JP2009270610A - Pad spring for disc brake, and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve a function of smoothly guiding the sliding operation of pad plates and at the same time, a function of reducing vibration to be applied from the pad plates to a carrier. <P>SOLUTION: A disc bake has the pair of pad plates to the opposed inner faces of which friction pads are deposited for pressing both faces of a disc to be rotated together with a wheel, and which is stored in the carrier fixed to a vehicle body slidably to the disc side, and pad springs 40 laid between each of the pad plates and the carrier for suppressing the transmission of vibration from the pad plates to the carrier while guiding the sliding operation of the pad plates. The pad spring 40 for the disc brake has one face coated with a low friction material 50 for contacting the pad plates and the other face coated with an elastic body 60 for contacting the carrier. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a disc brake, and more particularly to a pad spring for guiding a sliding operation of a pad plate and reducing vibration applied to the pad plate and a manufacturing method thereof in the disc brake.

Generally, a disc brake is a device that brakes and decelerates a vehicle through this frictional force by forcibly bringing a friction pad into close contact with both side surfaces of a disc that rotates together with a vehicle wheel.
Such a disc brake has a caliper housing in which a piston that moves forward and backward is received by a braking hydraulic pressure, and a pair of pad plates each having the friction pads attached to the inner surface facing each other. And a disk in which a part of the outer peripheral edge is inserted between the pair of pad plates while rotating together with the wheel.
The piston is disposed at the rear portion of the caliper housing so as to push the outer surface of the pad plate on one side toward the disk side, and the outer portion of the pad plate on the other side is covered on the front portion of the caliper housing on the opposite side of the piston. Thus, a finger part is formed.
Therefore, when the piston is operated so that the pad plate on one side presses one side of the disc, the pad plate on the other side is guided by the finger portion to press the other side on the opposite side of the disc. Between the friction pads.

  On the other hand, the carrier is attached to a knuckle of a vehicle body through a bolt, and the pad plates are slidably installed inside the carrier. A pad spring is provided between the pad plate and the carrier for suppressing the vibration of the pad plate while guiding the sliding operation of the pad plate. Usually, the pad spring is provided by press-molding a metal plate made of stainless steel or spring steel and then bending the metal plate.

However, in the conventional disc brake as described above, during the sliding operation of the pad plate for pressurizing the disc, a large amount of friction is caused by friction in the direct contact process between the pad plate made of a metal material and the pad spring. There was a problem that sound was generated and the smooth sliding operation of the pad plate was disturbed.
Therefore, in order to solve the above problems, recently, grease or the like is applied to the friction surface between the pad plate and the pad spring, and the friction between the pad plate and the pad spring is improved while smoothing the sliding operation of the pad plate. Reduces stuttering. However, since this grease has a property of gelling with the passage of a predetermined time, there is a trouble that it should be replenished frequently, and when wear dust generated during friction between the disc and the friction pad sticks, There was a problem that the original lubricating action could not be performed.
The pad spring is provided so as to elastically support between the pad plate and the carrier, and during the sliding operation of the pad plate, the carrier of vibration generated while the pad plate vibrates in a direction perpendicular to the sliding direction. The pad spring absorbs the transmission to the side, but due to the characteristics of the material, there is a problem that such a damping function is lowered while the elastic deformation and restoration ability is reduced with the passage of time. .

  The present invention is intended to solve the above-mentioned problems, and its purpose is to simultaneously improve the function of smoothly guiding the sliding operation of the pad plate and the function of reducing vibration applied to the carrier from the pad plate. In addition, it is an object of the present invention to provide a disc brake pad spring and a method for manufacturing the same, which are provided in order to continuously maintain the improved function for a long time.

  In order to achieve the above-mentioned object, the present invention fixes a pair of pad plates to which friction pads are respectively attached to opposite inner surfaces of a disk rotating together with a wheel. The inside of the carrier is slidably accommodated on the disk side, and vibrations applied to the pad plate are guided between the pad plate and the carrier while guiding the sliding operation of the pad plate to the carrier side. In the disc brake in which the pad spring is interposed so as to suppress the friction, the pad spring is coated with a low friction material on one surface in contact with the pad plate, and an elastic body is coated on the other surface in contact with the carrier. And

The low friction material includes Teflon (registered trademark, the same applies to others).
The low friction material has a thickness in the range of 15 to 25 μm and is thinly coated on the outer surface of the pad spring.
Further, the elastic body is characterized by including a heat-resistant reinforced rubber.
The elastic body includes a synthetic resin including a heat-resistant reinforced rubber and urethane, carbon black, a vulcanization accelerator, an antioxidant, and a fluoropolymer.
The elastic body has a thickness in the range of 25 to 35 μm and is thinly coated on the outer surface of the pad spring.

