KR20230160720A - Disk brake system - Google Patents

Abstract

The present invention provides a first housing having a brake disc, at least one first piston for actuating a first brake pad, the first brake pad being configured to press against a first surface of the brake disc. a second housing having at least one second piston for actuating a second brake pad, wherein the second brake pad is configured to press against a second surface of the brake disc opposite the first surface. It relates to disc brakes for vehicles, including. The first housing and the second housing form separate, individual units.

Description

Disk brake system {Disk brake system }

The present invention relates to the field of mechanical engineering. The present invention relates to vehicle technology, particularly vehicle brakes. The present invention proposes to provide a disc brake system having two housings.

Disc brake systems are known brake systems that include a brake disc that rotates with a wheel. Disc brake systems typically include a caliper that holds a set of brake pads. Calipers according to the prior art can be performed as fixed calipers or floating calipers.

Known disc brake systems show some undesirable residual drag after the brakes are released. Additionally, known calipers are relatively heavy components, which is a disadvantage in view of ongoing efforts to make vehicles lighter.

The object of the present invention is to provide a more efficient disc brake system and solve at least some of the above problems.

This object is achieved by the disc brake system according to claim 1. Advantageous embodiments can be found in the dependent claims and the following description and drawings.

Accordingly, a disc brake system for a vehicle includes a brake disc, a first housing, and a second housing. The first housing has at least one first piston for actuating a first brake pad, the first brake pad being configured to be pressed against a first surface of the brake disc. The second housing has at least one second piston for actuating a second brake pad, the second brake pad being configured to press against a second surface of the brake disc, the second surface being opposite the first surface. . The first housing and the second housing form separate, individual units.

This represents a departure from known caliper designs which include a bridge portion that extends over the circumferential outer edge of the disc brake and thus takes up significant space. Systems shown herein can have reduced weight. Additionally, the amount of brake fluid displaced in each housing may be smaller than the amount of brake fluid displaced in a caliper according to the prior art. This can improve pedal feel and increase efficiency.

Each of the first housing and the second housing may have its own brake fluid supply unit. Each brake fluid supply may include, for example, a separate container for brake fluid.

Each of the first housing and the second housing may include two or more pistons. In particular, the first housing may include two first pistons or three first pistons or four first pistons or five first pistons for actuating the first brake pad. Additionally or alternatively, the second housing may comprise two second pistons or three second pistons or four second pistons or five second pistons for actuating the second brake pad. Several first pistons in the first housing and/or several second pistons in the second housing may, for example, be arranged next to each other along the length of the individual brake pad, in each case. Any statements made herein with respect to a first piston or a second piston may apply to all of the first pistons and/or to all of the few second pistons, or to any selection thereof.

The first housing and/or the second housing may be connected to a knuckle and/or a carrier. The first housing may be on an axially outer side and the second housing may be on an axially inner side. The knuckle and/or carrier may be designed to extend around the brake disc to retain the first housing on the axially outer side.

In possible embodiments, the first housing is located on the first side of the brake disc, the second housing is located on the second side of the brake disc, and the housings extend, in the radial direction, beyond the outer circumferential edge of the brake disc. It is not extended.

The distance between the circumferential outer edge of the brake disc and the inner side of the rim may, for example, be less than 3 cm, preferably less than 2 cm. The space-saving setup with two housings makes it possible to bring the brake disc closer to the rim compared to known calipers, as the bridge part is omitted.

In one embodiment, a dust collector may be provided to collect brake dust from brake pads.

According to the present application, two separate housings are provided. The mechanical loads acting on each housing and the movement of each housing can be handled individually for each housing. The housings may be configured to move and/or function independently during braking, where known calipers connect two brake pads via a bridge portion and do not allow independent movement of the two sides of the caliper.

The first cavity of the first housing for holding the first piston may have a rear wall opposite the first brake pad. The rear wall of the first housing may be at an angle with respect to the first surface of the brake disc. Additionally or alternatively, the rear wall of the first housing may be at an angle relative to the pressure surface of the first piston, which pressure surface typically forms the rear wall of the first piston. This can create a tapered hollow space within the first cavity of the first housing, the tapered hollow space defining a volume to be filled with brake fluid.

