JP2002333040A - Caliper body for vehicular disc brake and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a good caliper body product with a parking brake mounting mechanism part, giving good melt running property to a reaction part, a bridge part and a part forming a hydraulic cylinder and offering required strength for an action part and the reaction part. SOLUTION: The method of manufacturing a caliper body for a vehicular disc brake, having the action part with the hydraulic cylinder 74 provided on one side of an opposite position across a disc rotor, the reaction part 72 consisting of a reacting pawl provided on the other side and the parking brake mechanism mounting part 70 provided on the bottom side of the hydraulic cylinder 74, comprises filling a molten metal from a sprue 60 provided on the side of the parking brake mechanism mounting part 70 to a cavity 56 of a casting mold 50 for casting operation.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a caliper body for a vehicle disk brake and a method for manufacturing the same.

[0002]

2. Description of the Related Art FIG. 6 shows the structure of a main part of a disc brake provided with a parking brake mechanism. The disc brake includes a caliper body 10 and a hydraulic operating mechanism 20 for a brake operated by a brake pedal.
And a mechanical operating mechanism 30 for a parking brake operated by a hand lever or a foot pedal. The caliper body 10 includes an operating portion 10a and a reaction portion 10b having a reaction force claw disposed on both sides of the disk rotor 40 so as to face each other.
0b and a bridge portion 10c connecting the disk portion 40 across the outside of the disk rotor 40.
A pair of friction pads 12a and 12b are formed so that the disk rotor 40 is sandwiched between the friction pads 12a and 12b.

The working portion 10a has a disk rotor 4 at its end.
A hydraulic cylinder 14 and a bearing hole 16 opening on the 0 side are provided. A piston 22 is provided in the hydraulic cylinder 14, and a hydraulic chamber 24 is formed between the piston 22 and the bottom of the hydraulic cylinder 14. Reference numeral 26 denotes an adjustment bolt provided so as to be constantly biased toward the bottom of the hydraulic cylinder 14. The hydraulic chamber 24 communicates with a hydraulic operating mechanism in which the pressing of the piston 22 is controlled by operating a brake pedal, and the clamping operation of the disk rotor 40 by the friction pads 12a and 12b is controlled to perform the brake operation.

The bearing hole 16 is provided in a direction orthogonal to the axial direction of the hydraulic cylinder 14, and a cam shaft 32 is rotatably mounted in the bearing hole 16. 34 is the camshaft 3
2 is a push rod that engages with the second cam groove. The push rod 34 has a rear end in contact with the camshaft 32 and a front end in contact with the rear surface of a sleeve piston 36 which is mounted so as to be able to advance and retreat in the axial direction of the hydraulic cylinder 14. A wire associated with a hand lever or a foot pedal is linked to the cam shaft 32 via a cam lever (not shown). By operating the hand lever or the foot pedal, the cam shaft 32 rotates, and the push rod 34 is moved. The sleeve piston 36 advances and retreats via this, and a parking brake operation is performed.

[0005]

The caliper body used for the above-mentioned disc brake is generally manufactured by gravity casting. Normally, caliper bodies for automobiles are made of iron, but recently there are products that are cast from aluminum in order to reduce the weight of parts. The gravity casting method uses the weight of the riser to fill the molten metal into the cavity when casting the molten metal into the cavity from the gate of the casting mold to prevent internal defects such as unfilled molten metal. It is a method of casting. In this case, when the molten metal is poured into the cavity from the sprue, the molten metal finally solidifies in the sprue portion. Therefore, defects such as sink marks are likely to occur in the gate section. The gravity casting method also has an effect of suppressing defects at the gate by the action of the feeder.

In a conventional casting mold for manufacturing a caliper body, a cavity is arranged in such a manner that the caliper body is cast in a horizontal position, and a molten metal is poured into the cavity from a gate to perform casting. For this reason, internal defects such as sink marks may occur in the vicinity of the gate, which may cause problems in the denseness and quality of the cast product. The present invention
The purpose of the present invention is to solve these problems, and an object of the present invention is to provide a non-defective vehicle disc brake having no internal defects or the like, and a suitable manufacturing method thereof.

[0007]

The present invention has the following configuration to achieve the above object. That is, an action portion having a hydraulic cylinder is provided on one side of an opposing position straddling the disk rotor, a reaction portion comprising a reaction force claw is provided on the other side, and a parking brake mechanism mounting portion is provided on the bottom side of the hydraulic cylinder. The caliper body of a vehicle disc brake provided with a gate is cast by arranging a gate on the parking brake mechanism mounting portion side. Further, in the caliper body of the vehicle disk brake, the parking brake mechanism mounting portion is formed in a rectangular shape. Thus, the number of processing steps after casting the caliper body can be reduced, and the molten metal can be easily injected into the caliper body. Further, in the caliper body of the disc brake for a vehicle, the parking brake mechanism mounting portion is arranged so that a side direction of the rectangular shape is inclined with respect to a left-right symmetric line direction of the caliper body. As a result, a high-quality caliper body for a vehicle disk brake can be obtained.

