JP4996761B2 - Disc rotor for disc brake - Google Patents

Description

  The present invention relates to a disc brake disk rotor in which a central portion is attached to a rotating body to be braked and a peripheral portion is sandwiched between a pair of friction pads.

  As a brake device mounted on a vehicle or the like, a disc brake is known in which a disc rotor that rotates together with a wheel is sandwiched between a pair of friction pads to apply a braking force to the wheel.

  The disk rotor used for this disk brake is often made of cast iron for reasons of frictional performance. However, the disk rotor made of cast iron has a large specific gravity and a low thermal conductivity. Therefore, it is necessary to increase the volume to prevent an excessive temperature rise.

On the other hand, in recent years, the weight of the disk rotor has been reduced for the purpose of improving the fuel efficiency of the vehicle. And the disk rotor which casts a cast iron piece in the aluminum alloy whose specific gravity is small compared with cast iron and whose heat conductivity is high is proposed (for example, refer patent document 1).
JP 58-152945 A

  However, although the disk rotor described in Patent Document 1 can be reduced in weight, the adhesive strength between the aluminum alloy and the cast iron piece is weak, so that it cannot be put into practical use. Further, due to the weak adhesive strength, a gap is formed between the aluminum alloy and the cast iron piece, and the heat conduction from the cast iron piece to the aluminum alloy is hindered.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a lightweight disc brake disc rotor that has good heat dissipation and can withstand practical use.

  In order to solve the above-mentioned problems, the present invention provides (1) a disc brake disc rotor in which a central portion is attached to a braking target and a peripheral portion is sandwiched between a pair of friction pads, Two circular plate members that are arranged to be opposed to each other, an aluminum plating layer that is provided on each of the inner surfaces facing each other of the circular plate members, and the circular plate members that are interposed via the both aluminum plating layers An aluminum casting portion formed by casting a metal, and both outer surfaces of the circular plate members facing each other are friction sliding surfaces that frictionally slide with respect to the friction pads when sandwiched by the friction pads. A disc rotor for a disc brake characterized by having

  Moreover, this invention WHEREIN: The said structure (1) WHEREIN: (2) The said circular plate member is provided with the some hole which penetrates in a plate | board thickness direction, respectively, and the said aluminum casting part has penetrated in the middle of the said hole. The disc rotor for disc brakes characterized by the above is provided.

  Moreover, the present invention is characterized in that, in the configuration (1), (3) each of the circular plate members includes a plurality of recesses on the inner surface, and the cast aluminum part enters the recess. A disc rotor for a disc brake is provided.

  According to the present invention, in the configuration (2) or (3), (4) a disc rotor for a disc brake, wherein the hole or the concave portion is formed in a tapered shape that tapers inward. It is to provide.

  Further, in the present invention, in any one of the above configurations (1) to (4), (5) the circular plate member is formed of an annular iron plate, and the center portion of the aluminum casting portion protrudes to one side in the axial direction and is attached. And a disc rotor for a disc brake characterized in that the frustoconical side wall is formed to have a plurality of fins.

  The present invention also provides a disc rotor for a disc brake characterized in that, in the configuration (5), (6) the mounting portion is casted with a steel plate for reinforcement.

  Further, in the present invention, in any one of the above configurations (1) to (6), (7) the aluminum casting portion provided with a plurality of grooves is provided in each of the two circular plate members, and the grooves are matched. The disk brake disk rotor, wherein the circular plate members are connected by mechanical connecting means in the plate thickness direction, and a plurality of heat radiation holes are provided in the circumferential direction in the cast aluminum part. It is to provide.

  Moreover, this invention WHEREIN: In any one of said structure (1)-(6), (8) The several heat radiating pipe extended in the radial direction is arrange | positioned in the said aluminum casting part at the circumferential direction, The said heat radiating pipe is Further, the present invention provides a disc rotor for a disc brake, the periphery of which is cast by the aluminum casting part.