  And the manufacturing method of the pad spring for disc brakes according to the present invention includes a coating preparation stage in which sanding treatment or corrosion treatment is performed on both surfaces of the metal plate material for forming the pad spring, and the metal plate material that has undergone the coating preparation stage. A coating process in which a low friction material is coated on one surface and an elastic body is coated on the other surface, and a metal plate material subjected to the coating step is subjected to pressing and bending, and the metal plate material is processed into the form of the pad spring. And a stress relief heat treatment step of removing stress applied to the bending portion of the pad spring in the shape processing step.

  Further, the disk brake pad spring manufacturing method according to the present invention includes performing a pressing and bending process on the metal plate material, and processing the metal plate material into the shape of the pad spring, and the shape processing step is performed through the shape processing step. A coating preparation stage in which sanding treatment or corrosion treatment is performed on both sides of the pad spring, a coating stage in which a low friction material is coated on one surface of the pad spring that has undergone the coating preparation stage, and an elastic body is coated on the other surface, and the shape In order to remove the stress applied to the bending portion of the pad spring in the processing step, the method includes a stress removal heat treatment step of performing a heat treatment on the pad spring that has undergone the coating step.

  The pad brake pad spring according to the present invention is provided such that one surface in contact with the pad plate is coated with a low friction material and the other surface in contact with the carrier is coated with an elastic body. Therefore, the pad brake pad spring according to the present invention has improved the function of smoothly guiding the sliding operation of the pad plate and the function of reducing the vibration applied to the carrier from the pad plate at the same time. The friction reducing function and the buffer function can be continuously maintained for a long time.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.
As shown in FIG. 1, the disc brake according to the present invention has a caliper housing 10 in which a piston 11 that moves forward and backward by receiving a braking hydraulic pressure is built, and friction pads 21 and 22 are attached to opposing inner surfaces thereof. A part of the outer peripheral edge is inserted between the pair of pad plates 23 and 24 while rotating together with the carrier 20 fixed to the vehicle body and the wheel so that the pair of pad plates 23 and 24 are installed. And the disk 30.
The piston 11 is disposed in the rear part of the caliper housing 10 so as to push the outer surface of the pad plate 24 on one side toward the disk 30, and the pad on the other side is disposed on the front part of the caliper housing 10 on the opposite side of the piston 11. Finger portions 10 a are formed so as to cover the outer surface of the plate 23, and the caliper housing 10 is slidably coupled to the carrier 20. For reference, the unexplained code “10b” is a cylinder that houses the piston 11.
Therefore, when the piston 11 operates so that the pad plate 24 on one side presses one surface of the disk 30, the pad plate 23 on the other side is guided by the finger portion 10a to press the other surface on the opposite side of the disk 30. As a result, the disk 30 is pressurized between the pair of friction pads 21 and 22.

The carrier 20 is fixed to the knuckle of the vehicle body with bolts, and the pad plates 23 and 24 are installed inside the carrier 20 so as to be slidable. A pad spring 40 is provided between the pad plates 23 and 24 and the carrier 20 to suppress vibration of the pad plates 23 and 24 while guiding the sliding operation of the pad plates 23 and 24.
More specifically, both sides of the carrier 20 and both ends of the corresponding pad plates 23, 24 have a concavo-convex structure corresponding to each other, and each pad spring 40 is connected to the end of the pad plate 23 on one side. 1st support part 41 which supports a part, 2nd support part 42 which supports the edge part of the other side pad plate 24, and the connection part which connects the upper part of the 1st support part 41 and the 2nd support part 42 integrally 43. Here, the first and second support portions 41 and 42 that substantially support between the pad plates 23 and 24 and the carrier 20 have an uneven structure corresponding to the end shape of the pad plates 23 and 24. Bending formed.