[0008] Further, an operating portion having a hydraulic cylinder is provided on one side of an opposing position straddling the disk rotor, a reactive portion comprising a reaction claw is provided on the other side, and a parking brake is provided on the bottom side of the hydraulic cylinder. A method for manufacturing a caliper body of a vehicle disc brake having a mechanism mounting portion, wherein a gate is provided on the parking brake mechanism mounting portion side, and molten metal is poured into the casting mold cavity from the gate to perform casting. And Further, in the method for manufacturing a caliper body of a disc brake for a vehicle, the arrangement of the cavity for molding the caliper body in the casting mold is such that a part for molding a parking brake mechanism mounting part is an upper position, and a part for molding a reaction part is By casting using the casting mold in the lower position, the flowability of the molten metal to the reaction part and the part where the hydraulic cylinder is formed is further improved, and the required strength and quality are provided as the caliper body main body. A caliper body having a parking brake mechanism mounting portion can be easily obtained.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 shows a configuration of a casting mold 50 for casting a caliper body by applying a method for manufacturing a caliper body of a vehicle disc brake according to the present invention. In the figure, 50a and 50b are upper and lower molds of a casting mold, and 52 and 54 are core molds used in combination with the lower mold 50b. By combining the lower mold 50b and the core molds 52 and 54, a cavity 56 for molding a caliper body is formed in the casting mold 50. Numeral 58 denotes a feeder portion arranged in communication with the cavity 56, and numeral 60 denotes a gate.

A characteristic configuration of a casting mold 50 for casting a caliper body according to the present embodiment is an arrangement of a cavity 56 and a gate 60 formed in the casting mold 50. That is, in the caliper body manufacturing method according to the present embodiment, the arrangement of the cavity 56 formed in the casting mold 50 is performed by using the parking brake mechanism mounting portion 3 with the caliper body.
The caliper body is molded in the vertical position in the casting mold 50 with the part 70 for molding the nozzle part 0a being the uppermost position in the cavity 56 and the part 72 for molding the reaction part 10b being the lower position. The brake mechanism mounting portion 30a is connected to a portion to be formed. 74 is a portion of the caliper body for forming the hydraulic cylinder 14, and 76 is a working portion 1 of the caliper body.
This is a portion where a bridge portion 10c connecting the reaction portion 0a and the reaction portion 10b is formed.

When casting the caliper body, the gate 6
0, the molten metal is injected into the cavity 56,
The molten metal is solidified and cast inside. The material of the molten metal is not particularly limited, and iron, aluminum, an aluminum alloy or the like can be used. FIG. 2 shows a state in which the molten metal is injected into the cavity 56. The molten metal flows from the gate 60 to the cavity 5
6 and the filling section 58 are filled. In the gravity casting method, the cavity 56 is utilized by utilizing the weight of the molten metal in the feeder 58.
The volume of the feeder 58 may be appropriately set according to the volume of the cast product or the like because the molten metal is caused to circulate around the entirety.

In the present embodiment, since the portion for forming the parking brake mechanism mounting portion 30a is located at the highest position in the cavity 56, the portion for forming the hydraulic cylinder 14 located below this position, and The gravity of the molten metal filled in the feeder unit 58 suitably acts on the portion where the reaction unit 10b having the reaction claw at the lower position is formed,
The meltability is improved and the entire cavity 56 is reliably filled with the molten metal. Parking brake mechanism mounting part 30
a is located above the part where the hydraulic cylinder 14 is formed, and the parking brake mechanism mounting part 30a
Is formed in a rectangular shape (quadratic prism shape) and has a relatively large volume occupied by the molten metal. It also contributes to the effect of making it good.

As shown in FIG. 2, in this embodiment, since the portion 70 for forming the parking brake mechanism mounting portion 30a is located at the uppermost position in the cavity 56, the molten metal solidifies last in the cavity 56. This is where the parking brake mechanism mounting portion 30a is formed. Therefore, regarding the parking brake mechanism mounting portion 30a, there is a possibility that sink marks or the like at the time of solidification of the molten metal may affect as defects. However, as described above, only the mechanical operation member operated by the hand lever or the like is mounted on the parking brake mechanism mounting portion 30a, and the hydraulic pressure does not significantly act on the acting portion and the reaction portion. In addition, even when sinks occur when the molten metal solidifies, it is possible to suppress direct connection to product defects.

