DE202017104627U1 - Damped brake components - Google Patents

Abstract

A brake component comprising: a body; and at least one sheathed cable positioned within the body and including a plurality of cables, each of the plurality of cables having a surface in sliding contact with at least one adjacent wire of the plurality of wires, wherein, during the braking of the motor vehicle, the relative sliding movement attenuates a resonant vibration of the component between the surfaces of the plurality of wires.

Description

Technical area

The present disclosure generally relates to vehicle braking components with increased damping capacity. In particular, the present disclosure relates to brake components with cables positioned within the components.

General state of the art

Automotive disc brake systems generally utilize a disc brake rotor on each respective wheel. For example, each rotor generally includes two oppositely directed annular friction surfaces which, during operation of the brakes, are engaged by two blocks of friction material (eg, brake pads) contacting each other the two friction surfaces are moved, are engaged, so that frictional forces occur and slow down the rotation of the rotor and thus the wheel of the vehicle.

Under low brake pressures (i.e., used to control the speed of the vehicle), brake pads can only partially contact the rotor surfaces, resulting in unstable friction forces between the rotor and the brake pads. This unstable behavior of the rotor / lining friction pairing can produce high dynamic contact forces, which can, for example, stimulate a strong vibration of the brake pads. Since conventional brake rotors (which are generally formed of gray cast iron) have multiple resonant frequencies in the audible frequency range, the vibration of the brake pads can in turn excite resonant vibration in the brake rotor, producing an unpleasant squeaking noise during operation of the brakes.

In order to prevent the occurrence of creaking noise, brake components such as, for example, brake pads and rotors may be configured with dampers to reduce the vibration of the brake pad and suppress the rotor resonance vibration. For example, conventional damped pads and rotors may include dampers that utilize friction damping (eg, Coulomb damping) from the contact pressure between two surfaces that have movement of the entire body relative to each other (i.e., complete slippage may develop between the surfaces). Such dampers may include, for example, solid inserts and damper rings which provide contact pressure between an area of the insert / ring and a surface of the pad / rotor or a filler within the pad / rotor.

Although such damped rotor / pad designs include slight vibration suppression, the damper efficiency of such embodiments varies with brake temperature. The full slip condition between the sliding surfaces of such components changes with the brake temperature, which may, for example, result in a change in contact pressure between the surfaces and a consequent change in damper efficiency (i.e., a reduction in damper efficiency). Since the operating temperature range for a conventional brake component is very extensive (eg, from about -40 ° C after one night in a cold climate to about 500 ° C during emergency braking from a high speed or during continual use of the brakes during a ride in a mountainous area), the frictional damping efficiency of such designs is also highly variable and can not prevent squeaking noise during certain temperature conditions.

For this reason, it may be advantageous to provide a brake component (eg, a brake rotor and / or a brake pad) with improved damping capability that continuously prevents creaking noise during braking. It may also be advantageous to provide a brake component having a fixed damper efficiency that is unaffected by changes in brake temperature.

SUMMARY

According to various exemplary embodiments, a brake component for a motor vehicle may include a body and at least one sheathed cable positioned within the body. The at least one sheathed cable may include a plurality of wires, wherein each of the plurality of wires has a surface in sliding contact with an area of at least one adjacent wire of the plurality of wires. During braking of the motor vehicle, the relative sliding movement between the surfaces of the Variety of wires attenuate a resonant vibration of the components.

According to various additional exemplary embodiments, a brake rotor may include a cheek section and at least one sheathed cable positioned within the cheek section. The at least one sheathed cable may include a plurality of wires, each of the plurality of wires having a surface in sliding contact with at least one surface of an adjacent one of the plurality of wires. During braking of the motor vehicle, the sliding movement between the surfaces of the plurality of wires can dampen a resonant vibration of the components.

According to various other exemplary embodiments, a method of manufacturing a brake component may include encapsulating a cable within a shell. The cable may include a plurality of wires in sliding contact with each other. The method may further include positioning the sheathed cable within the brake component. The sheathed cable may be positioned within the brake component such that the sheathed cable during braking of the motor vehicle is configured to dampen resonant vibration of the braking component via friction generated by sliding movement between the plurality of wires.

Additional objects and advantages of the disclosure will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the disclosure. The objects and advantages of the disclosure will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.

It should be understood that both the foregoing general description and the following detailed description are merely exemplary and explanatory and are not intended to limit the disclosure of the claims.

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and, together with the description, serve to explain the principles of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

At least some features and advantages will become apparent from the following detailed description of the embodiments consistent therewith, which description should be considered with reference to the accompanying drawings, in which:

1 FIG. 10 is a perspective view of an exemplary embodiment of a damped brake rotor according to the present disclosure; FIG.

2 is a plan view of the brake rotor 1 with a remote section to show a cable tray;

3 is a plan view of the cable insert of the brake rotor 1 ;

4 is a side view of the brake rotor off 1 ;

5 is a cross-sectional view of the brake rotor 1 along the line 5-5 off 4 ;

6 is an enlarged, partial cross-sectional view of the brake rotor 1 ;

7 shows a detailed view of a cable of the cable insert of the brake rotor 1 ;

8th FIG. 12 is a perspective view of an exemplary embodiment of a mold according to the present disclosure for casting the brake rotor. FIG 1 ;

9 FIG. 10 is a plan view of another exemplary embodiment of a damped brake rotor according to the present disclosure having a removed portion to show a cable insert; FIG.

10 is a plan view of the cable insert of the brake rotor 9 ;

11 FIG. 10 is a top view of another exemplary embodiment of a damped brake rotor according to the present disclosure having a removed portion to show a cable insert; FIG.