Additionally or alternatively, the second cavity of the second housing for retaining the second piston may have a rear wall opposite the second brake pad. The rear wall can be at any angle relative to the second surface of the brake disc. Additionally or alternatively, the rear wall of the second housing may be at an angle relative to the pressure surface of the second piston, which pressure surface typically forms the rear wall of the second piston. This may create a tapered hollow space within the second cavity of the second housing, the tapered hollow space defining a volume to be filled with brake fluid.

In relation to angled rear walls, for example, the radially inner side of the rear wall of the first housing and/or the rear wall of the second housing can be inclined away from the brake disc relative to the respective radially outer side. This means that the tapered hollow space between the rear wall of the individual housing and the pressure surface of the individual piston can be reduced in the radially outward direction. Specifically, the axial width can be reduced. This can be achieved, for example, by having a varying wall-thickness of the individual rear walls, with the walls becoming thinner from the outer radial side to the inner radial side. Alternatively, the wall thickness can be held constant, where the entire wall is tilted.

If several first pistons and/or several second pistons are envisioned, a separate cavity may be defined for each of the several pistons. Possibly several cavities in each housing may be connected to each other within the housing and/or they may share a common brake fluid supply. If several pistons are envisioned, the possible modifications of the cavity described herein can be envisioned for each of the pistons.

In a disc brake system, the movement of the first piston towards the first surface of the brake disc for braking may have a non-orthogonal component with respect to the first surface. Additionally or alternatively, the movement of the second piston towards the second surface of the brake disc for braking may have a non-orthogonal component with respect to the second surface. Thereby, unwanted tilting of the housings can be avoided or reduced. Non-orthogonal movement may be achieved, for example, by modifying the arrangement of the first and/or second housing and/or by modifying the brake disc, as will be explained further hereinafter.

For example, the first piston may be arranged at an angle with respect to the first surface and/or the axial direction of the brake disc; and/or the second piston may be arranged obliquely with respect to the axial direction and/or the second surface of the brake disc. In these cases, the housing holding the piston can also be arranged at an angle. In particular, the cavities of the individual housings may extend non-perpendicularly to the surface of the brake disc.

In one example, the first piston and/or the second piston are configured such that the movement of the first piston and/or the second piston towards the brake disc for braking has a radially outward component, i.e. in addition to the axial component. They are arranged obliquely to have an outward component.

Additionally or alternatively, it can be envisaged that the first and second surfaces of the brake disc are at a non-vanishing angle with respect to each other. For example, brake discs can be tapered. For example, the first surface and the second surface may approach each other in a radially outward direction. In this case, the brake pad can be said to be thicker in the center and tapered outward.

In one example, the first piston and/or the second piston have the shape of a cylinder cut at an angle. This can achieve an oblique arrangement of the brake pads arranged on the individual pistons, in order to align the friction surfaces of the brake pads with the friction surfaces of the brake disc. Additionally or alternatively, the backplate and/or friction material of the first brake pad and/or the second brake pad may have a thickness that varies along the radial direction. When the friction material and/or backplate have such varying thicknesses, they may be said to be wedge shaped. Overall, having obliquely cut pistons and/or wedge-shaped friction material and/or backplate provides for tapering and/or of the brake disc to bring the friction surface parallel to the first and second surfaces of the brake disc. Alternatively, the inclination of the piston can be compensated. The friction surfaces of the brake pads then engage evenly with the surfaces of the brake pads, and the pressure distribution can be adjusted to avoid unwanted tilting of the housings.

In one example, the first housing includes a main seal and a secondary seal for the first piston. Additionally or alternatively, the second housing includes a main seal and a secondary seal to the second piston. Having a secondary seal in addition to the main seal helps prevent the piston from tilting within the cavity of the individual housing.

In one example, a disc brake system may include a dust collector. In particular, the dust collector may be positioned on the radially outer side of the first housing and/or on the radially outer side of the second housing. Optionally, the dust collector may extend over the outer circumferential edge of the brake disc. The omission of the bridge part provided for the calipers according to the prior art creates additional free space for the placement of the dust collector.