On the other hand, as shown in FIGS. 2 and 3, the pad spring 40 according to the present invention is coated with the low friction material 50 on one surface in contact with the pad plates 23 and 24 and the elastic body 60 on the other surface in contact with the carrier 20. Provided. As a result, the function of the pad spring 40 for smoothly guiding the sliding operation of the pad plates 23 and 24 and the function of the pad spring 40 for reducing vibration applied to the carrier 20 from the pad plates 23 and 24 are simultaneously improved. Thus, the improved friction reduction function and cushioning function of the pad spring 40 can be maintained continuously for a long period of time.
That is, during the sliding operation of the pad plates 23 and 24 for pressurizing the disk 30, when the pad plates 23 and 24 made of a metal material and the pad spring 40 are in direct contact with each other, the friction between the two members is large. While the noise is generated, the smooth sliding operation of the pad plates 23 and 24 is disturbed. However, like the pad spring 40 according to the present embodiment, one surface of the pad spring 40 in contact with the pad plates 23 and 24. In the state where the low friction material 50 is coated, the sliding operation of the pad plates 23 and 24 is performed more smoothly while the contact friction between the pad plates 23 and 24 and the pad spring 40 is reduced.

Further, in the case of the low friction material 50, even if it is used for a predetermined time or longer, it is not necessary to replace it. Of course, even if the wear dust generated during the friction between the disk 30 and the friction pads 21, 22 is stuck, this wear dust As a result, the smooth sliding operation of the pad plates 23 and 24 is continuously maintained for a longer period of time.
The pad spring 40 is provided so as to elastically support between the pad plates 23 and 24 and the carrier 20, and the pad plates 23 and 24 are perpendicular to the sliding direction during the sliding operation of the pad plates 23 and 24. The pad spring 40 absorbs the vibration generated while trembling in the direction to be transmitted to the vehicle body through the carrier 20, but the pad spring 40 is elastically deformed over time due to the characteristics of stainless steel and spring steel. There is a concern that such a damping function is lowered while the restoration ability is reduced.

However, as described above, when the elastic body 60 is coated on the other surface of the pad spring 40 on the carrier 20 side, the pad spring 40 is doubled by the elastic force of the pad spring 40 through the elastic force of the elastic body 60. Therefore, the pad spring 40 can be used for a long time. As a result, even when the elastic force of the pad spring 40 itself is reduced, the pad spring 40 can continuously perform a basic damping action by the elastic force of the elastic body 60.
The low friction material 50 and the elastic body 60 may be locally coated on a partial region of the pad spring 40, and are uniform in all regions on both sides of the pad spring 40 as shown in the drawing. May be coated.

Hereinafter, the manufacturing process of the pad spring 40 according to the present invention configured as described above will be described.
The pad spring 40 according to the present invention includes a coating preparation step (100), a coating step (200), a shape processing step (300), and a stress relief heat treatment step (400) sequentially according to the first embodiment shown in FIG. It is manufactured after passing.
Of the above-described steps, in the coating preparation step (100), first, a sanding process or a corrosion process is performed on both surfaces of a stainless steel plate for forming the pad spring 40 or a metal plate made of a spring steel material. Smooth the coating of the elastic body 60. In the coating step (200), the low friction material 50 and the elastic body 60 are coated on both sides of the metal plate material that has been sanded or corroded as described above.

At this time, Teflon is employed as the low friction material 50 so that it can withstand high heat in the stress removal heat treatment stage (400) described later, and the elastic body 60 includes heat-resistant reinforced rubber and urethane. . In the coating step (200), the low friction material 50 and the elastic body 60 are thinly coated on the surface of the metal plate material in order to prevent the thickness of the metal plate material from excessively increasing. In the case of the low friction material 50, it is preferably formed with a thickness in the range of 15 to 25 μm, and in the case of the elastic body 60, it is preferably formed with a thickness in the range of 25 to 35 μm. At this time, the metal plate is maintained at a thickness of about 0.3 to 0.5 mm.
In addition, in the case of Teflon used as the low friction material 50, it is preferable that the surface of the metal plate material is sprayed and coated, but unlike this, the coating can also be performed by electrostatic painting or a general painting method. Is possible. The elastic body 60 includes a mixture in which a predetermined amount of carbon black, a vulcanization accelerator, an antioxidant, and a fluoropolymer are added to a synthetic resin including a heat-resistant reinforced rubber and urethane. 60 is coated on the surface of the plate-shaped metal plate through various methods such as a spraying method and a roller coating method.