12 is a plan view of the cable insert of the brake rotor 11 ;

13 FIG. 10 is a top view of another exemplary embodiment of a damped brake rotor according to the present disclosure having a removed portion to show a cable insert; FIG.

14 is a plan view of the cable insert of the brake rotor 13 ;

15 FIG. 10 is an enlarged, partial cross-sectional view of another exemplary embodiment of a damped brake rotor according to the present disclosure; FIG.

16 is a perspective view of a cable insert of the brake rotor 15 ;

17 FIG. 10 is an enlarged, partial cross-sectional view of another exemplary embodiment of a damped brake rotor according to the present disclosure; FIG.

18 FIG. 10 is an enlarged, partial cross-sectional view of another exemplary embodiment of a damped brake rotor according to the present disclosure; FIG.

19 FIG. 10 is an enlarged, partial cross-sectional view of another exemplary embodiment of a damped brake rotor according to the present disclosure; FIG.

20 FIG. 15 is a perspective view of an exemplary embodiment of a damped brake pad according to the present disclosure with portions cut away to show the various layers of the brake pad; FIG.

21 FIG. 4 is a perspective view of an exemplary embodiment of a damped caliper assembly according to the present disclosure showing cables integrated within a caliper and a caliper anchor bracket of the assembly; FIG.

22 is a perspective view of the caliper of the assembly from 21 ;

23 is a perspective view of a cable insert of the caliper from 22 ;

24 is a perspective view of the caliper anchor bracket of the assembly 21 ;

25 is a perspective view of a cable insert of the caliper anchor bracket 24 ;

26 FIG. 13 is a perspective view of an exemplary embodiment of a steering knuckle in accordance with the present disclosure; FIG. and

27 is a perspective view of a cable insert of the steering knuckle 26 ,

Although the following detailed description refers to the illustrative embodiments, many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, it is intended that the claimed subject matter be considered broadly.

DESCRIPTION OF THE EMBODIMENTS

Reference will now be made in detail to the various embodiments, examples of which are illustrated in the accompanying drawings. The various exemplary embodiments are not intended to limit the disclosure. Rather, the disclosure is intended to cover alternatives, modifications, and equivalents.

The present disclosure contemplates brake components that utilize cables that are positioned (eg, integrated) within the components to enhance the damping capacity of the components. As disclosed in US Patent Application No. 14 / 505,296, incorporated herein by reference, according to various exemplary embodiments, for example, the exemplary embodiments described herein utilize friction provided by the relative movement (eg, sliding) between individuals Wires of the integrated cable (ie Coulomb friction) is generated to dampen a resonance vibration of the component. The exemplary embodiments described herein further contemplate encapsulating the integrated cable in a jacket configured to prevent molten cast material from entering the cable during casting of the brake component, thereby shielding the individual wires of the integrated cable from the molten material and continue to move freely relative to each other. For example, various exemplary embodiments described herein contemplate a brake component including at least one cable positioned within a body of the component and a sheath encapsulating the at least one cable. The at least one cable includes a plurality of wires positioned relative to one another, wherein each of the plurality of cables has a surface in sliding contact with at least one surface of at least one adjacent wire of the plurality of wires, such that the sliding movement of the surfaces relative to each other during the braking of the vehicle is generated, can damp a resonance vibration of the component. In other words, during braking of the motor vehicle, the at least one cable may attenuate the resonant vibration of the component via Coulomb friction created by the sliding movement between the surfaces of the individual wires contained within the cable (ie, friction between the wires ). Additionally, contact pressure between an outer surface of the cable and an inner surface of the sheath may also dampen the resonant vibration of the component via sliding movement of the surfaces relative to each other (i.e., via dry friction).

As those skilled in the art would understand, the terms "sliding contact" and "sliding motion" as used herein refer to movement between respective contact surfaces under certain conditions, such as during braking of a motor vehicle, for example. In this way, such areas are only below certain circumstances relative to each other and not always move relative to each other.

Further, due to its flexible structure, the at least one cable may undergo relatively large elastic distortions without appreciable change in contact pressure between the individual wires of the cable. Thus, the brake components according to the present disclosure (which rely on "static" frictional forces between the wires to dampen unwanted creaking brake noises) are also relatively insensitive to brake temperature variations.

As will be understood by those skilled in the art, Coulomb friction is a simplified quantification of the frictional force created between two dry contacting surfaces.

Accordingly, as will be understood by those skilled in the art, the attenuation of Coulomb friction as used herein is the effect of the frictional force to dissipate energy from a vibrating component and / or a vibrating system. In other words, damping of Coulomb friction relates to a type of constant mechanical damping in which energy is absorbed via sliding friction. For example, according to the present disclosure, kinetic energy is converted by the sliding friction of a vibrating brake component into thermal energy or heat.

The 1 - 7 illustrate an exemplary embodiment of a damped brake rotor 100 according to the present disclosure. The brake rotor 100 includes a body 101 , at least one cable 108 (eg two cables 108 in the exemplary brake rotor 100 in the 5 - 7 shown) within the body 101 are positioned, and a coat 110 that has at least one cable 108 encapsulates (eg two coats 110 in the exemplary brake rotor 100 be shown, so every cable 108 through a corresponding coat 110 is encapsulated). As described in more detail below, various embodiments of the present disclosure contemplate encapsulating the cables 108 inside the coats 110 to the cables 108 from molten cast material during the rotor casting process.

The body 101 includes a fixed cheek section 102 and a mounting surface 104 , In various exemplary embodiments, the attachment surface extends 104 from the cheek section 102 to the brake rotor 100 with a wheel (not shown) of a motor vehicle (not shown) via, for example, a steering knuckle 700 to connect (see 31 ).

