KR101883732B1 - Caliper device and brake device and manufacturing method - Google Patents

Abstract

The present invention relates to a caliper device, a brake device and a manufacturing method which can fundamentally remove heat distortion and noise while maintaining the weight of a monobloc aluminum caliper, and more particularly, to a caliper device and a brake device, And a caliper body made of a second material and formed in a shape surrounding the reinforcing frame.

Description

Technical Field The present invention relates to a caliper device and a brake device,

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a caliper device, a brake device and a manufacturing method thereof, and more particularly, to a caliper device, a brake device, and a manufacturing method which can remove heat deformation and noise from a source while maintaining weight reduction of a monobloc aluminum caliper will be.

Generally, a brake system is classified into a main brake used mainly for driving and a parking brake used for parking the automobile. The main brake generates a braking force by using a hydraulic brake for braking the hydraulic pressure generated by the operation of the brake pedal, and an output brake and a compressed air which are used when a large braking force is required, And the hydraulic brakes are provided with disc brakes which are braked by hydraulic pressures of the brake pads on both sides of the disc rotated together with the wheels.

Here, the general configuration of the caliper in the brake includes first and second caliper housings formed in a saddle shape and attached to the knuckle spindle, pressing means provided on both sides of the caliper housing to advance and retract by hydraulic pressure, A first and a second pad plate provided with friction pads for braking the disc by generating friction force on both sides of the disc and moving forward and backward by the pressing means, have

In addition, a piston boot and an oil seal are respectively provided to prevent foreign matter such as moisture and dust from entering into the pressurizing means, and the two caliper housings are bolted together.

Also, in the case of a high-performance vehicle, a multi-piston which increases the number of pistons that press the brake pads to two or four or more, instead of one, is applied. In the case of a multi-piston block, aluminum is applied to reduce the weight. Aluminum calipers are divided into monoblocks manufactured by casting process and multi-blocks assembled by forging and machining. Monoblocks are more economical by manufacturing hydraulic lines by casting process.

However, the monobloc caliper of the conventional caliper device, the brake device and the manufacturing method must have a large size for the purpose of securing the rigidity. Nevertheless, the brake caliper device has to be structured to stiffen the reinforcement material in order to prevent deformation and noise when the brake is operated. Further, in order to reinforce the monoblock, rigidity is ensured even after casting after the reinforcement is inserted, but there is a difficulty in constituting the hydraulic line.

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems and it is an object of the present invention to provide an aluminum caliper for a monobloc, And a braking device and a method of manufacturing 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 caliper device comprising: a reinforcing frame made of a first material; And a caliper body made of a second material different from the first material and configured to surround the reinforcing frame.

According to an aspect of the present invention, the reinforcing frame further includes: a cylinder portion that receives the piston; And a cylinder connecting portion connecting the cylinder portion to another cylinder portion adjacent to the cylinder portion.

According to an aspect of the present invention, the cylinder connection portion may be formed with a passage through which a working fluid is supplied to apply pressure to the cylinder portion.

According to an aspect of the present invention, the reinforcement frame may be inserted into a casting mold so as to reinforce the strength of the caliper body, and insert casting may be integrally formed with the caliper body.

According to an aspect of the present invention, the first material may be iron or an iron alloy, and the second material may be aluminum or an aluminum alloy.

According to an aspect of the present invention, the caliper body further includes: a first side portion facing the first surface of the disc; A second side facing the second side of the disc; And at least one bridge portion connecting the first side portion and the second side portion.

According to the present invention, the reinforcing frame may further include a connection reinforcing portion provided between the cylinder connecting portion and the other cylinder connecting portion adjacent to the cylinder connecting portion so as to support the other cylinder connecting portion adjacent to the cylinder connecting portion .

According to the present invention, the reinforcing frame may further include a nut member installed at an upper reinforcing portion or a lower reinforcing portion provided to the cylinder portion or the cylinder connecting portion so as to be screwed by the bolt member .

According to another aspect of the present invention, there is provided a braking device comprising: a reinforcing frame made of a first material; And a caliper body made of a second material different from the first material and formed by surrounding the reinforcing frame.

According to another aspect of the present invention, there is provided a method of manufacturing a caliper device, comprising the steps of: preparing a reinforcing frame including a cylinder portion and a cylinder connecting portion connecting the cylinder portion and preparing a reinforcing frame made of a first material; A reinforcing frame insert step of inserting the reinforcing frame into a casting mold; A caliper body casting step of injecting a second material into the casting mold into which the reinforcing frame is inserted to form a caliper body; And a separating step of separating the caliper body, from which the reinforcing frame is insert-molded, from the casting mold, inside the casting mold.