  The disc rotor of the present invention is constituted by an aluminum casting portion having a small specific gravity except for a portion that frictionally slides on the friction pad. Furthermore, since the aluminum casting part has high heat dissipation and suppresses an excessive temperature rise, it is not necessary to increase the volume in order to increase the heat capacity. Therefore, according to the disk rotor of the present invention, a significant weight reduction can be realized.

  An aluminum plating layer is provided at the interface between the circular plate member and the aluminum casting part. Therefore, according to the disk rotor of the present invention, the adhesion between the circular plate member and the aluminum casting part is improved, and the circular plate member can be prevented from peeling off. Moreover, the heat conductivity from a circular board member to an aluminum casting part improves by the adhesive improvement of a circular board member and an aluminum casting part.

It is a perspective view which shows an example of the disc rotor for disc brakes concerning this invention. FIG. 2 is a front view, a cross-sectional view taken along line XX, and a rear view of the disk rotor of FIG. 1. It is a figure which shows the process of manufacturing the disk rotor of FIG. It is a figure following FIG. It is a figure following FIG. It is a figure for demonstrating the usage condition of the disc rotor of FIG. It is a figure which shows a modification. It is a figure which shows the example of the disk rotor provided with the steel plate for reinforcement. It is a figure which shows the example of the disc rotor provided with the heat radiating hole. It is a figure which shows the example of the disk rotor provided with the heat radiating pipe. It is a figure for demonstrating a thermal radiation pipe.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.

[Constitution]
As shown in FIGS. 1 and 2, the disk brake disk rotor 1 according to the present embodiment includes two circular plate members 2, 3 that are arranged with a space therebetween so that one inner surface 2 a, 3 a faces each other. And an aluminum casting part 4 formed by casting between the circular plate members 2 and 3.

  In this embodiment, each circular plate member 2 and 3 is comprised by the cyclic | annular iron plate which consists of substantially the same shape. The circular plate members 2 and 3 are made of, for example, a hot rolled steel plate, and are formed to have an outer diameter of 334 mm, an inner diameter of 220 mm, and a thickness of 5.5 mm. The circular plate members 2 and 3 are arranged coaxially with an interval of 9 mm.

  Further, the circular plate members 2 and 3 are provided with a plurality of through holes 2c and 3c penetrating in the axial direction (plate thickness direction). The through holes 2c and 3c have a diameter of 9.5 mm and are provided on the first pitch circle C1 to the fifth pitch circle C5. The diameters of the pitch circles C1 to C5 are the first pitch circle C1: φ304 mm, the second pitch circle C2: φ296 mm, the third pitch circle C3: φ280 mm, the fourth pitch circle C4: φ258 mm, and the fifth pitch circle C5: φ250 mm. ing.

  The through-holes 2c and 3c have a third pitch circle C3, a fourth pitch circle C4, and a second pitch circle as viewed from any one of the through-holes 2c and 3c arranged on the first pitch circle C1. C2 and the fifth pitch circle C5 are arranged in the order of 7.2 ° in the clockwise direction (clockwise when viewed from the outer side surfaces 2b and 3b of the circular plate members 2 and 3, respectively). Further, the circular plate member 2 and the circular plate member 3 are disposed so that the through holes 2c and 3c on the first pitch circle C1 are coaxial.

  As shown in FIG. 2B, the circular plate members 2 and 3 are further provided with aluminum plating layers 2d and 3d on the peripheral surfaces of the inner side surfaces 2a and 3a and the through holes 2c and 3c. The aluminum plating layers 2d and 3d are formed by a molten aluminum plating process.

  The cast aluminum part 4 is formed by aluminum die casting. The aluminum casting portion 4 is cast (cast) while being interposed between the circular plate members 2 and 3 arranged at intervals. At this time, the aluminum casting part 4 casts the circular plate members 2 and 3 such that the outer surfaces 2b and 3b and the inner and outer peripheral surfaces of the circular plate members 2 and 3 are exposed.

  A central portion 41 of the aluminum casting portion 4 protrudes from the circular plate member 2 and has a substantially truncated cone shape. A plurality of attachment holes 43 are provided at the top of the central portion (attachment portion) 41 for attachment to a rotating body to be braked. A plurality of fins 44 are formed on the side wall portion of the central portion 41. In this way, by configuring the mounting portion for mounting the braking target with the aluminum casting portion 4, it is possible to reduce weight and improve heat dissipation.

