KR101548547B1 - Brake disk and vehicle including the same - Google Patents

Abstract

The present invention relates to a brake disc having a low risk of breakage and excellent heat dissipation performance and a light weight brake disc and a vehicle including the brake disc. The brake disc includes a first disc, a second disc facing the first disc, A plurality of legs connecting between the first disk and the second disk and a lightweight material filling the space between the first disk and the second disk, And a second disk, An outer ring coupled to at least one of the second disk and the third disk and an inner ring connectable to a wheel of the vehicle, and a housing bent at least once so that the inner ring and the outer ring are not located on the same plane A brake disc and a vehicle including the brake disc.

Description

A brake disk and a vehicle including the brake disk,

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a lightweight brake disc and a vehicle including the brake disc.

In general, the vehicle brakes are largely divided into a disk type and a drum type. The disc method is referred to as disc brake, which presses the caliper pad on both sides of the disc rotating with the wheel, and then generates friction to generate braking force. And the drum brake gets the braking force by pressing the brake shoe with the lining (friction material) inside the drum rotating with the wheel.

In recent years, as technologies such as ABS or VDS / ESP have been developed to improve the stability of the vehicle through braking, it is possible to use the drum brake, which has the disadvantage of not being braked due to expansion when used repeatedly, Disk method. As a result, the overall speed of the vehicle increases as the engine develops, and a technique for improving the braking force is developed every day. However, when the distribution of the braking force generated by the vehicle is examined, the braking force transmitted to the front wheel This is considerably larger than the rear wheel. Therefore, even if the disk type is applied to the front and rear wheels of the vehicle, the brake of the front wheel becomes the main brake, and the rear brake does not adopt the same disk type by the theory of the auxiliary brake. In other words, vehicles shipped by OEMs have been made to differentiate the disk system of the front wheel and the disk system of the rear wheel in order to save most manufacturing costs as much as possible.

The conventional disk type includes a caliper (C) having a hydraulic cylinder and a pad, a disk which is pressed by the caliper (C) to generate a braking force, and a housing . At this time, in order to lower the manufacturing cost of the automobile brake apparatuses of most of the OEMs, the disc and the housing are integrally formed through the casting.

However, since the conventional brake disc is made of a cast iron having a considerably heavy weight and low heat dissipation property, there is a problem that the fuel efficiency of the vehicle is lowered and the braking force is lowered, and a crack is formed in the bent portion at the time of casting.

It is an object of the present invention to solve the above problems and to provide a brake disk having a low risk of breakage, excellent heat dissipation performance and light weight, and a vehicle including the same. However, these problems are exemplary and do not limit the scope of the present invention.

According to an aspect of the present invention, there is provided a magnetic disk drive comprising: a first disk, a second disk facing the first disk, and a second disk disposed between the first disk and the second disk, And a third disk that fills the gap between the first disk and the second disk and includes a material that is lighter than the first disk and the second disk; An outer ring coupled to at least one of the second disk and the third disk and an inner ring connectable to a wheel of the vehicle, and a housing bent at least once so that the inner ring and the outer ring are not located on the same plane A brake disc is provided.

The inner ring and the outer ring of the housing may be integrally formed by casting.

The housing may comprise aluminum.

The third disk may be formed by casting between the first disk and the second disk connected by the plurality of legs.

The third disk may include aluminum having a range of 7 wt% to 20 wt%.

The third disk may include a cooling hole extending in a central axis direction of the housing.

The cooling holes may be reduced in size from the outside to the inside of the third disk.

The first disk and the second disk may have fixing grooves or protrusions formed on at least one surface thereof facing each other.

The fixing groove or the protrusion may extend in an oblique direction with respect to a vertical direction of the central axis of the housing.

The first disk, the second disk, and the plurality of legs may be integrally formed.

The plurality of legs may be disposed adjacent to the outer and inner edges of the first disk and the second disk.

At least one of the first disk, the second disk and the third disk may be bolted to the outer ring of the housing.