In various exemplary embodiments, the jacketed cables are 108 in the firm cheek section 102 integrated. As described in more detail below, various embodiments of the present disclosure contemplate integrating the jacketed cables 108 in a cheek section 102 during the rotor casting process, so that the sheathed cables 108 inside the cheek section 102 are centrally positioned. In various exemplary embodiments, and as it is believed best in the 2 and 3 Shown are the sheathed cables 108 (ie the cables 108 in the coats 110 encapsulated) as an insert 107 configured in the cheek section 102 is integrated. The use 107 can, for example, at least one positioning feature 109 include (eg seven positioning features 109 in the exemplary brake rotor 100 shown) configured to both the cables 108 together and the shape of each cable 108 (and the entire form of the insert 107 ) to maintain. As also explained below, this becomes at least one positioning feature 109 In addition, in various additional embodiments, during the rotor casting process, the insert is used 107 inside a mold 120 to locate (see 8th )). That way the cables can 108 inside the cheek section 102 (of the cast rotor 100 ) should be properly positioned and aligned to maximize their damping capacity.

As above, the use can 107 relatively centrally within the cheek section 102 Be positioned to expose the sheathed cable 108 to prevent when the rotor 100 begins to deteriorate (ie, when the cheek section 102 begins to wear). In various embodiments, for example, in which the cheek section 102 has a thickness t of about 12 mm, each sheathed cable 108 be positioned such that an outer surface of the sheathed cable 108 at least about 3 mm from an outer surface of the rotor 100 is. In other words, any sheathed cable can 108 be positioned such that a distance D _R of at least about 3 mm between the sheathed cable 108 and an outer surface of the cheek portion 102 present (see 6 ).

As probably in the enlarged view 7 best shown, includes every cable 108 a variety of wires 114 , For example, in various embodiments, each cable has 108 a diameter d _c of about 3 mm to about 6 mm and includes approximately 7 until about 60 wires 114 , The expert, however would understand that in 7 illustrated cables 108 is merely exemplary and serves to illustrate an embodiment of the present disclosure. For this reason, the present disclosure contemplates cables 108 of any number, type, and / or configuration (ie, dimension and / or geometry) of the wires 114 based on a specific application. For example, according to various embodiments, the wires 114 a helical stranded cable 108 , a parallel wire cable or a stranded cable with a closed coil, as understood by those skilled in the art. The person skilled in the art would further understand that the wires 114 (ie the each cable 108 form) the same diameter (eg d _w , as in 7 illustrated) or may have different diameters.

As probably best in the 6 and 7 shown, as above, encapsulates a corresponding coat 110 each of the cables 110 fully in to prevent the molten casting material being used around the rotor 100 to form into the cables 108 penetrates and the wires 114 every cable 108 affected. With reference to 7 For example, the wires remain 114 every cable 108 therefore in contact with each other, so that a state of Coulomb friction between the wires 114 arises. In other words, the individual wires can 114 every cable 108 continue to move freely in relation to each other and corresponding areas 116 the wires 114 are in contact with each other, so that a frictional force (Coulomb friction) between each corresponding pair of contacting surfaces 116 the wires 114 arises (ie build up of friction between the wires). During braking of the motor vehicle, the cables can 108 Therefore, a vibration resonance of the rotor 100 about Coulomb friction between the wires 114 dampen the kinetic energy of the rotor 100 absorb (ie that of the vibration of the rotor 100 is generated) and convert it into thermal energy. As those skilled in the art would understand, the attenuation capability of each cable is 108 a function of the total area contact area of the individual wires 114 that the cable 108 form. Accordingly, the larger the surface contact area between the wires 114 The higher the damping capacity of the cable 108 , In this way, the size, density and spacing of the wires 114 based on a desired damping capacity of the cables 108 to be selected.

Furthermore, each cable can 108 in terms of the coat 110 in which it is encapsulated, continue to move freely, leaving an outer surface 119 of the cable 108 and an inner surface 121 of the coat 110 touch each other, so also between the contact areas 119 and 121 a frictional force arises (ie build up of a dry friction). During braking of the motor vehicle, this contact pressure (ie between surfaces 119 and 121 ) also dampen the resonant vibration of the component.

According to various exemplary embodiments, each sheath exists 110 from a shielding material 112 , such as, for example, a metal alloy having a higher melting point than the molten casting material used to form the rotor 100 to build. For example, in various embodiments, the coats 110 are formed from a steel-based alloy, such as, for example, pure carbon steel alloys (eg 1040 or 1241 or 1520), low alloy steels (eg 4120, 4325, 8339 or 8610) and / or stainless steel alloys (eg. 202 . 304 . 316 . 409 or 430 ) having a melting point between about 1353 ° C to about 1530 ° C. In addition, the rotor can 100 cast with a cast iron having a melting point of between about 1120 ° C to about 1250 ° C. Accordingly, this difference in melting temperatures (ie between the alloy and the cast iron) in combination with the fact that the cast iron begins to cool when it is with the coats 110 comes in contact that the coats 110 melt, and allows the coats 110 , the cables 108 shield from cast iron.

As further discussed below, each sheath becomes 110 according to various embodiments, by covering a web of the shielding material 112 to a corresponding cable 108 so the shielding material 112 the cable 108 completely encapsulated. Thus, various embodiments of the present disclosure contemplate the use of a deformable metal alloy as the shielding material 112 so the shielding material 112 rolled into a thin sheet and around a circumference of the cable 108 can be wrapped around the coat 110 to build. For example, in various embodiments, each jacket may 110 have a thickness, t _s , of greater than or equal to about 0.005 inches (0.127 mm). However, those skilled in the art would understand that the thickness, t _s , of each shell 110 is a function of specific metal alloy used to coat 110 to build; and in general, the higher the melting point of the metal alloy, the thinner the sheath can be. Also, the maximum thickness of the jacket 110 only by the malleability of the metal alloy used and the diameter d _{c of} the cable to be wrapped 108 limited.