The present invention will now be explained in an exemplary manner with reference to the accompanying drawings. In the drawings,
1, 2 show disc brake systems with two separate housings.
Figure 3 shows a disc brake system axially supporting two housings via a carrier.
4, 5 show a disc brake system axially supporting two housings via a carrier and a knuckle.
Figure 6 shows tilting of the housings of a disc brake system.
Figure 7 shows a disc brake system whose housings have auxiliary seals.
Figure 8 shows a disc brake system in which the housings have an angled rear wall.
Figure 9 shows a disc brake system with angled housings and wedge-shaped friction material.
Figure 10 shows a disc brake system with angled housings and a wedge-shaped backplate.
Figure 11 shows a disc brake system with a tapered brake disc.
12, 13 show a disc brake system with dust collector.

Figure 1 shows a disc brake system for a vehicle. The disc brake system includes a brake disc 30, a first housing 10, and a second housing 20.

The first housing has a first piston (11) for actuating the first brake pad (12). The first brake pad 12 is configured to be pressed against the first surface 31 of the brake disc 30. The second housing 20 has a second piston 21 for operating the second brake pad 22. The second brake pad 22 is configured to press against a second surface 32 of the brake disc 30 , where the second surface 32 is opposite the first surface 31 .

Each of the first housing 10 and the second housing 20 is typically arranged next to the first 11 and the second piston 21 respectively, as can be seen in the cutaway views in each case. It should be noted that it includes at least one additional piston. That is, several pistons are thus arranged in each housing 10, 20 next to each other along the length of the respective brake pad. With reference to any of the drawings, the descriptions made regarding the first piston 11 and the second piston 21 also apply to additional first pistons in the first housing and additional second pistons in the second housing. You can.

The first housing 10 and the second housing 20 are connected to the carrier 50. By this, the two housings are held and supported axially and tangentially by the carrier 50 .

The first housing 10 and the second housing 20 form separate, individual units. Accordingly, the bridge part between the two housings 10, 20 (this bridge part should extend around the circumferential edge 33 of the brake disc 30) is omitted. This makes it possible to bring the circumferential outer edge 33 of the brake disc 30 closer to the rim 40 of the vehicle's wheels, since typically only the carrier or knuckle extends around the edge. The distance between the circumferential outer edge 33 of the brake disc 30 and the inner side of the rim 40 is less than 2 cm. Accordingly, compared to disc brake systems according to the prior art, the brake disc 30 can be larger and the friction surfaces 31, 34 can be increased. Additionally, omitting the bridge portion reduces the weight of the brake system.

The first housing 10 on the left is the axially outer housing and the second housing 20 on the right is the axially inner housing.

Each of the first housing 10 and the second housing 20 may have its own brake fluid supply 15, 25 with separate containers of brake fluid, which are supplied to the two housings 10, 20. Separate fluid systems for The brake fluid flows into the first cavity 16 of the first housing 10 and into the second cavity of the second housing 20 to press the individual brake pads 12, 22 into close contact with the brake disc 30. 26) It is injected into the body. After the brakes are released, the flexible first main seal 18 in the first housing 10 and the flexible second main seal 28 in the second housing 20 are connected to the pistons 11, 21. Helps retreat. If several first pistons and/or several second pistons are envisioned, a separate cavity may be defined for each of the several pistons. Possibly several cavities in each housing may be connected to each other within the housings, and they may share a common brake fluid supply.

According to the embodiment shown in FIG. 1, the axial lengths of the first piston 11 and the second piston 12 may each be 40 to 60 mm. The axial thickness of the first friction material 14 and the second friction material 24 (in each case including the possible underlayer) may each be between 10 and 15 mm.

Figure 2 also shows a disc brake system comprising a brake disc 30, a first housing 10 and a second housing 20, where the first housing 10 and the second housing 20 are separated from each other. Form individual units. Compared to the embodiment of Figure 1, Figure 2 shows shorter pistons 11, 21 and thinner friction materials 14, 24.