According to one embodiment of the present invention as described above, a reinforcing frame capable of forming a cylinder portion and a cylinder connecting portion in a hydraulic line, which is to be manufactured as a hollow body at the time of casting a monobloc caliper, And then cast into a mold and cast into a single body. Therefore, by optimizing the aluminum part which is applied largely to secure rigidity during caliper casting, it is possible to compensate for the increase in weight by inserting the reinforcing frame and to reduce the occurrence of heat deformation and noise, and the reinforcing frame serves as a jig And a caliper device, a brake device, and a manufacturing method that have the effect of enabling the brake pads to be replaced can be realized. Of course, the scope of the present invention is not limited by these effects.

1 is an external perspective view schematically illustrating a caliper device according to one embodiment of the present invention.
Figures 2 and 3 are cross-sectional views schematically showing a caliper device according to one embodiment of the present invention.
4 is an external perspective view schematically illustrating a reinforcing frame of a caliper device according to one embodiment of the present invention.
5 is a cross-sectional view schematically showing a reinforcing frame of a caliper device according to one embodiment of the present invention.
6 and 7 are cross-sectional views schematically illustrating a process of casting a caliper body of a caliper device according to one embodiment of the present invention.
8 is a flow chart illustrating a method of manufacturing a caliper device in accordance with one embodiment of the present invention.
9 is an external perspective view schematically illustrating a reinforcing frame of a caliper device according to another embodiment of the present invention.
10 is an external perspective view schematically showing a reinforcing frame of a caliper device according to still another embodiment of the present invention.
11 is an external perspective view schematically showing a reinforcing frame of a caliper device according to still 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, It 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.

FIG. 1 is an external perspective view schematically illustrating a caliper device 100 according to some embodiments of the present invention, and FIGS. 2 and 3 are cross-sectional views schematically showing the caliper device 100 of FIG.

1 to 3, the caliper device 100 according to one embodiment of the present invention may include a reinforcing frame 10 and a caliper body 20. More specifically, for example, as shown in FIGS. 1 to 3, the reinforcing frame 10 may be made of a first material.

For example, the caliper body 20 may be formed of a second material different from the first material, and may be formed to surround the reinforcing frame 10. Here, the first material may be iron or an iron alloy, and the second material may be aluminum or an aluminum alloy. The caliper body 20 also includes a first side 21 opposite the first side of the disc, a second side 22 opposite the second side of the disc, and a first side 21, And one or more bridge portions (23) connecting the second side portions (22).

1 to 3, the caliper device 100 may be configured such that the reinforcing frame 10 is inserted into the casting mold M so as to reinforce the strength of the caliper body 20, And insert casting integrally with the caliper body 20.

Here, the casting is carried out in the order of designing casting, preparing a casting method, preparing a model, dissolving and injecting, and finishing with a product in order to make a casting. First, you have to think about how to cast a cheap and high quality product for the product you want to make. In order to do this, it is important to design and combine molds. As a general rule, it is devised to divide the whole into two parts (two parts) so that the core is not used as much as possible. In addition, there are some defects in the product due to the mixing of bubbles and inclusions, cracking due to volume reduction during solidification, lack of flowability, and failure of the melt to reach all corners. It should be devised not to. In order to achieve this, it is necessary to thoroughly investigate past data on the casting of the material, to examine the cooling state of each part in the mold, the progress of solidification, and the like, and the degree of roundness of the chill and nodules.

Also, since very large castings are cooled and solidified at a much slower rate, the size of the castings is a very important factor, so care must be taken accordingly. Among the main components, fluidity and shrinkage during solidification are particularly important. When the fluidity is not good, consideration should be given to increase the injection temperature or to improve the fluidity of the melt by other methods (external force).

In addition, since the coagulation shrinkage is a shrinkage margin and there is a difference depending on the material, the model is designed to be larger than the product by this margin. There are many kinds of wood (metal), plaster (wood), plastic (wood), and metal (metal mold). The shrinkage margin is about 1% for gray cast iron and 2% for white iron cast iron among cast iron. The steel castings are usually 2%, 1.5 ~ 1.8% brass, 0.8 ~ 1.6% bronze, and sand castings of aluminum alloy are roughly 1 ~ 1.5%. More details will vary depending on the type of alloy, so prepare a preformed additive in advance and use it to make a model.

There are various kinds of materials that are practically used from 7 / 1,000 for malleable cast iron to 25 / 1,000 for large cast iron casting. For aluminum alloy, 10 / 1,000-12 / 1,000 is used. Also, the model is called the model slope, and it is easy to subtract the model from the mold by attaching a slope of about 1/4 to 1.. As the material of the casting mold, there are sand metal and the like, and it is appropriately selected in consideration of the production number of the product, the required dimensional accuracy and the shape of the product.