According to another aspect of the present invention, there is provided an automobile including a caliper and the above-described brake disk installed adjacent to the caliper.

According to an embodiment of the present invention as described above, it is possible to realize a brake disc having a reduced risk of breakage, excellent heat dissipation performance and light weight, and a vehicle including the brake disc. Of course, the scope of the present invention is not limited by these effects.

1 is an exploded perspective view schematically showing a brake disk according to an embodiment of the present invention.
2 is a partial cut-away plan view schematically illustrating a third one of the brake discs according to one embodiment of the present invention.
3 is a side sectional view schematically showing a brake disk according to an embodiment of the present invention.
4 is a partial cross-sectional view schematically showing a brake disk according to another embodiment of the present invention.

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

The embodiments of the present invention are described in order to more fully explain the present invention to those skilled in the art, and the following embodiments may be modified into various other forms, The present invention is not limited to the embodiment. Rather, these embodiments are provided so that this disclosure will be more thorough and complete, and will fully convey the concept of the invention to those skilled in the art. In the drawings, the thickness and size of each layer are exaggerated for convenience and clarity of explanation.

It is to be understood that throughout the specification, when an element such as a film, region or substrate is referred to as being "on", "connected to", "laminated" or "coupled to" another element, It will be appreciated that elements may be directly "on", "connected", "laminated" or "coupled" to another element, or there may be other elements intervening therebetween. On the other hand, when one element is referred to as being "directly on", "directly connected", or "directly coupled" to another element, it is interpreted that there are no other components intervening therebetween do. Like numbers refer to like elements. As used herein, the term "and / or" includes any and all combinations of one or more of the listed items.

Although the terms first, second, etc. are used herein to describe various elements, components, regions, layers and / or portions, these members, components, regions, layers and / It is obvious that no. These terms are only used to distinguish one member, component, region, layer or section from another region, layer or section. Thus, a first member, component, region, layer or section described below may refer to a second member, component, region, layer or section without departing from the teachings of the present invention.

Also, relative terms such as "top" or "above" and "under" or "below" can be used herein to describe the relationship of certain elements to other elements as illustrated in the Figures. Relative terms are intended to include different orientations of the device in addition to those depicted in the Figures. For example, in the figures the elements are turned over so that the elements depicted as being on the top surface of the other elements are oriented on the bottom surface of the other elements. The term "topsheet " as used herein, therefore, may encompass both" bottom "and" top "orientations depending on the particular orientation of the figures. If the elements are oriented in different directions (rotated 90 degrees with respect to the other direction), the relative descriptions used herein can be interpreted accordingly.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms "a," "an," and "the" include singular forms unless the context clearly dictates otherwise. Also, " comprise "and / or" comprising "when used herein should be interpreted as specifying the presence of stated shapes, numbers, steps, operations, elements, elements, and / And does not preclude the presence or addition of one or more other features, integers, operations, elements, elements, and / or groups.

Hereinafter, embodiments of the present invention will be described with reference to the drawings schematically showing ideal embodiments of the present invention. In the figures, for example, variations in the shape shown may be expected, depending on manufacturing techniques and / or tolerances. Accordingly, the embodiments of the present invention should not be construed as limited to the particular shapes of the regions shown herein, but should include, for example, changes in shape resulting from manufacturing.

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, a molding apparatus using ultrasonic vibration according to some preferred embodiments of the present invention will be described in detail with reference to the drawings.

1 is an exploded perspective view schematically showing a brake disk according to an embodiment of the present invention. The brake disk according to an embodiment of the present invention may include a first disk 100, a second disk 200, a plurality of legs 400, a third disk 300, and a housing 500.

The first disk 100 is formed in a disk shape, and may include a cast iron. However, the present invention is not limited thereto, and the first disk 100 may include another metal.