The present disclosure contemplates securing opposing ends 111 . 113 of the shielding material 112 to the coat 110 by means of various methods and techniques known to those skilled in the art. As probably best in 7 illustrates, the shielding material 112 in various exemplary embodiments around the circumference of the cable 108 wrapped so that the opposite ends 111 . 113 of the shielding material 112 an overlap 115 form.

Various additional exemplary embodiments contemplate providing an overlap that is large enough to substantially prevent the molten casting material from entering an area 117 between the opposite ends 111 . 113 of the shielding material 112 penetrates. For example, in various embodiments, the overlap extends 115 at least about 25% of the circumference of the cable 108 , In various additional exemplary embodiments, the opposite ends become 111 . 113 of the shielding material 112 by welding, clinching and / or clamping the ends 111 . 113 fastened together. In such embodiments, the ends may 111 . 113 be attached directly to each other without overlapping 115 provide.

Thus, each corresponding coat 110 the wires 114 of the cable 108 inside the coat 110 are encapsulated, before the cast iron that is used to the rotor 110 to pour, to shield. Thus, the outer surface of each shell becomes 110 during the Rotorgießverfahrens rigid with the cast iron of the rotor 100 connected during the individual wires 114 every cable 108 allows one to remain unbound and to be able to move freely in relation to each other. In this way, the use becomes 107 in the position inside the rotor cheek 102 firmly fixed and prevents relative movement of the entire body between inner surfaces of the rotor cheek 102 and the outer surface of the coats 110 (ie preventing complete slippage between the faces of the rotor 100 and the coats 110 arises). This compound can additionally help maintain the structural integrity of the rotor 100 otherwise, due to the integrated cable 108 could arise.

The expert, however, would understand that in the 6 and 7 illustrated coats 110 are merely exemplary and serve to illustrate an embodiment of the present disclosure. Accordingly, the shells of the present disclosure may be formed from various materials having different properties (such as aluminum alloys, including, for example, 1100, 2124, 3003, 5452, 6061, and / or 7075), and having various configurations using various commercially available fastening techniques various layers of shielding material are formed (ie the shielding material 112 can be several times around the circumference of the cable 108 be wrapped to a desired thickness t _{s of} the jacket 110 without departing from the scope of the disclosure and claims. One skilled in the art would also understand that the coats disclosed 110 can be preformed so that a corresponding cable 108 in every coat 110 can be inserted (in contrast to a shielding material 112 that around each cable 108 is shrouded to every coat 110 to build).

According to various exemplary embodiments, the at least one cable 108 shaped and / or configured to a specific pattern or a spatial distribution of the damping capacity at the cheek portion 102 to provide the damping capacity in the area of the cheek 102 , which have the highest vibration amplitudes during rotor resonances, to increase the most. Thus, the sheathed cables 108 as in the 1 - 7 Illustrated in various embodiments, for example, form a series of circular rings that the damping capacity of the fixed rotor cheek portion 102 increase. However, the present disclosure contemplates brake rotors, including any number, configuration (ie, dimension and / or geometry), shape (ie, pattern), and / or orientation of the cables 108 with any number and / or configuration of wires 114 based on a specific application. The skilled person would therefore understand that in the 1 - 7 illustrated brake rotor 100 is merely exemplary and serves to illustrate an embodiment of the present disclosure. Accordingly, damped brake rotors according to the present disclosure may have various configurations and / or orientations of the cheeks and sheathed cables (eg, inserts) positioned therein without departing from the scope of the present disclosure and claims, and are not specific Geometries and / or alignments bound.

Thus, a damped brake rotor according to various embodiments of the present disclosure may include inserts having different numbers of sheathed cables forming different patterns (ie, having different spatial distributions). As in the 9 - 12 Illustrated may be a damped brake rotor 150 . 160 in various embodiments, for example, an insert 157 . 167 with a sheathed cable (with only one sheath 151 . 161 shown) forming a wave pattern (eg, a sine wave, wherein a period of a wave, the of the sheathed cable in the 9 and 10 is formed larger than a period of a wave from the sheathed cable in the 11 and 12 is formed). In addition, a damped brake rotor 170 in various additional embodiments an insert 177 with sheathed cables (with only one sheath 171 shown) that form a pattern that combines circular rings with a wave pattern (eg, a sine wave) as shown in FIGS 13 and 14 illustrated. Similar to the above use 107 of the rotor 100 can any of the stakes 157 . 167 . 177 also in each case at least one positioning feature 159 . 169 . 179 which is used, for example, to use 159 . 169 . 179 within a mold during the rotor casting process.

In accordance with various additional embodiments of the present disclosure, a damped brake rotor may include a vented cheek portion. The 15 - 19 For example, illustrate an exemplary embodiment of a damped vented brake rotor 200 according to the present disclosure. The brake rotor 200 includes a cheek section 202 with an outer friction element 203 that with an internal friction element 205 by a plurality of rib elements 206 connected is. The brake rotor 200 for example, further includes a mounting surface 204 extending from the inner friction element 205 extends to the brake rotor 200 to a wheel (not shown) of a motor vehicle (not shown) to connect. In this way, the outer friction element 203 configured to straighten away from the vehicle when the rotor 200 is mounted on the wheel, and the inner friction element 205 is configured to face the vehicle when the rotor 200 mounted on the wheel.