Here, the carbon black increases the heat resistance of the elastic body 60 together with the heat resistant reinforced rubber and urethane, and the vulcanization accelerator and the anti-aging agent are elastic while increasing the elastic force of the heat reinforced rubber. The oxidation of the body 60 is suppressed, and the fluoropolymer serves to promote the reaction between them.
Then, the metal plate material that has undergone the coating step (200) is in the form of a pad spring 40 through the pressing and bending in the shape processing step (300). Here, at the time of the bending process, stress concentrates on bending parts such as the first and second support portions 41 and 42, so that the pad spring 40 that has undergone the shape processing stage (300) becomes 350 in the stress relief heat treatment stage (400). By passing through an annealing method heat treatment at a temperature of ˜370 ° C., the stress of the pad spring 40 applied in the shape processing stage (300) is removed, and the manufacture of the pad spring 40 is completed. Therefore, in the manufacturing process of the pad spring 40 according to the first embodiment, the low friction material 50 and the elastic body 60 are coated on the outer surface of the metal plate material before the shape processing of the pad spring 40. The friction material 50 and the elastic body 60 are naturally coated uniformly on the surface of the pad spring 40.

Also, the pad spring 40 according to the present invention is different from the first embodiment described above in that the shape processing stage (500), the coating preparation stage (600), and the coating stage (700) according to the second embodiment shown in FIG. In addition, it is manufactured through a stress relief heat treatment step (800) sequentially.
First, in the shape processing step (500), the metal plate material made of stainless steel or spring steel is subjected to pressing and bending to form the pad spring 40. In the coating preparation stage (600), sanding or corrosion treatment is performed on both sides of the pad spring 40 to smoothly coat the low friction material 50 and the elastic body 60. In the coating step 700, the low friction material 50 and the elastic body 60 are coated on both surfaces of the pad spring 40 that has been sanded or corroded as described above.

Further, in the coating stage (700), Teflon is adopted as the low friction material 50 so that it can withstand the high heat in the stress relief heat treatment stage (800) described later, and the elastic body 60 is made of heat-resistant reinforced rubber, urethane, or the like. It is comprised including. In the coating step 700, the low friction material 50 and the elastic body 60 are thinly coated on the surface of the pad spring 40 in order to prevent the thickness of the pad spring 40 from excessively increasing. The low friction material 50 is preferably coated with a thickness in the range of 15 to 25 μm, and the elastic body 60 is preferably coated with a thickness in the range of 25 to 35 μm. At this time, the pad spring 40 is maintained at a thickness of about 0.3 to 0.5 mm.
Also, in the case of Teflon used as the low friction material 50, it is preferable that the surface of the pad spring 40 is sprayed and coated, but unlike this, coating is also performed by electrostatic painting or general painting methods. Is possible. The elastic body 60 includes a mixture in which a predetermined amount of carbon black, a vulcanization accelerator, an antioxidant, and a fluoropolymer are added to a synthetic resin including a heat-resistant reinforced rubber and urethane. 60 is coated on the surface of the pad spring 40 through a spraying method.

In the coating step 700, the outer surface of the pad spring 40 to be coated with the elastic body 60 is preferably preheated before the elastic body 60 is coated on the outer surface of the pad spring 40. As a result, the elastic body 60 is more smoothly coated on the surface of the pad spring 40 that has already been bent while undergoing the bending process of the shape processing stage (500).
Here, the carbon black increases the heat resistance of the elastic body 60 together with the heat resistant reinforced rubber and urethane, and the vulcanization accelerator and the anti-aging agent are elastic while increasing the elastic force of the heat reinforced rubber. The oxidation of the body 60 is suppressed, and the fluoropolymer serves to promote the reaction between them.