  As shown in FIG. 2B, the aluminum casting part 4 has entered the through holes 2c and 3c of the circular plate members 2 and 3. In the present embodiment, the aluminum casting part 4 enters the through holes 2c and 3c from the inner side surfaces 2a and 3a of the circular plate members 2 and 3 to a position of 3.5 mm.

[Production method]
The disk rotor 1 is manufactured as follows, for example.
First, the circular plate members 2 and 3 are prepared. The circular plate members 2 and 3 are formed by pressing as described above, and then the whole is immersed in molten aluminum and subjected to molten aluminum plating treatment.

  Next, the circular plate members 2 and 3 are respectively attached to the fixed mold 11 and the movable mold 12 (see FIG. 3). Protrusions 13 and 14 are provided at positions corresponding to the through holes 2c and 3c of the circular plate members 2 and 3 at the portions where the circular plate members 2 and 3 of the fixed die 11 and the movable die 12 are attached. The circular plate members 2 and 3 are attached to the fixed mold 11 and the movable mold 12 with the protrusions 13 and 14 inserted into the through holes 2c and 3c. At this time, the protrusions 13 and 14 are inserted from the inner side surfaces 2a and 3a of the through holes 2c and 3c to a position of 3.5 mm.

  Next, as shown in FIG. 3, the movable mold 12 moves toward the fixed mold 11, and the mold is clamped. Then, the molten aluminum AD for casting is injected into the sleeve 15.

  Next, as shown in FIG. 4, the plunger 16 inserted into the sleeve 15 moves in a direction toward the movable mold 12. Thereby, the molten metal AD is pressurized and injected into the mold.

  When the molten metal AD is solidified, as shown in FIG. 5, the movable mold 12 moves away from the fixed mold 11, and the mold is opened. Then, the pin 17 moves so as to protrude toward the fixed mold 11, and the disk rotor 1 is taken out. The disc rotor 1 is completed by deburring and finishing the outer surfaces 2b and 3b serving as friction sliding surfaces. By this finishing process, all the aluminum plating layers formed on the outer side surfaces 2b and 3b are removed.

[Usage]
The disc rotor 1 manufactured in this way is used as a disc rotor of the disc brake 5 as shown in FIG. As shown in FIG. 6, the disk rotor 1 has a central portion 41 of the aluminum casting portion 4 attached to a rotating body (braking target) R. The circular plate members 2 and 3 are sandwiched between the friction pads 6 and 6. At this time, the outer surfaces 2b and 3b of the circular plate members 2 and 3 are frictionally slid against the friction pads 6 and 6, whereby a braking force is applied to the disk rotor 1, that is, the rotating body R.

[effect]
In the disk rotor 1 of the present invention, the circular plate members 2 and 3 are cast by the aluminum casting part 4. Then, the outer surfaces 2 b and 3 b of the circular plate members 2 and 3 are frictionally slid against the friction pads 6 and 6. That is, according to the disk rotor 1, the frictional sliding is performed by the circular plate members 2 and 3, and therefore, good friction performance can be obtained.

  Further, the disc rotor 1 is constituted by an aluminum casting portion 4 having a small specific gravity except for a portion that frictionally slides against the friction pads 6 and 6. Furthermore, since the aluminum casting part 4 has high thermal conductivity and good heat dissipation, it is not necessary to increase the volume in order to increase the heat capacity. Therefore, according to the disk rotor 1, a significant weight reduction can be realized.

  Further, aluminum plating layers 2d and 3d are provided on the inner side surfaces 2a and 3a of the circular plate members 2 and 3, respectively. The aluminum plating layers 2d and 3d form a dense alloy layer (Fe—Al), and when the aluminum casting part 4 is formed by aluminum die casting, the aluminum plating layers 2d and 3d are welded to the aluminum casting part 4 by the heat. Therefore, according to the disk rotor 1, the circular plate members 2 and 3 and the aluminum casting part 4 are strongly adhered and integrated, and thus the circular plate members 2 and 3 can be prevented from being peeled off. Further, since the molecular bond is obtained between the circular plate members 2 and 3 and the aluminum casting part 4, the thermal conductivity from the circular plate members 2 and 3 to the aluminum casting part 4 is improved.