In a vehicle disk brake, the strength and durability of the action portion 10a and the reaction portion 10b of the caliper body and the hydraulic operating mechanism 2
The reliability of the zero operation is particularly important. For this reason, when the caliper body is manufactured by casting, the working portion 10
a, consideration is given to the ability of the reaction portion 10b and the portion where the hydraulic cylinder 14 is to be formed to run the molten metal and fill the molten metal. However, in the sprue portion, since a defect such as a sink is liable to occur, in the present embodiment, the sprue is connected to a portion where the parking brake mechanism mounting portion 30a is formed so that the sink is not directly connected to a product failure. It is. This is because the required function of the parking brake mechanism mounting portion 30a can be sufficiently exhibited as long as the mechanical strength can be secured.

As described above, the method for manufacturing the disc brake for a vehicle according to the present invention ensures that the molten metal is filled in the portion where the working portion 10a, the reaction portion 10b and the hydraulic cylinder 14 of the caliper body are formed during casting. This enables the action portion 10a and the reaction portion 10b and the like to be provided as a reliable product having a required strength, and a parking brake mechanism mounting portion 30a having a sufficient mechanical strength. It is possible to provide as a product with. According to the production method of the present invention,
Since it can be obtained as a product according to the characteristics of each part of the caliper body, it is possible to improve the yield of the product and improve the productivity.

When aluminum or an aluminum alloy is used as the molten metal to reduce the weight of the caliper body, aluminum is easily oxidized and an oxide film is easily formed on the surface of the molten aluminum or aluminum alloy. The runnability of aluminum or aluminum alloy in the mold cavity may be a problem. In other words, when the molten metal has insufficient circumfluence, problems such as unfilling or sinking of the molten metal are likely to occur, but even in such a case, according to the production method of the present invention, the required quality and function can be obtained. It can be provided as a caliper body product equipped.

FIGS. 3, 4, and 5 are a front view, a side view, and a plan view of the caliper body 10 obtained by casting by the above-described manufacturing method.
FIG. After removing the cast product from the casting mold 50, the caliper body 10 cuts and removes a metal portion solidified in the feeder unit 58 from the body of the caliper body 10,
It is obtained by subjecting a required part of the casting to processing such as grinding. 30a is a parking brake mechanism mounting portion formed in a block shape. The parking brake mechanism mounting portion 30a is provided with a bearing hole 16 for mounting a camshaft. The shapes of the action portion 10a provided on the caliper body 10, the reaction portion 10b having the reaction force claw, the bridge portion 10c, and the like are basically the same as those of the conventional caliper body. The outer surface of the caliper body is provided with a union hole for connecting to the master cylinder and a bleeder hole for bleeding air from the piping.

A characteristic configuration of the caliper body 10 of the present embodiment is a parking brake mechanism mounting portion 30a.
It is a structure about. That is, as shown in FIGS. 3 to 5, the parking brake mechanism mounting portion 30 a is formed in a rectangular shape, and as shown in FIG. The direction (the direction of the long side) of the portion 30a is arranged to be inclined with respect to the direction of the left-right symmetry line AA of the caliper body 10. As described above, in the casting mold 50, the parking brake mechanism mounting portion 30a
Since the feeder portion 58 is provided in connection with the portion 70 where the mold is formed, and the sprue 60 is disposed, the sprue 60 also
-A will be arrange | positioned with respect to the direction.

If the gate is arranged symmetrically with respect to the left-right symmetry line AA, the cavity 56 of the casting mold 50
When flowing into the reaction portion 10b side from the upper portion of the cavity 56, the melt injected into the reaction portion 10b is substantially equally divided into right and left and flows into the reaction portion 10b, as opposed to the caliper body 10 of the present embodiment. , Parking brake mechanism mounting part 3
0a, that is, when the sprue portion is inclined with respect to the left-right symmetry line AA and has a left-right asymmetric arrangement, the molten metal injected into the cavity is not equally divided right and left and unbalanced in the inflow amount. Will occur.

When the molten metal is injected into the cavity 56, and when a substantially symmetrical product is cast like the caliper body of the present embodiment, a flow in which the molten metal is divided right and left in the cavity 56 easily occurs. If the gate is arranged so that the molten metal flows in equally to the left and right, as the molten metal is filled into the cavity 56, the molten metal divided into right and left comes to be joined at the center of the cavity 56. May decrease in strength. In the present embodiment, the parking brake mechanism mounting portion 30a is arranged to be asymmetrical with respect to the line of symmetry of the caliper body 10, so that a difference occurs in the inflow amount of the molten metal at the left and right positions of the cavity 56, and the mating surface of the molten metal Thus, the problem of reduced strength of the cast product can be solved.