In addition, there are die casting molds in which a few percent of water is added and hardened to foundry sand, and dried molds are heated and used. Casting molds are a poor method of producing castings with poor dimensional accuracy and surface finish. If the number of products to be manufactured is not large, there is a problem of profitability due to a large mold processing cost, and there is no air permeability in the mold, so consideration should be given to discharging the gas generated at the time of solidification. In addition, since the casting mold is not broken and the casting is not taken out of the casting mold, it is necessary to pay careful attention to the mold design. However, the product has good dimensional accuracy and the obtained casting is finer than the casting mold. Molds other than molds and molds include shell molds and gas molds used for precision casting.

In addition, as a method of injecting molten metal during casting, gravity is usually used, but there is also a die casting method in which molten metal is injected into a mold, and explosive casting is also carried out with a stronger pressure as explosive force of explosive (explosive) . Compared to casting molds and die castings injected by gravity, diecasting process can produce products with an accurate external dimension, but because of quenching and solidification, there is a problem, and since molds are expensive, It is advantageous. However, for metal having a melting point higher than copper (1083 ° C), there is a problem such as heat resistance of the metal mold, so that diecasting is difficult.

In order to melt base metals and alloy elements for casting, they are usually put in a melting furnace and put in a crucible. The heating method of the melting furnace can be coke, electric, heavy oil, arc, induction melting etc. depending on the desired heating temperature. As the crucible, graphite is the most used, and lining is used to prevent the reaction with the molten metal.

The caliper device 100 includes the reinforcing frame 10 made of iron or an iron alloy and the caliper body 20 made of aluminum or aluminum alloy and formed in a shape surrounding the reinforcing frame 10 The reinforcing frame 10 may be inserted into the casting mold M and inserted into the caliper body 20 so as to reinforce the strength of the caliper body 20.

Therefore, in the caliper device 100 according to one embodiment of the present invention, after the caliper body 20 is integrally formed with the reinforcing frame 10 capable of serving as a reinforcing material and an iron pipe during casting, By inserting the reinforcing frame 10 into the mold M and then integrally casting it, optimizing the aluminum part which is largely applied for securing rigidity during casting of the caliper body 20 compensates for the increased weight by inserting the reinforcing frame 10, And the caliper device 100 having less noise generation can be provided.

4 is an external perspective view schematically showing the reinforcing frame 10 of the caliper device 100 according to one embodiment of the present invention and FIG. 5 is a sectional view schematically showing the reinforcing frame 10 of FIG. 4 to be.

4 and 5, the reinforcing frame 10 includes a cylinder portion 11 for accommodating a piston and another cylinder portion 11 adjacent to the cylinder portion 11. [ (Not shown). The cylinder connection portion 12 may be formed with a flow path 12a through which a working fluid is supplied to the cylinder portion 11 so as to apply operating pressure.

Here, the operating pressure is an operating pressure using the hydraulic pressure, and the hydraulic brake using the hydraulic brake is a device applying Pascal's principle. When the brake pedal is depressed, the driver's pressure is immediately transmitted to the closed brake fluid in the master cylinder through the piston of the master cylinder. By this force, pressure is generated in the brake fluid in the master cylinder. This pressure is transferred to each wheel cylinder via the brake pipe and back to the wheel cylinder (or caliper) piston, according to the Pascal principle. The pressure transferred to the wheel cylinder (caliper) piston is again converted into an expansion force (or compression force) that acts on the brake shoe (or pad).

In addition, when the force is transmitted by using the liquid, the amplification of the force is easy. Since the hydraulic brake operates at high pressure (up to 120 bar, instantaneously up to 180 bar), a large force can be obtained even if the size of the braking device components, such as the diameter of the wheel cylinder, is small. In addition, since the brake fluid is incompressible, it is possible to operate several wheel cylinders at the same time with a small flow rate if the air gap is small. That is, when the brake pedal is depressed, the circuit pressure rises rapidly, and the piston of each wheel cylinder immediately operates by this pressure to generate braking force on each wheel.

The reinforcing frame 10 of the caliper device 100 is provided with the cylinder portion 11 for accommodating the piston and the cylinder connecting portion 11 for connecting the cylinder portion 11 and the adjacent cylinder portion 11 12 are provided with the oil passage 12a through which the working fluid is supplied, and a frame capable of acting as a reinforcement material can be integrally formed in the hydraulic line.