  A plurality of fins 44 are provided on the side wall portion of the central portion 41 of the aluminum casting portion 4. Therefore, according to the disk rotor 1, the heat generated during the frictional sliding can be radiated well.

  Further, the circular plate members 2 and 3 are provided with through holes 2c and 3c, and the aluminum casting portion 4 enters the through holes 2c and 3c. Therefore, according to the disk rotor 1, the contact area between the circular plate members 2 and 3 and the aluminum casting part 4 is increased, and the heat dissipation and the adhesive strength can be improved. Further, according to the disk rotor 1, since the part that has entered this counteracts the shearing force generated between the aluminum casting part 4 and the circular plate members 2 and 3 during frictional sliding, the circular plate member 2 is caused by the shearing force. 3 can be prevented from peeling off.

[Modification]
Although the embodiments of the present invention have been specifically described above, the present invention can be implemented with the following modifications.

  For example, the disk rotor 1 is configured such that the circular plate members 2 and 3 are provided with the through holes 2c and 3c, and the aluminum casting part 4 enters partway through them, but is not limited thereto. Instead of the through holes 2c and 3c, as shown in FIG. 7A, recesses 2e and 3e (not reaching the outer surfaces 2b and 3b) are provided on the inner side surfaces 2a and 3a of the circular plate members 2 and 3, and aluminum is provided. You may comprise so that the casting part 4 may enter in the recessed part.

  Further, the through holes 2c and 3c and the recesses 2e and 3e can be formed in a tapered shape that tapers inward as shown in FIGS. 7B and 7C. In this case, the portion of the aluminum casting portion 4 that has entered the through holes 2c and 3c or the recesses 2e and 3e serves as a wedge, and the circular plate members 2 and 3 can be prevented from peeling off.

  In addition, when the shearing force produced at the time of friction sliding is comparatively low, it is not necessary to provide the through holes 2c and 3c and the recesses 2e and 3e.

  In the disk rotor 1, the plurality of fins 44 are formed on the side wall portion of the central portion 41 of the aluminum casting portion 4, but the present invention is not limited to this. If the amount of heat generated during friction sliding is relatively small, the fins 44 may not be provided.

  In addition, as shown in FIG. 8, when the portion attached to the braking target in the central portion 41 of the disk rotor 1 is configured by the aluminum casting portion 4, a reinforcing steel plate 7 may be cast in the central portion 41. In this case, it is preferable to provide an aluminum plating layer at the interface between the steel plate 7 and the aluminum casting part 4 as well as the circular plate members 2 and 3.

  Next, a modified example of the disk rotor provided with the heat radiating holes will be described. 9A is a front view showing the disk rotor, FIG. 9B is a cross-sectional view taken along line YY of FIG. 9A, and FIG. 9C is an enlarged cross-sectional view of the upper circular portion of FIG. 9B. As shown in FIG. 9, the disk rotor 1 includes a plurality of heat radiation holes 47 radially in the circumferential direction. The heat radiating hole 47 is provided in the aluminum casting part 4 and efficiently radiates heat generated during braking or the like. As shown in FIG. 9A, the heat radiating hole 47 is formed in an arc shape in a plan view so that when the disk rotor 1 rotates, heat easily flows and heat dissipation is good.

  As shown in FIG. 9B, in the present embodiment, one circular plate member 2 includes a mounting portion 20 that protrudes in the center to mount a braking target. The mounting portion 20 is substantially cylindrical, and includes a plurality of mounting holes 23 for mounting a rotating body to be braked on the top surface portion thereof. Unlike the above-mentioned embodiment, since the attachment part 20 is not the aluminum casting part 4, since heat conductivity is a little inferior, in order to improve a cooling effect, the several thermal radiation hole 47 is provided. And the other circular board member 3 consists of an annular member similarly to the said embodiment. The circular plate members 2 and 3 are made of cast iron, stainless steel, or the like.