Similar to the brake rotor 100 includes the brake rotor 200 at least one cable 208 (eg four cables 208 in the exemplary brake rotor 200 shown) within the cheek section 202 integrated, and a coat 210 , of each of the cables 208 encapsulates. Every cable 208 includes a variety of wires 214 in contact with each other, so that a Coulomb friction between the wires 214 arises. As above, various embodiments of the present disclosure contemplate integrating the jacketed cables 208 in the cheek section 202 during the Rotorgießverfahrens, wherein the coats 210 are configured to prevent molten cast material from entering the cables 208 penetrates and the wires 214 every cable 208 impaired. In various exemplary embodiments, the jacketed cables are 208 in one or both of the external and internal friction elements 203 and 205 integrated. As in the 15 and 16 Illustrated are the jacketed cables 208 in various embodiments, for example, as inserts 207 configured in each of the outer and inner friction elements 203 and 205 are integrated. Every use 207 For example, at least one positioning feature 209 include (eg seven positioning features 209 that on every exemplary use 207 shown) which, as above, is configured to the sheathed cables 208 to hold together the shape of each sheathed cable 208 (and the entire form of each mission 207 ) and every use 207 to locate within the mold. Thus, the sheathed cables 208 as above, within each corresponding friction element 203 . 205 (of the cast rotor 200 ) are correctly positioned and aligned to maximize their damping capacity.

Similar to the mission 107 can any use 207 for example, relatively centrally within each respective friction element 203 . 205 Be positioned to expose the sheathed cable 208 to prevent when the rotor 200 begins to deteriorate (ie, when the cheek section 202 begins to wear). In various embodiments, for example, in which each friction element 203 . 205 has a thickness T of about 7 mm to about 13 mm, each sheathed cable 208 be positioned such that an outer surface of the sheathed cable 208 at least about 3 mm from an outer surface of the rotor 200 and at least about 5 mm from a peripheral edge of the rotor 200 is. In other words, any sheathed cable can 208 be positioned such that a distance D _f of at least about 3 mm between the cable 208 and an outer surface of the cheek portion 202 and a distance D _p of at least about 5 mm between the cable 208 and a peripheral edge of the cheek portion 202 is present. (please refer 15 ).

As above, the sheathed cables 208 shaped and / or configured to a specific pattern or a spatial distribution of the damping capacity at the cheek portion 202 to provide the damping capacity in the area of the cheek 202 , which have the highest vibration amplitudes during rotor resonances, to increase the most. As in the 15 and 16 Illustrated, the jacketed cables 208 For example, in various embodiments, form a series of circular rings that represent the damping capacity of each of the outer and inner friction elements 203 and 205 increase. As above, however, the present disclosure also contemplates ventilated brake rotors, including any number, configuration (ie, dimension and / or geometry), shape (ie, pattern), and / or orientation of cables 208 that are inside the coats 210 that have any number and / or or configuration of wires 214 has, are integrated.

The skilled person would therefore understand that in the 15 and 16 illustrated ventilated brake rotor 200 is merely exemplary and serves to illustrate an embodiment of the present disclosure. Accordingly, damped, ventilated brake rotors according to the present disclosure may include various configurations and / or orientations of the friction elements and cables (eg, inserts) positioned therein without departing from the scope of the present disclosure and claims, and are not bound to specific geometries and / or orientations. In addition, the outer friction element 203 a different deployment configuration than the inner friction element 205 have (see 17 ). As in the 17 - 19 Illustrated may be a damped, ventilated brake rotor 250 . 260 . 270 in various embodiments, for example, each inserts 257 . 267 . 277 include the cables 258 . 268 . 278 show in the coats 251 . 261 . 271 which are arranged in different configurations and have different diameters encapsulated.

The skilled person would further understand that the in the 1 - 19 illustrated brake rotors 100 . 200 . 250 . 260 . 270 are merely exemplary and are intended to illustrate one type of brake component contemplated by the present disclosure. As disclosed in U.S. Patent Application No. 14 / 505,296, incorporated herein by reference, the present disclosure contemplates various additional types and configurations of brake components that utilize cables positioned within the components to reduce the damping capacity of the brake components To improve components. Further, the present disclosure also contemplates, similar to the brake rotors disclosed above, encapsulating such cables within shrouds to prevent molten cast material from entering the cables during the casting process of the components.

For example, various additional embodiments of the present disclosure contemplate brake pads that utilize Coulomb friction between individual wires of a cable positioned within the pad to dampen resonant vibration of the pad. Similar to the rotors disclosed above, the brake pads also include a sheath that encapsulates the cable. 20 For example, an exemplary embodiment of a damped brake pad assembly is illustrated 300 according to the present disclosure. The brake pad 300 includes a rigid support structure, such as, for example, a metallic support plate 302 , and a friction material 304 that from the support plate 302 will be carried. The friction material 304 For example, it consists of a material and / or a combination of materials which have a high coefficient of friction and which can also absorb and disperse large amounts of heat. For example, in various embodiments, the friction material 304 contain asbestos-free organic, semi-metallic and / or ceramic material.

However, one skilled in the art would understand that brake pads according to the present disclosure may include various types and / or configurations of support structures and friction materials formed of different materials based on a particular brake application. In addition, brake pads according to the present disclosure may include additional components and / or materials, including, for example, an underlayer material 306 that is between the support plate 302 and the friction material 304 is positioned, and a sub-component 307 attached to an outer surface of the support plate 302 is attached to correct small differences (which can sometimes cause noise) between the support plate 302 and a caliper to which it is attached to help.