The second disc 200 may face the first disc 100. Specifically, the first disk 100 and the second disk 200 may be parallel. In particular, since the first disc 100 and the second disc 200 are rubbed with each other by the caliper, it is necessary to keep them parallel to each other to improve the braking ability. The second disk 200 may be substantially the same as or similar to the first disk 100.

The plurality of legs 400 are provided between the first disk 100 and the second disk 200 to connect the first disk 100 and the second disk 200. [ As described above, the first disc 100 and the second disc 200 are required to be parallel to each other. However, the parallel disc may be distorted during manufacturing of the brake disc. Concretely, when the second disk 200 to be described later is filled between the first disk 100 and the second disk 200, the parallelism between the first disk 100 and the second disk 200 may be displaced. The plurality of legs 400 may fix the first disk 100 and the second disk 200 to prevent parallelism in the manufacturing process. The plurality of legs 400 may transfer heat generated from the first disk 100 and the second disk 200 to the cooling holes 310 to be described later.

The plurality of legs 400 may be cylindrical. For example, as will be described later, when the third disk 300 is cast between the first disk 100 and the second disk 200, a gap between the first disk 100 and the second disk 200 There are many problems that can not be satisfied sufficiently. Thus, the plurality of legs 400 may have a curved side surface to minimize flow resistance. Of course, the shape of the plurality of legs 400 is not limited thereto.

In addition, the plurality of legs 400 may be disposed adjacent to only one of the outer side and the inner side of the first disk 100 and the second disk 200. In this case, the third disk 300 can be manufactured without parallelism by gravity or other forces before it is cast. To prevent this, the plurality of legs 400 may be disposed adjacent to the inner and outer edges of the first disk 100 and the second disk 200. Specifically, the plurality of legs 400 may be disposed adjacent to the outer and inner edges of the first disk 100 and the second disk 200, as described above, But also between the edges. For example, the plurality of legs 400 may be arranged side by side at regular intervals in the radial direction or the radial direction of the central axis C.

 Meanwhile, the first disk 100, the second disk 200, and the plurality of legs 400 may be integrally formed. The first disk 100, the second disk 200, and the plurality of legs 400 may be separately manufactured, but may be integrally formed by casting in order to shorten manufacturing time and improve productivity.

The third disc 300 fills the space between the first disc 100 and the second disc 200 and may be made of a material different from that of the first disc 100 and the second disc 200. In particular, the third disc 300 may include a lightweight material than the first disc 100 and the second disc 200. Details of the materials of the first to third disks 100 to 300 will be described later.

For example, the third disk 300 may have a hollow disk shape, and the inner side thereof may be selectively coupled to the housing 500, which will be described later.

The third disk 300 may be cast between the first disk 100 and the second disk 200 connected by a plurality of legs 400. That is, in the state where the first disk 100 and the second disk 200 are provided in the metal mold, a light metal is cast and cured to form the third disk 300.

The third disc 300 is made of a material which is hard to be cured after casting between the first disc 100 and the second disc 200 or with the first disc 100 and the second disc 200 The shrinkage rate is different and cracks may occur.

For example, the first disk 100 and the second disk 200 may include cast iron, and the third disk 300 may include lightweight aluminum than cast iron. In this case, the first disk 100 and the second disk 200 are not substantially contracted according to the temperature change, but the third disk 300 can be contracted. Specifically, cracks or voids may be formed due to coagulation shrinkage at the interface between the first disk 100 and the third disk 300, or at the interface between the second disk 200 and the third disk 300.

In consideration of the difference in shrinkage ratio, the third disk 300 may include an aluminum alloy. Specifically, the content of silicon in the aluminum alloy of the third disk 300 may be in the range of 7 wt% (inclusive) to 20 wt% (inclusive). In the case of an aluminum alloy having a silicon content of less than 7%, in the case of less than 7%, a gap is formed between the cast iron and the aluminum interface due to shrinkage during aluminum casting, And therefore the application of aluminum casting is generally limited. For this reason, particularly, the third disk 300 may be an aluminum alloy containing 12 wt% (or more) to 20 wt% (or less) silicon. Therefore, when the third disk 300 is cast, a void space due to shrinkage is not formed, cracks can be prevented, and casting defects can be drastically reduced. Also, since the third disk 300 is cast into a flat plate without being bent unlike the prior art, the casting defects can be reduced as compared with the conventional one. Also, since the third disk 300 includes an aluminum alloy, the heat can be smoothly discharged due to a high specific heat, thereby preventing a fade-out phenomenon of the brake disk.

