in particular in dip coating, air bubbles or cavities are formed which remain free of coating liquid. The coating can in particular be in the form of a galvanic coating. It has been shown that a uniform coating forms if the brake caliper has a further opening 30 which is arranged between the application segment 6 and the bearing segment 5 and which connects the two cavities when the openings 104 and 106 are in the closed state.

This opening 30 is like in particular 5 and 6 can see, provided in the partition 25 and has several functions. On the one hand, it serves to drain off coating liquid, in particular electroplating liquid, after coating has taken place. The cavities are optimally wetted, in particular flooded, with coating liquid during the coating process. This prevents both the risk of pool formation and the formation of bubbles.

Optionally or additionally, other processing fluids such as drilling emulsion or lubricant can also be optimally drained. Furthermore, blasting media for processing the respective segments 5 and/or 6 are diverted.

Furthermore, through the opening 30, a compensating volume can be provided for one or more of the bellows 15 and 18, which inflate due to increased temperature within the respective bearing and application segment 5 and/or 6 and can be damaged as a result. The opening 30 thus serves as an alternative for one or more bellows, which increases the overall durability of the brake.

Through the opening 30, the fixed bearing, which is medium-tight and closed in the operating state, can also be provided with a possibility of pressure equalization.

The opening 30 has rounded edge areas 21 to avoid mechanical damage.

A one-piece casting core 125 can be used for production through the additional opening 30 , a first casting core section 130 for forming the bearing segment 5 being connected to a second casting core section 131 for forming the application segment 6 via a bridge 132 . The mean cross section is preferably at least twice smaller than the mean cross section of the first casting core section 130. This in 3 and 4 shown.

The casting core 125 has 3 and 4 a core connector 133 or a sprue piece. This is only optional and can possibly be omitted due to the bridge 132.

A particularly outstanding advantage results from the combination of the one-piece cast core and the manufacturing process of the brake caliper as a result of a metal casting process. Due to the one-piece construction of the cast core, the core can be positioned particularly precisely.

Reference List

1

disc brake

2

brake carrier

3

fixed bearing

4

caliper

5

storage segment

6

clamping segment

7

Pressure piece

8th

bridge tour

9

compression spring

10

Bridge

11

guide sleeve

12

screw

13

bearing bush

14

cover

15

bellows

16

Step

17

screw head

18

bellows

19

undercut

20

clamping device

21

edge area

23

Annular indentation

25

partition wall

30

opening

50

brake pad

100

first opening

104

third opening (mounting opening)

106

fifth opening (bearing segment)

107

opening (bearing segment)

117

roundings

119

head Start

125

cast core

130

first casting core section

131

second casting core section

132

Bridge

133

core connector

140

Second bearing segment (loose bearing

200

brake disc

A

axis of rotation

B

fixed bearing axis

Claims (17)

Brake caliper (4) of a disc brake (1) made of a cast material comprising an application segment (6) as a cavity for arranging an application device (20) and comprising a first bearing segment (5) as a cavity for arranging a fixed bearing (3) and/or floating bearing, with a Partition (25) between the clamping segment (6) and the bearing segment (5) is made of cast material and has an opening (30), characterized in that the walls of the bearing segment (5) and/or the clamping segment (6) have an anti-corrosion layer have, with a layer thickness of 200-1000 µm in all areas of the bearing segment (5) and/or clamping segment (6), in particular also in the area of undercuts (19) and/or projections (119). caliper after claim 1 , characterized in that the bearing segment (5) is essentially cylindrical and has a uniform cross section over at least 30% of its length, the opening (30) having a mean cross-sectional area which is smaller, preferably at least half as large, as the cross-sectional area the uniform cross-section of the bearing segment (5). caliper after claim 1 or 2 , characterized in that the brake caliper (4) has at least one projection (119) and/or an undercut (19). Brake caliper according to one of the preceding claims, characterized in that the brake caliper (4) has the clamping device (20), comprising at least one pressure piece (7) acting on a brake lining (50) and a bridge (10) connected to the pressure piece (7). , wherein the aforesaid projection (119) is designed as a bridge guide (8) for guiding the bridge (10). Brake caliper according to one of the preceding claims, characterized in that the projection (119) forms the undercut (19) with the partition (25) of the brake caliper (4), the opening (30) being arranged inside this undercut (19). Brake caliper according to one of the preceding claims, characterized in that the opening (30) has a length of 8 to 15 mm. Brake caliper according to one of the preceding claims, characterized in that the opening (30) has rounded edge areas, preferably with a rounding radius of 1 to 6. Brake caliper according to one of the preceding claims, characterized in that the brake caliper (4) has a second bearing segment (140), the first bearing segment (5) being part of a fixed bearing (3) and the second bearing segment (140) being part of a floating bearing and wherein the clamping segment (6) is arranged between the bearing segments (5, 140). caliper after claim 8 , characterized in that the second bearing segment (140) has no opening (30) to the application segment (6). Brake caliper according to one of the preceding claims, characterized in that the fixed bearing (3) is designed as a sliding bearing of the brake caliper (4), in which a bearing bush (13) is movable, in particular axially to the axis of rotation of the brake disc (200), in a fixed position with the caliper (4) associated guide sleeve (11) is led to the axial displacement of the brake caliper (4), based on the brake disc (200), relative to the stationary brake carrier (3). Brake caliper according to one of the preceding claims, characterized in that the bearing bush (13) is connected, in particular screwed, to the brake carrier (2) via a fixing means with a head, in particular a screw (12). Disc brake (1) comprising a brake disc (200) and a brake caliper (4) according to one of the preceding claims, characterized in that the brake caliper (4) has a brake caliper back (101) which in some areas extends radially above the brake disc (200) and the bearing segment (5) and the application segment (6) being arranged at least in regions next to the brake disc (200) in relation to the axis of rotation (A) of the brake disc (200). disc brake after claim 12 , characterized in that the brake caliper (1) has a brake caliper back with an opening for installing and/or removing brake pads (50), the opening having a securing bracket for securing the position of the brake pads (50). Method for producing a brake caliper (4) according to one of the preceding claims, the method comprising the following steps: a) providing a casting mold for delimiting the outer wall of the brake caliper (4) b) providing a casting core (125) for forming cavities within the Brake caliper (4), wherein a first cast core section (130) for forming the bearing segment (5) is essentially cylindrical and wherein a second cast core section (131) is provided for forming the application segment (6); c) introducing metal to form a casting; and d) cooling of the casting and preferably post-processing of the casting to form the brake caliper (4), characterized in that the casting core (125) has a bridge (132) between the first casting core section (130) and the second casting core section (131), which consists of the lateral surface of the first casting core section (130) protrudes. procedure after Claim 14 , characterized in that after step c) or d) a mechanical post-processing takes place procedure after Claim 14 or 15 , characterized in that the outer and inner surfaces of the brake caliper (4) are coated with an anti-corrosion layer Method according to any of the preceding Claims 14 - 16 , characterized in that the coating takes place as a dip coating, in particular as a galvanic deposition.

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