In various embodiments, the friction material is 304 to a surface of the support plate 302 bonded to produce a friction surface configured to face a brake rotor when positioned within the motor vehicle (not shown) and the support component 307 is on an opposite surface of the support plate 302 tied (which is configured to be attached to a caliper (see 22 ) when positioned inside the vehicle). In various embodiments, for example, two brake pads 300 contained within the caliper (ie positioned over a cheek portion of the rotor), while their friction surfaces facing the rotor. In this way, when the brakes are applied, the caliper clamps or pushes the two pads 300 on the spinning rotor together to slow down and / or stop the vehicle.

Similar to the aforementioned damped brake rotors, the brake pad assembly includes 300 In addition, according to various exemplary embodiments, at least one cable 308 (eg a cable 308 that in the exemplary brake pad 300 shown) within the brake pad 300 is positioned, and a coat 310 that's the cable 308 encapsulates. For example, in various embodiments, the cable may 308 inside the support plate 302 be positioned, and the coat 310 can prevent molten Casting material during casting of the support plate 302 in the cable 308 penetrates.

Similar to the cables 108 above includes the cable 308 a plurality of wires (not shown). For example, in various embodiments, the cable has 308 about 1 mm to about 3 mm in diameter, and includes about 3 to about 20 Wires, each having a diameter of about 0.1 mm to about 1.4 mm. As above are the wires of the cable 308 Also in contact with each other, so that a state of Coulomb friction between the wires is present. Thus, the cable can 308 , similar to the cables 108 During the braking of the motor vehicle, a resonance vibration of the brake pad 300 Coulomb friction between the contacting surfaces of the wires dampens the kinetic energy of the brake pad 300 absorb and convert into thermal energy.

Similar to the above cables 108 Can this be at least one cable 308 shaped and / or configured to a specific pattern or a spatial distribution of the damping capacity on the printing plate 302 to provide the damping capacity in the areas of the printing plate 302 , which have the highest vibration amplitudes during brake pad resonances, to increase the most. For example, in various embodiments, the sheathed cable 308 form a wave pattern (eg a sine wave), which is the damping capacity of the brake pad 300 elevated. However, the present disclosure contemplates brake pads, including any number, configuration (ie, dimension and / or geometry), shape (ie, pattern), and / or orientation of the cables 308 with any number and / or configuration of wires. The skilled person would therefore understand that the in 20 illustrated brake pad 300 is merely exemplary and serves to illustrate an embodiment of the present disclosure.

Accordingly, damped brake linings according to the present disclosure may include various configurations and / or orientations of the pressure plates and sheathed cables positioned therein without departing from the scope of the present disclosure and claims, and are not bound to specific geometries and / or orientations.

Various additional embodiments of the present disclosure contemplate caliper assemblies, including a caliper and a caliper armature, which utilize Coulomb friction between individual wires of cables positioned within the assembly to cause resonant vibration of the assembly (ie, caliper and / or caliper) Anchor bracket). Similar to the rotors and brake pads disclosed above, the caliper assemblies also include sheaths that encapsulate the cables. The 21 - 25 illustrate an exemplary embodiment of a damped caliper assembly 400 according to the present disclosure. As in 21 shown includes the caliper assembly 400 a caliper 500 and a caliper anchor bracket 600 that is configured to apply a brake pad to the caliper 500 to assemble. As above, two brake pads in various exemplary embodiments may be incorporated within the caliper 500 be contained (ie, which is positioned over a cheek portion of a rotor), while their friction surfaces facing the rotor. In this way, when the brakes are applied, the caliper is tensioned or pressed 500 the two pads on the spinning rotor together to slow down and / or stop the vehicle.

Similar to the above damped brake rotors and brake pads, the caliper assembly includes 400 In addition, according to various exemplary embodiments, at least one cable within the assembly 400 is positioned, and a jacket which encapsulates the at least one cable. For example, in various embodiments, a sheathed cable (with only one sheath 510 visible) within the caliper 500 be integrated as in 23 shown. In various additional embodiments, a sheathed cable (with only one sheath 610 visible) within the anchor bracket 600 be integrated as in 25 illustrated. Similar to the above brake rotor 100 Various embodiments of the present disclosure contemplate integrating the respective sheathed cables within the caliper 500 and the anchor strap 600 during the casting process so that the cables are positioned so as to maximize the corresponding damping capacity of each component. Additionally, embodiments of the present disclosure contemplate that the coats 510 . 610 shield the appropriate cables from the molten cast material used to cast the components during the casting process.

As in the 23 respectively. 25 As shown, the jacketed cables are in various embodiments as inserts 507 . 607 configured, respectively within the caliper 500 and the anchor strap 600 are integrated. Similar to the mission 107 above can be any use 507 . 508 For example, in each case at least one positioning feature 509 . 609 include (eg three positioning features 509 . 609 that in the exemplary caliper 500 and anchor bracket 600 shown) used during the casting process for each use 507 . 607 to locate within a mold. In this way, the sheathed cables within the caliper can 500 and the anchor strap 600 each correctly positioned and aligned to maximize the corresponding damping capacity of each component.

Similar to the cables 108 and 308 above include the cables inside the coats 510 . 610 a plurality of wires (not shown) in contact with each other to form a state of Coulomb friction between the contacting surfaces of the wires. Thus, the cables, similar to the cables 108 . 308 , During each of the braking of the motor vehicle, a resonance vibration of the caliper 500 and the anchor strap 600 (and the entire resonant vibration of the caliper assembly 400 ) about the Coulomb friction between the wires, which is the kinetic energy of the caliper assembly 400 absorbed and converted into thermal energy, dampen.

The skilled person, however, would understand that the caliper assembly 400 including the brake caliper 500 and the anchor strap 600 that in the 21 - 25 are merely exemplary and illustrate an embodiment of the present disclosure. Accordingly, brake caliper assemblies according to the present disclosure may have various configurations, including various caliper and anchor bracket configurations, without departing from the scope of the present disclosure and claims, and are not bound to specific configurations, geometries, and / or orientations.