In addition, the third disk 300 is formed of an aluminum alloy material, unlike the first disk 100 and the second disk 200, so that the entire weight of the brake disk can be reduced. That is, in order to prevent casting defects, the thickness of the third disc 300 is considerably increased. However, according to the embodiment of the present invention, it is possible to reduce the thickness of the third disc 300, And the stability of the brake disk can be secured by drastically reducing the possibility of breakage.

2 is a partial cross-sectional view of a portion of the third disk 300 described above. The third disk 300 includes a cooling hole 310 to improve the cooling efficiency of the brake disk. The cooling holes 310 may not be in contact with the first and second disks 100 and 200 and may be located between the first and second disks 100 and 200. [

Further, the cooling hole 310 may be smaller in size from the outside to the inside of the third disk 300 to more effectively discharge the heat generated during the brake operation. Specifically, the cooling hole 310 may be larger than the diameter D2 of the portion closer to the outer side of the third disk 300, where the diameter D1 is closer to the inner side. At this time, the cooling hole 310 may be continuously reduced in size from the outer side to the inner side of the third disk 300 as shown in FIG.

The center of the cooling hole 310 may be perpendicular or approximately perpendicular to the center axis C of the brake disc.

3 is a cross-sectional view schematically showing a cross section of the brake disk shown in Fig. The combination of the first disk 100 to the third disk 300 will be described in more detail with reference to the drawings.

The first disk 100 and the second disk 200 have the fixing grooves 620 or the protrusions 610 formed on at least one surface thereof facing each other. The third disk 300 is filled in the fixing groove 620 or the protrusion 610 is inserted into the third disk 300. This is possible because the third disc 300 is cast between the first disc 100 and the second disc 200.

The protrusion 610 may be formed in a substantially hemispherical shape on the inner surface of the first disc 100 or may have various shapes such as a shape in which the inner surface of the first disc 100 is rounded. In particular, the protrusion 610 may extend obliquely with respect to the vertical direction of the central axis C in order to maximize the contact area.

The protrusion 610 may increase the coupling force with the third disc 300 to prevent the first disc 100 and / or the second disc 200 from being separated from the third disc 300 even when the second disc 200 receives frictional force. The protrusion 610 can maximize the contact area between the first disc 100 and / or the second disc 200 and the third disc 300, thereby widening the heat transfer area and improving the heat dissipation function.

The fixing groove 620 may be formed in substantially the same or similar shape as the protrusion 610, so that detailed description is omitted.

The housing 500 will be described below with reference to FIG.

The housing 500 includes an outer ring 520 coupled with at least one of the first disk 100, the second disk 200 and the third disk 300 and an inner ring 510 connected to the wheel of the vehicle I have. At this time, the housing 500 is bent at least once so that the inner ring 510 and the outer ring 520 are not located on the same plane.

For example, the inner ring 510 of the housing 500 is formed in the shape of a disk, and a plurality of engagement holes for coupling with the wheels of the vehicle are formed. The outer ring 520 of the housing 500 is disposed along the outer side of the inner ring 510 and has a coupling hole for coupling the first disk 100 to the third disk 300. Here, the outer ring 520 of the housing 500 may have a sawtooth shape as shown in FIG. This reduces the weight of the brake disc. Of course, the shape of the outer ring 520 of the housing 500 is not limited thereto.