  The pad spring 40 in this state is in a state in which stress is concentrated on bending portions such as the first and second support portions 41 and 42 during the bending process in the shape processing stage (500). 700) is subjected to an annealing method heat treatment at a temperature of 350 to 370 ° C. in the stress removal heat treatment step (800), so that the stress of the pad spring 40 applied in the shape processing step (500) is removed. Thus, the manufacture of the pad spring 40 according to the second embodiment is completed. Accordingly, the stress applied to the pad spring 40 in the shape processing stage (500) is removed in the stress removing heat treatment stage (800) performed after the coating stage (700), but the pad spring 40 is removed in the coating stage (700). The low-friction material 50 and the elastic body 60 that are thinly coated on the surface thereof are not greatly affected by the high heat in the stress-relieving heat treatment step (800).

1 is an exploded perspective view showing the structure of a disc brake according to the present invention. It is sectional drawing which showed the principal part structure of the disc brake which concerns on this invention. It is an expanded sectional view showing the section structure of the pad spring in the disc brake concerning the present invention. 3 is a flowchart illustrating a manufacturing process of a pad spring according to the first embodiment of the present invention. 6 is a flowchart illustrating a manufacturing process of a pad spring according to a second embodiment of the present invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Caliper housing 11 Piston 20 Carrier 21, 22 Friction pad 23, 24 Pad spring 30 Disc 40 Pad spring 41 1st support part 42 2nd support part 43 Connection part 50 Low friction material 60 Elastic body

Claims (10)

In order to press and fix both sides of the disc rotating with the wheel, a pair of pad plates with friction pads attached to the opposite inner surfaces can slide on the disc side inside the carrier fixed to the car body A disc brake in which a pad spring is interposed between the pad plate and the carrier so as to suppress transmission of vibration applied to the pad plate to the carrier side while guiding a sliding operation of the pad plate. In
The pad spring is a pad brake for a disc brake, wherein one surface in contact with the pad plate is coated with a low friction material and the other surface in contact with the carrier is coated with an elastic body.   The disk brake pad spring according to claim 1, wherein the low friction material includes Teflon.   3. The disk brake pad spring according to claim 2, wherein the low friction material has a thickness in the range of 15 to 25 [mu] m and is thinly coated on the outer surface of the pad spring.   The disk spring pad spring according to claim 1, wherein the elastic body includes heat-resistant reinforced rubber.   5. The disc brake according to claim 4, wherein the elastic body includes a synthetic resin including heat-resistant reinforced rubber and urethane, carbon black, a vulcanization accelerator, an antioxidant, and a fluoropolymer. Pad spring.   5. The disk brake pad spring according to claim 4, wherein the elastic body has a thickness in a range of 25 to 35 [mu] m and is thinly coated on an outer surface of the pad spring. A coating preparation stage in which sanding treatment or corrosion treatment is performed on both sides of the metal plate material for forming the pad spring,
A coating step of coating a low friction material on one surface of the metal plate material that has undergone the coating preparation step, and coating an elastic body on the other surface;
Performing a pressing and bending process on the metal plate material that has undergone the coating step, and processing the metal plate material into the form of the pad spring; and
A method for manufacturing a pad brake pad spring, comprising: a stress relief heat treatment step of removing stress applied to a bending portion of the pad spring in the shape processing step. The low friction material is configured to include Teflon, and the elastic body is configured to include heat-resistant reinforced rubber,
In the coating step, the low friction material and the elastic body have a thickness of 15 to 25 μm and a thickness of 25 to 35 μm, respectively, and are thinly coated on the outer surface of the pad spring. The manufacturing method of the pad spring for disk brakes of Claim 7. Performing a pressing and bending process on a metal plate, and processing the metal plate into the form of the pad spring; and
A coating preparation step of performing sanding treatment or corrosion treatment on both surfaces of the pad spring that has undergone the shape processing step;
A coating step in which a low friction material is coated on one surface of the pad spring that has undergone the coating preparation step, and an elastic body is coated on the other surface;
A disc brake pad comprising: a stress removal heat treatment step of performing a heat treatment on the pad spring that has undergone the coating step in order to remove the stress applied to the bending portion of the pad spring in the shape processing step. Spring manufacturing method. The low friction material is configured to include Teflon, and the elastic body is configured to include heat-resistant reinforced rubber,
In the coating step, the low friction material and the elastic body have a thickness in the range of 15 to 25 μm and a thickness in the range of 25 to 35 μm and are thinly coated on the outer surface of the pad spring. Item 10. A method for manufacturing a pad spring for a disc brake according to Item 9.

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