  Next, a manufacturing method will be described. Only parts different from the manufacturing method of the above embodiment will be described in detail. In the present embodiment, first, cast aluminum parts 4 'and 4 "are separately cast on the inner side surfaces of the respective circular plate members 2 and 3 (FIG. 9C). Each aluminum casting part 4 ', 4 "is cast in an annular shape at a position corresponding to the friction sliding surface. At this time, a plurality of groove portions 47a and 47b are provided in the respective aluminum casting portions 4 'and 4' '. The concave grooves 47a and 47b are formed by providing linear protrusions on the molds 11 and 12. Then, by aligning the groove portions 47a and 47b and connecting the circular plate members 2 and 3 having the aluminum casting portions 4 ′ and 4 ″, a plurality of heat radiation holes 47 are formed in the aluminum casting portion 4. . In addition, when connecting, the grinding | polishing process is given to the connection surface in each aluminum casting part 4 ', 4' '.

  The circular plate members 2 and 3 having the aluminum casting portions 4 ′ and 4 ″ are connected by a plurality of rivets (mechanical connecting means) 45. In this case, as shown in FIG. 9C, the circular plate members 2 and 3 have portions 2f and 3f connected by a rivet 45 pre-pressed in a U-shaped cross section. The mechanical connecting means 45 may be a bolt member or the like. The circular plate members 2 and 3 contact the connecting portions 2f and 3f with each other, and in this state, connect the connecting portions 2f and 3f in the plate thickness direction (axial direction) with the rivets 45 (FIG. 9B).

  In the present embodiment, since the aluminum casting parts 4 and 4 ″ are cast into the respective circular plate members 2 and 3, when the aluminum casting parts 4 and 4 ″ are removed from the molds 11 and 12, the respective aluminum casting parts 4 ′ and 4 ″. Contracts in a direction in close contact with the respective circular plate members 2 and 3. Therefore, the circular plate members 2 and 3 and the aluminum casting part 4 are excellent in heat transfer efficiency without being peeled off, and the strong connection can be maintained by the mechanical connection means (rivet) 45.

  Next, a modified example of the disk rotor provided with the heat radiating pipe will be described. FIG. 10A is a front view showing a disk rotor, and FIG. 10B is a side view. As shown in FIG. 10, the disk rotor 1 includes a plurality of heat radiating pipes 46 in the aluminum casting part 4. The heat radiating pipe 46 is for efficiently radiating heat generated in the disk rotor 1 during braking or the like.

  As shown in FIG. 10A, the heat radiating pipes 46 extend in the radial direction of the disk rotor 1, and a plurality of heat radiating pipes 46 are arranged at equal intervals (radially) in the circumferential direction. As shown in FIG. 10B, the heat radiating pipe 46 is provided in the aluminum casting part 4. Therefore, the heat generated in the circular plate members 2 and 3 sandwiched between the friction pads 6 (FIG. 6) during braking is effective through the aluminum casting portion 4 and through the hollow portion of the heat radiating pipe 46 by the rotation of the disk rotor 1. Heat is released.

  11A is a perspective view showing a state in which a plurality of heat radiating pipes are radially arranged, FIG. 11B is a perspective view showing the heat radiating pipe, and FIG. 11C is a side view showing a state in which the heat radiating pipes are installed on the disk rotor. As shown in FIG. 11, the heat radiating pipe 46 has a pipe shape by welding the first member 460 and the second member 461 pressed into a groove shape (U-shape) with their opening portions facing each other. Is formed.

  As shown in FIG. 11B, the heat radiating pipe 46 includes a plurality of convex portions 46a that protrude in the axial direction at a predetermined interval. In this example, the convex portion 46 a is provided at two places on both side surfaces of the heat radiating pipe 46. Furthermore, the convex part 46a is provided with the positioning claw 46b on the top part. As shown in FIG. 11C, the circular plate members 2 and 3 include positioning holes 2g and 3g for fitting the positioning claws 46b into the inner side surfaces 2a and 3a facing each other.