One skilled in the art would further appreciate that the present disclosure is caliper assembly 400 , including any number, configuration (ie, dimension and / or geometry), shape (ie, pattern), and / or orientation of jacketed cables having any number and / or configuration of wires and within the caliper 500 and / or the anchor bracket 600 are integrated.

Various other embodiments of the present disclosure contemplate stub axles that utilize Coulomb friction between individual wires of cables positioned within the leg to dampen resonant vibration of the leg. Similar to the rotors, brake pads, and caliper assemblies disclosed above, the disclosed steering knuckles also include sheaths that encapsulate the cables. The 26 and 27 illustrate an exemplary embodiment of a damped steering knuckle 700 according to the present disclosure. For example, in various embodiments, a wheel and tire assembly of a motor vehicle (not shown) may extend over the leg 700 be mounted on the suspension of the vehicle (ie the leg 700 may allow the tire / wheel to rotate while being held in a stable plane of motion).

Similar to the above brake components, the leg includes 700 According to various exemplary embodiments, at least one cable inside the leg 700 integrated, and a coat 710 that at least encapsulates a cable. As in 27 Shown is the sheathed cable (being just a sheath 710 is visible) in various embodiments as an insert 707 configured inside of the thigh 700 is integrated. The use 707 For example, at least one positioning feature 709 include (eg three positioning features 709 that in the exemplary thigh 700 shown) used during the casting process to locate the insert within a mold.

Similar to the cables discussed above, the cable includes within the jacket 710 a plurality of wires (not shown) in contact with each other so as to create a state of Coulomb friction between the contacting surfaces of the wires. Thus, during braking of the motor vehicle, the cable may resonate the leg 700 attenuate the Coulomb friction between the wires.

Further, as disclosed in US Patent Application No. 14 / 505,296, incorporated herein by reference, the present invention also contemplates methods of making a brake component, such as those discussed above with reference to FIGS 1 - 27 described components 100 . 150 . 160 . 170 . 200 . 250 . 260 . 270 . 300 . 400 . 500 . 600 and 700 to increase the damping capacity of the component. According to various exemplary embodiments, the damping capacity of the brake component 100 . 150 . 160 . 170 . 200 . 250 . 260 . 270 . 300 . 400 . 500 . 600 . 700 can raise a cable 108 . 208 . 258 . 268 . 278 . 308 within the brake component 100 . 150 . 160 . 170 . 200 . 250 . 260 . 270 . 300 . 400 . 500 . 600 . 700 be positioned. To the cable 108 . 208 . 258 . 268 . 278 . 308 to protect against the molten casting material during the manufacture of the brake component 100 . 150 . 160 . 170 . 200 . 250 . 260 . 270 . 300 . 400 . 500 . 600 . 700 is used, the present disclosure further contemplates the encapsulation of the cable 108 . 208 . 258 . 268 . 278 . 308 in a coat 110 . 151 . 161 . 171 . 210 . 251 . 261 . 271 . 310 . 410 . 510 . 610 . 710 ,

For example, in various embodiments, the cable may 108 . 208 . 258 . 268 . 278 . 308 include a plurality of wires in sliding contact with each other and the sheath 110 . 151 . 161 . 171 . 210 . 251 . 261 . 271 . 310 . 410 . 510 . 610 . 710 is configured to the cable 108 . 208 . 258 . 268 . 278 . 308 to shield from molten casting material and to prevent molten casting material from interfering with the sliding contact between the plurality of wires. In this way, the jacketed cable 108 . 208 . 258 . 268 . 278 . 308 within the brake component 100 . 150 . 160 . 170 . 200 . 250 . 260 . 270 . 300 . 400 . 500 . 600 . 700 be positioned so that the at least one cable 108 . 208 . 258 . 268 . 278 . 308 during braking of the motor vehicle resonant vibration of the component 100 . 150 . 160 . 170 . 200 . 250 . 260 . 270 . 300 . 400 . 500 . 600 . 700 due to friction generated by the sliding movement between the plurality of wires.

The brake components 100 . 150 . 160 . 170 . 200 . 250 . 260 . 270 . 300 . 400 . 500 . 600 . 700 may be prepared by any known method and / or technique known to those skilled in the art. For example, in various embodiments, the components may be 100 . 150 . 160 . 170 . 200 . 250 . 260 . 270 . 300 (eg the support plate 302 ) 400 . 500 . 600 . 700 be cast from a molten metal, such as iron, which is poured into a mold. In various additional embodiments, the components may be molded from a composite material such as, for example, carbon reinforced carbon, a ceramic matrix composite, or a composite blend of materials with a phenolic plastic resin that is hot formed in a curing press.

With reference to the above described and in the 1 - 8th described brake rotor 100 For example, a variety of cables 108 according to various exemplary embodiments in the corresponding coats 110 be encapsulated. In various embodiments, each coat becomes 110 for example, by covering a web of the shielding material 112 to a corresponding cable 108 formed so that the shielding material 112 the cable 108 completely encapsulated. Thus, as discussed above, various embodiments of the present disclosure contemplate the use of a malleable metal alloy, such as, for example, pure carbon steel alloys (eg, 1020), low alloy steels (eg, 4110), stainless steel alloys (e.g. 304 ), Copper alloys (eg C10100), brass and bronze alloys (eg C60800), magnesium alloys (eg AM60), aluminum alloys (eg 1100 Al), titanium (eg grade 5) ), Tungsten and / or other known wires (eg Chromel, Alumel and / or Konstantan), as the shielding material 112 such as the shielding material 112 , curled in a thin bow and around a circumference of the cable 108 can be wrapped around the coat 110 to build.