The inner ring 510 and the outer ring 520 of the housing 500 are interconnected and connected to each other by a cylindrical connecting portion that is inclined or substantially parallel to the center axis C of the brake disk. For example, it may include aluminum which is light in weight and excellent in heat radiation. Specifically, the aluminum alloy disk is bent through casting to manufacture the third disk 300 having the inner ring 510 and the outer ring 520. At this time, the inner ring 510 and the outer ring 520 can be substantially parallel. That is, the disk is folded twice by casting to form the housing 500.

Hereinafter, the coupling relationship between the first disk 100 and the second disk 200 and the housing 500 will be described with reference to FIGS. 3 and 4. FIG.

At least one of the first disk 100, the second disk 200 and the third disk 300 is coupled to the outer ring 520 of the housing 500 by bolts 700. Although not shown, a nut coupled to the bolt 700 may be additionally provided.

Referring to FIG. 3, the housing 500 may be coupled to the third disk 300. That is, the bolt 700 can pass through the housing 500 and the third disk 300 and can be fastened.

Or the housing 500 may be coupled to both the first disk 100, the second disk 200, and the third disk 300 as shown in FIG. 4A.

Or the housing 500 may be coupled to the second disk 200 and the third disk 300 except for the first disk 100 as shown in FIG. 4B.

The housing 500 may be coupled to the first disk 100 and the third disk 300 except for the second disk 200 as shown in FIG.

The housing 500 may be coupled to the first disk 100 and the second disk 200 except for the third disk 300 as shown in FIG.

In this way, the housing 500 and the first disk 100 to the third disk 300 can be coupled to each other in various cases. For example, when it is required to reduce the weight of the brake disk, the coupling between the housing 500 and the first disk 100 to the third disk 300 can be selected as a condition suitable for lightening.

While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention. Accordingly, the true scope of the present invention should be determined by the technical idea of the appended claims.

100: first disc 200: second disc
300: third disk 400: plural legs
500: housing 610:
620: Fixing groove 700: Bolt

Claims (13)

A first disk;
A second disk facing the first disk;
A plurality of legs provided between the first disk and the second disk to connect the first disk and the second disk;
A third disk filling between the first disk and the second disk, the third disk comprising a material that is lighter than the first disk and the second disk; And
The first disk. An outer ring coupled to at least one of the second disk and the third disk and an inner ring connectable with a wheel of the vehicle, and the housing being bent at least once so that the inner ring and the outer ring are not located on the same plane and,
Wherein the first disk, the second disk and the plurality of legs are integrally formed by casting,
Wherein the third disk is formed and cured between the first disk and the second disk connected by the plurality of legs,
Wherein the third disk includes a cooling hole extended from the outer side to the inner side so as not to contact the first disk and the second disk and extending in the direction of the central axis of the housing,
Wherein the plurality of legs are such that parallelism between the first disk and the second disk is maintained and heat generated from the first disk and the second disk is transferred to the inside of the third disk and discharged to the cooling hole, The first and second disks being disposed adjacent to the outer and inner edges of the first and second disks,
Wherein the plurality of legs comprise side surfaces of a curved surface to reduce flow resistance when the third disc is cast. The method according to claim 1,
Wherein the housing is formed integrally with the inner and outer rings by casting. The method according to claim 1,
Wherein the housing comprises aluminum. delete The method according to claim 1,
Wherein the third disk is an aluminum alloy and the content of silicon in the whole composition is in the range of 12 wt% to 20 wt%. delete The method according to claim 1,
Wherein the cooling holes are smaller in size from the outside to the inside of the third disk. The method according to claim 1,
Wherein the first disk and the second disk have fixing grooves or protrusions formed on at least one surface thereof facing each other. 9. The method of claim 8,
Wherein the fixing groove or the protrusion extends in an oblique direction with respect to a vertical direction of the central axis of the housing. delete delete The method according to claim 1,
Wherein at least one of the first disk, the second disk and the third disk is bolted to the outer ring of the housing. Calipers; And
A brake disc according to any one of claims 1 to 3, 5, and 7 to 9 and 12, which is installed adjacent to the caliper;
A car containing.

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