  Next, a manufacturing method will be described. Only parts different from the manufacturing method of the above embodiment will be described in detail. First, a plurality of heat radiation pipes 46 are arranged radially with respect to the circular plate members 2 and 3. The circular plate members 2 and 3 are provided with a plurality of positioning holes 2g and 3g, and the positioning claws 46b of the heat radiating pipe 46 are fitted into the positioning holes 2g and 3g. By sandwiching 4, the plurality of heat radiation pipes 46 are temporarily fixed (positioned) radially to the circular plate members 2 and 3.

  Then, the circular plate members 2 and 3 to which the heat radiating pipe 46 is temporarily fixed are attached to the molds 11 and 12, and the molten aluminum AD for casting is injected into the molds 11 and 12 (FIG. 3). At this time, caps (not shown) are fitted into the opening portions at both ends of the heat radiating pipe 46 so that the opening portions at both ends of the heat radiating pipe 46 are not blocked by the molten metal AD.

  Since the space S (FIG. 11C) is formed between the heat radiating pipe 46 and the circular plate members 2 and 3 by the convex portions 46 a, the molten metal AD flows into the periphery of the heat radiating pipe 46 through the space S. Thereby, the periphery of the heat radiating pipe 46 can be cast with the aluminum casting part 4. By casting the heat radiating pipe 46 in the aluminum casting part 4, the heat conduction surface is increased and the heat radiating effect is improved, and the adhesion between the circular plate members 2 and 3 and the aluminum casting part 4 is strengthened and peeling is performed. More can be prevented. Further, in order to further improve the adhesion, the periphery of the heat radiating pipe 46 may be subjected to a molten aluminum plating process and cast through an aluminum plating layer (not shown).

AD Molten metal C1 to C5 Pitch circle R Rotating body 1 Disc rotor 2, 3 Circular plate members 2a, 3a Inner side surface 2c, 3c Through hole 2d, 3d Aluminum plating layer 2e, 3e Recess 4 Aluminum casting part 5 Disc brake 6 Friction pad 11 Movable die 12 Fixed die 13, 14 Protrusion 15 Sleeve 16 Plunger 17 Pin 41 Central portion 43 Mounting hole 44 Fin 45 Rivet 46 Heat radiation pipe 47 Heat radiation hole

Claims (6)

A disc rotor for a disc brake in which a central portion is attached to a braking target and a peripheral portion is sandwiched between a pair of friction pads,
Two circular plate members arranged so as to face each other on the inner surface, an aluminum plating layer provided on each of the inner surfaces facing each other of the circular plate members, and both the aluminum plating layers An aluminum casting part formed by casting the both circular plate members,
The outer surfaces of the circular plate members that do not face each other have a friction sliding surface that frictionally slides against the friction pad when sandwiched between the friction pads,
The cast aluminum part provided with a plurality of grooves is provided in each of the two circular plate members, and the circular plate members are connected by a mechanical connecting means in the plate thickness direction so that the grooves match each other. A disc brake disk rotor comprising a plurality of heat radiating holes in a circumferential direction in the cast aluminum part.   2. The disk rotor for a disk brake according to claim 1, wherein each of the circular plate members includes a plurality of holes penetrating in the plate thickness direction, and the aluminum casting portion is inserted partway through the holes. .   2. The disk rotor for a disk brake according to claim 1, wherein each of the circular plate members includes a plurality of recesses on the inner side surface, and the aluminum casting portion enters the recess.   4. The disk rotor for a disk brake according to claim 2, wherein the hole or the recess is formed in a tapered shape that tapers inward.   The circular plate member is made of an annular iron plate, and the center portion of the aluminum casting portion projects to one side in the axial direction to form the mounting portion, and the side wall of the truncated cone has a plurality of fins. The disc rotor for a disc brake according to any one of claims 1 to 4, wherein the disc rotor is a disc rotor.   6. The disk rotor for a disk brake according to claim 5, wherein a steel plate for reinforcement is cast in the mounting portion.