Therefore, in the caliper device 100 according to one embodiment of the present invention, the reinforcement frame 10, in which an iron pipe and a frame capable of acting as a reinforcing material are integrally implemented, is mounted on the caliper body 20 It is possible to provide the caliper device 100 which is reinforced with the strength of the caliper body 20 made of aluminum or an aluminum alloy and less in thermal deformation and noise.

6 and 7 are cross-sectional views schematically illustrating a process of casting the caliper body 20 of the caliper device 100 according to one embodiment of the present invention.

More specifically, for example, as shown in FIGS. 6 and 7, the reinforcing frame 10 made of the first material can be seated on the lower mold of the casting mold M. Subsequently, the upper mold of the casting mold M is closed to the lower mold, and then the second material is injected into the casting mold M to cast the caliper body 20.

Therefore, the caliper device 100 can insert cast the integrated frame 10 with the caliper body 20 by inserting the reinforcing frame 10 into the casting mold M. Therefore, in the caliper device 100 according to one embodiment of the present invention, the caliper body 20 is insert-cast with the reinforcing frame 10 to reinforce the strength of the caliper body 20, And the caliper device 100 having less noise generation can be provided.

8 is a flow chart illustrating a method of manufacturing the caliper device 100 according to one embodiment of the present invention.

8, the manufacturing method of the caliper device 100 according to one embodiment of the present invention includes a cylinder connecting portion 12 connecting the cylinder portion 11 and the cylinder portion 11 A reinforcing frame insert step (S20) for inserting the reinforcing frame (10) into the casting mold (M), a reinforcing frame insert step (S20) for preparing a reinforcing frame (10) A caliper body casting step S30 for injecting a second material into the casting mold M into which the frame 10 is inserted to form a caliper body 20 and a caliper body casting step S30 for inserting the reinforcing frame 10 inside the caliper body 10, And a separating step S40 of separating the body 20 from the casting mold.

On the other hand, although not shown, the present invention may include a brake device including the caliper device 100 described above. Here, the components of the brake device according to one embodiment of the present invention may have the same configuration and function as those of the caliper device 100 of the present invention described above. Therefore, detailed description is omitted.

Further, although not shown, the caliper device 100 of the present invention using various bolts can minimize deformation by reinforcing mechanical strength, replacing pads, or firmly supporting a coupling between a cylinder connecting portion and a flow path. Such ancillary fixtures can be modified and modified by those skilled in the art.

9 is an external perspective view schematically illustrating a reinforcing frame of a caliper device according to another embodiment of the present invention.

9, the reinforcing frame 10 of the caliper device according to the other embodiments of the present invention includes the cylinder connecting portion 12 in addition to the cylinder portion 11 and the cylinder connecting portion 12 described above. And a connection reinforcing part 13 provided between the cylinder connecting part 12 and the other cylinder connecting part 12 adjacent to the cylinder connecting part 12 so as to firmly support the neighboring other cylinder connecting part 12. The connection reinforcing portion 13 may have a rectangular bar shape and may be made of the same material as the cylinder connecting portion 12. [ In addition, various types of rod-like reinforced structures can be applied.

10 is an external perspective view schematically showing a reinforcing frame 10 of a caliper device according to still another embodiment of the present invention.

10, the reinforcing frame 10 of the caliper device according to the other embodiments of the present invention is provided with the bolt member 1, in addition to the cylinder portion 11 and the cylinder connecting portion 12 described above And a nut member 2 installed on the cylinder portion 11 or the cylinder connection portion 12 and the upper reinforcement portion 14 so as to be screwed into the cylinder portion 11 or the cylinder connection portion 12, . The upper reinforcing portion 14 may form a frame with a horizontal rod and a vertical rod, and may be made of the same material as the cylinder connecting portion 12. In addition, a wide variety of frames can be applied.

11 is an external perspective view schematically showing a reinforcing frame 10 of a caliper device according to still another embodiment of the present invention.

11, the reinforcing frame 10 of the caliper device according to the other embodiments of the present invention is provided with the bolt member 1 (not shown) in addition to the above-mentioned cylinder portion 11 and the cylinder connecting portion 12. [ And a nut member 2 installed on the cylinder portion 11 or the cylinder connection portion 12 and the lower reinforcement portion 15 so as to be screwed into the cylinder portion 11 or the cylinder connection portion 12 . The lower reinforcing portion 15 may form a frame with a horizontal rod and a vertical rod, and may be made of the same material as the cylinder connecting portion 12. In addition, a wide variety of frames can be applied. However, the shape of the reinforcing frame 10 is not limited to the drawings, and various shapes and shapes can be applied.

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.