In the embodiment, as shown in FIG.
The parking brake mechanism mounting section 30a and the action section 10a in which the hydraulic cylinder 14 is formed are arranged such that the center positions thereof are slightly displaced in a planar arrangement. As described above, even when the central position of the parking brake mechanism mounting portion 30a and the acting portion 10a is deviated, the amount of molten metal injected into the cavity 56 with respect to the left and right arrangement of the caliper body 10 can be reduced. It acts to unbalance.

The parking brake mechanism mounting portion 30a needs to be formed in a rectangular shape due to a demand for mounting on a vehicle, and is formed in a required shape at the time of casting. Since the number of processing steps can be reduced and the gate can be opened widely, it is easy to inject the molten metal into the cavity 56, and as described above, suitable casting can be performed from the arrangement positional relationship with the cavity 56. .

[0023]

According to the caliper body for a vehicle and the method of manufacturing the same according to the present invention, as described above, the hot water spillability to the portion where the reaction portion, the bridge portion and the hydraulic cylinder are formed is improved, and the action portion is formed. A product having a required strength as a reaction portion and having good quality without nests can be obtained, and can be obtained as a suitable product having a required function as a caliper body having a parking brake mechanism mounting portion. it can. ADVANTAGE OF THE INVENTION According to the manufacturing method which concerns on this invention, a product yield can be improved and productivity can be improved.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a configuration example of a casting mold for casting a caliper body by applying a manufacturing method according to the present invention.

FIG. 2 is an explanatory view of a state in which a molten metal is being injected into a cavity.

FIG. 3 is a front view of a caliper body obtained by a manufacturing method according to the present invention.

FIG. 4 is a side view of the caliper body obtained by the manufacturing method according to the present invention.

FIG. 5 is a plan view of a caliper body obtained by a manufacturing method according to the present invention.

FIG. 6 is an explanatory diagram showing a configuration of a vehicle disk brake and a caliper body.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Caliper body 10a Working part 10b Reaction part 10c Bridge part 14 Hydraulic cylinder 16 Bearing hole 20 Hydraulic operating mechanism 22 Piston 24 Hydraulic chamber 30 Mechanical operating mechanism 30a Parking brake mechanism mounting part 32 Camshaft 50 Casting type 50a Upper die 50b Lower mold 52, 54 Core mold 56 Cavity 58 Feeder 60 Gate

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 3J058 AA48 AA53 AA63 AA69 AA77 AA83 AA87 BA63 CA50 CC19 CC22 EA05 EA08 FA01 4E093 PA03 PB05

Claims (5)

[Claims] An operating portion having a hydraulic cylinder is provided on one side of an opposing position straddling a disk rotor, a reactive portion comprising a reaction claw is provided on the other side, and a parking brake is provided on a bottom side of the hydraulic cylinder. A caliper body for a vehicle disc brake having a mechanism mounting portion, wherein the caliper body is formed by casting a gate on the parking brake mechanism mounting portion side. 2. The caliper body of a disc brake for a vehicle according to claim 1, wherein said parking brake mechanism mounting portion is formed in a rectangular parallelepiped shape. 3. The caliper body for a vehicle disk brake according to claim 2, wherein the parking brake mechanism mounting portion is disposed so that a side direction of the rectangular parallelepiped is inclined with respect to a left-right symmetric line direction of the caliper body. A caliper body for a disc brake for a vehicle. 4. An operating portion having a hydraulic cylinder is provided on one side of an opposing position straddling the disk rotor, a reaction portion comprising a reaction force claw is provided on the other side, and a parking brake is provided on a bottom side of the hydraulic cylinder. A method for manufacturing a caliper body of a vehicle disc brake provided with a mechanism mounting portion, wherein a gate is provided on the parking brake mechanism mounting portion side, and molten metal is injected into the casting mold cavity from the gate to perform casting. A method of manufacturing a caliper body for a vehicle disk brake. 5. The method for manufacturing a caliper body for a vehicle disk brake according to claim 4, wherein the cavity for forming the caliper body in the casting mold is arranged such that a portion for forming a parking brake mechanism mounting portion is located at an upper position, A method for manufacturing a caliper body of a vehicle disc brake, wherein the caliper body is cast using a casting mold in which a portion where a reaction portion is formed is located at a lower position.