As above, the present disclosure contemplates mounting opposite ends 111 . 113 of the shielding material 112 to the coat 110 by means of various methods and techniques known to those skilled in the art. As in 7 illustrates, the shielding material 112 in various exemplary embodiments around the circumference of the cable 108 wrapped so that the opposite ends 111 . 113 of the shielding material 112 an overlap 115 form. Various additional exemplary embodiments contemplate providing an overlap that is large enough to substantially prevent molten cast material from forming during the manufacture of the rotor 100 is used in an area 117 between the opposite ends 111 . 113 of the shielding material 112 penetrates.

For example, in various embodiments, the overlap extends 115 at least about 25% of the circumference of the cable 108 , In various additional exemplary embodiments, the opposite ends may be 111 . 113 of the shielding material 112 by welding, clinching and / or clamping the ends 111 . 113 be fastened together. In such embodiments, the ends may 111 . 113 be attached directly to each other without overlapping 115 provide.

The plurality of sheathed cables may then enter a cheek section 102 of the rotor 100 to get integrated. As in 8th illustrated, the sheathed cables in various embodiments may be in at least one insert 107 be configured (an insert 107 , which in the exemplary embodiment according to 8th shown), in a mold 120 is positioned, which is configured to the rotor 100 to build. For example, in various embodiments, the insert may be 107 in the mold 120 be positioned by the insert 107 between an upper pattern 130 the mold 120 and a lower pattern 140 the mold 120 is positioned.

The use 107 can be between the top and the bottom pattern 130 and 140 be positioned by, for example, at least one positioning feature 109 (four positioning features 109 , which in the exemplary embodiment according to 8th shown) on the insert 107 with at least one corresponding positioning feature 139 . 149 in each of the upper and lower patterns 130 and 140 is aligned. That way the cables can 108 inside the mold 120 correctly positioned and aligned.

A brake rotor 100 can then be poured with a molten casting material, for example, in the mold 120 is poured, with the coat 110 configured to the cable 108 from the molten cast material and to prevent molten cast material from interfering with the sliding contact between the plurality of wires. As above, each coat exists 110 according to various exemplary embodiments of a shielding material 112 such as, for example, a malleable metal alloy having a higher melting point than the molten casting material used to form the rotor 100 to build. For example, in various embodiments, the coats 110 are formed from a steel-based alloy, such as, for example, pure carbon steel alloys (eg 1040 or 1241 or 1520), low alloy steels (eg 4120, 4325, 8339 or 8610) and / or stainless steel alloys (eg. 202 . 304 . 316 . 409 or 430 ) having a melting point between about 1353 ° C to about 1530 ° C. In addition, the rotor can 100 cast with a cast iron having a melting point of between about 1120 ° C to about 1250 ° C. Accordingly, this difference in melting temperatures (ie, between the alloy and the cast iron) combined with the fact that the cast iron begins to cool when used with it 107 comes in contact that the coats 110 melt, and allows the coats 110 , the cables 108 shield from cast iron.

In various additional embodiments, portions of the positioning features 109 extending over a periphery of the rotor 100 extend (see 1 ), after casting the brake rotor 100 separated (or removed) as the skilled person would understand.

While the present disclosure has been disclosed in terms of exemplary embodiments in order to facilitate a better understanding of the disclosure, it should be understood that the disclosure may be embodied in various ways without departing from the principle of the disclosure. For that reason, it is to be understood that the disclosure includes all possible embodiments that can be embodied without departing from the principle of the disclosure as set forth in the appended claims. In addition, although the present disclosure has been discussed with respect to automotive vehicles with disc brakes (ie, utilizing the rotors), those skilled in the art would understand that the present teachings as disclosed are equally well suited to any type of vehicle having a braking system, the brake rotors as well as for vehicles with other types of brake systems, such as drum brakes (ie, utilizing the brake drums with a sheathed cable positioned within the body of the brake drum) functioning.

For the purposes of this specification and the appended claims, it will be understood that all numbers expressing quantities, percentages or proportions and other numerical values used in the specification and claims are in all instances modified from the term "about"; unless otherwise stated. Accordingly, the numerical parameters set forth in the written description and claims, unless indicated to the contrary, are approximations that may vary depending on the desired characteristics to be obtained from the present disclosure. At least, and not as an attempt to limit the application of the doctrine of equivalent embodiments to the scope of the claims, each numerical parameter should be interpreted at least in light of the number of significant digits reported and the use of ordinary rounding techniques.

It should be noted that the singular forms "a," "one," and "the" as used in this specification and the appended claims, include plural referents unless expressly and unequivocally referenced limited. Thus, for example, reference to "one sensor" includes two or more different sensors. As used herein, the term "include" and its grammatical variations are not intended to be limiting, such that listing items in a list is not an option for excluding other similar items that may be removed from or added to the listed items.

It will be apparent to those skilled in the art that various modifications and variations can be made to the system and method of the present disclosure without departing from the scope of the teachings. Other embodiments of the disclosure will become apparent to those skilled in the art through consideration of the specification and practice of the teachings disclosed herein. It is intended that the specification and embodiment described herein be considered as exemplary only.

Claims (3)

A brake component comprising: a body; and at least one sheathed cable positioned within the body and comprising a plurality of cables, each of the plurality of cables having a surface in sliding contact with at least one adjacent wire of the plurality of wires, wherein, during the braking of the motor vehicle, the relative sliding movement between attenuates a resonant vibration of the component to the surfaces of the plurality of wires. The brake component of claim 1, wherein the brake component is a brake rotor. The brake component of claim 1, wherein the brake component includes a brake pad, a caliper, a caliper bracket, and / or a steering knuckle.

Images