10: reinforcement frame
11:
12: Cylinder connection
13:
14: Upper reinforcing portion
15: Lower reinforcement
20: Caliper body
21: first side
22: second side
23:
M: casting mold
100: caliper device

Claims (10)

A reinforcing frame made of a first material; And
A caliper body made of a second material different from the first material and formed in a shape surrounding the reinforcing frame;
Lt; / RTI >
The reinforcing frame
A cylinder portion for accommodating the piston; And
A cylinder connecting portion connecting the cylinder portion to another cylinder portion adjacent to the cylinder portion;
Lt; / RTI >
Wherein the cylinder connecting portion includes:
A flow path through which a working fluid is supplied to the cylinder portion to apply an operating pressure to the cylinder portion,
The reinforcing frame is inserted into the casting mold so as to reinforce the strength of the caliper body, and insert casting is integrally formed with the caliper body,
Wherein the reinforcing frame reinforcing the strength of the caliper body and the flow path through which the working fluid is supplied are integrally formed,
The reinforcing frame
A nut member installed at an upper reinforcing portion or a lower reinforcing portion provided at the cylinder portion or the cylinder connecting portion so as to be screwed by the bolt member;
Further comprising:
Wherein the upper reinforcing portion or the lower reinforcing portion includes at least one horizontal bar and a vertical bar,
Wherein the nut member is installed at an intersection of the vertical bar and the horizontal bar. delete delete delete The method according to claim 1,
Wherein the first material is an iron or iron alloy,
And the second material is aluminum or an aluminum alloy. The method according to claim 1,
The caliper body includes:
A first side facing the first side of the disc;
A second side facing the second side of the disc; And
At least one bridge portion connecting the first side and the second side;
. The method according to claim 1,
The reinforcing frame
A connection reinforcing portion provided between the cylinder connection portion and the other cylinder connection portion adjacent to the cylinder connection portion so as to support another cylinder connection portion adjacent to the cylinder connection portion;
Further comprising a caliper. delete A reinforcing frame made of a first material; And
A caliper body made of a second material different from the first material and formed by surrounding the reinforcing frame;
Lt; / RTI >
The reinforcing frame
A cylinder portion for accommodating the piston; And
A cylinder connecting portion connecting the cylinder portion to another cylinder portion adjacent to the cylinder portion;
Lt; / RTI >
Wherein the cylinder connecting portion includes:
A flow path through which a working fluid is supplied to the cylinder portion to apply an operating pressure to the cylinder portion,
The reinforcing frame is inserted into the casting mold so as to reinforce the strength of the caliper body, and insert casting is integrally formed with the caliper body,
Wherein the reinforcing frame reinforcing the strength of the caliper body and the flow path through which the working fluid is supplied are integrally formed,
The reinforcing frame
A nut member installed at an upper reinforcing portion or a lower reinforcing portion provided at the cylinder portion or the cylinder connecting portion so as to be screwed by the bolt member;
Further comprising:
Wherein the upper reinforcing portion or the lower reinforcing portion includes at least one horizontal bar and a vertical bar,
And the nut member is installed at an intersection of the vertical bar and the horizontal bar. A reinforcing frame preparing step of preparing a reinforcing frame including a cylinder part and a cylinder connecting part connecting the cylinder part and made of a first material;
A reinforcing frame insert step of inserting the reinforcing frame into a casting mold;
A caliper body casting step of injecting a second material into the casting mold into which the reinforcing frame is inserted to form a caliper body; And
A separating step of separating the caliper body in which the reinforcing frame is insert-cast from the casting mold, inside the casting mold;
Lt; / RTI >
The reinforcing frame
A cylinder portion for accommodating the piston; And
A cylinder connecting portion connecting the cylinder portion to another cylinder portion adjacent to the cylinder portion;
Lt; / RTI >
Wherein the cylinder connecting portion includes:
A flow path through which a working fluid is supplied to the cylinder portion to apply an operating pressure to the cylinder portion,
The reinforcing frame is inserted into the casting mold so as to reinforce the strength of the caliper body, and insert casting is integrally formed with the caliper body,
Wherein the reinforcing frame reinforcing the strength of the caliper body and the flow path through which the working fluid is supplied are integrally formed,
The reinforcing frame
A nut member installed at an upper reinforcing portion or a lower reinforcing portion provided at the cylinder portion or the cylinder connecting portion so as to be screwed by the bolt member;
Further comprising:
Wherein the upper reinforcing portion or the lower reinforcing portion includes at least one horizontal bar and a vertical bar,
Wherein the nut member is installed at an intersection of the vertical bar and the horizontal bar.

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