Due to the beneficial increase in the effective friction radius by bringing the circumferential outer edge 33 of the brake disc 30 closer to the rim 40 (e.g. at a distance of 2 cm or less), the performance of the brake system is improved. increases. Accordingly, a reduction in the length and/or diameter of the pistons as well as a reduction in the volume of the friction materials 14, 24 and a reduction in the dimensions of the housings 10, 20 can be envisaged. Specifically, the axial length of the pistons 11, 21 is between 20 and 30 mm and the axial thickness of the friction materials 14, 24 (including possible underlayers) is between 5 and 7 mm.

Figure 3 illustrates the support of the housings 10, 20 of a disc brake system by a modified carrier 50. Housings 10, 20 are connected to carrier 50. The carrier 50 axially supports the housings 10, 20 in each case in a radially inner position and in a radially outer position, in order to avoid tilting of the housings 10, 20 during braking. The carrier 50 also supports the backplates 13 and 23 in the tangential direction.

Figure 4 shows a different type of axial support for the housings 10, 20, where they are connected to the carrier 50 and to the knuckle 60. The housings 10, 20 are axially supported by a carrier 50 in radially internal positions and by a knuckle 60 in radially external positions. The carrier 50 also supports the backplates 13 and 23 in the tangential direction.

Figure 5 shows a further example of axial support of housings 10. The housings 10 , 20 are connected to the knuckle 60 and are axially supported by the knuckle 60 , in each case in a radially internal position and a radially external position. The carrier 50 is provided for tangential support of the backplates 13.

Figure 6 illustrates possible tilting of the housings during braking. This may be an undesirable effect that occurs because the bridge portion between the first housing 10 and the second housing 20 is omitted, which typically means that the housings can move independently. The following Figures 7 to 11 show embodiments aimed at reducing this type of tilting. These can advantageously be used in combination with the support-options of Figures 1 to 5 and/or they can be combined with each other.

Figure 7 shows an embodiment in which the first housing 10 comprises a main seal 18 for the first piston 11 and a further auxiliary seal 19, the auxiliary seal being axial from the main seal. It is provided on the outside in the direction. In the same way, the second housing 20 comprises a main seal 28 for the second piston 21 and a further auxiliary seal 29 axially outward from the main seal 28 . The auxiliary seals 19, 29 help center the pistons 11, 21, i.e. keep them aligned with their respective housings 10, 20 along the axial direction A. Avoid tilting of the pistons 11, 21 and housings 10, 20.

Figure 8 shows an embodiment in which the pressure conditions within the housings 10, 20 are modified. Here, the first cavity 16 of the first housing 10 for holding the first piston 11 has a first rear wall 17 opposite the first brake pad 12 . The first rear wall 17 is at an angle with respect to the first surface 31 of the brake disc 30 and with respect to the pressure surface 11a of the first piston. In the same way, the second cavity 26 of the second housing 20 for holding the second piston 21 is held against the second surface 32 of the brake disc 30 and the second piston 21 It has a rear wall 27 opposite the second brake pad 22, which is at an angle with respect to the pressure surface 21a.

In particular, the radially inner side of the rear wall 17 of the first housing 10 and the radially inner side of the rear wall 27 of the second housing 20 have respective radially outer sides of the respective rear walls 17, 27. Compared to , it is tilted away from the brake disc 30.

For both the first housing (10) and the second housing (20), the rear walls (17, 27) of the respective housings (10, 20) and the pressure surfaces (11a, 21a) of the respective pistons (11, 21). A tapered hollow space is created within the individual cavities 16 and 27 in between. Here, the tapered hollow space decreases in the radially outward direction (R). As the tapered hollow spaces receive brake fluid, taking into account their tapered shape, a greater amount of fluid is provided to the radially inner part of the hollow space than to the radially outer part.

Figure 9 shows a disc brake system in which the first housing 10 and the second housing 20 are arranged at an angle with respect to the brake disc 30. Here, the movement of the first piston 11 and the second piston 12 towards the brake disc 30 for braking is non-perpendicular to the individual surfaces 31, 32 of the brake disc 30 and in the axial direction (A). ) has a component at an angle that is not zero with respect to The first piston 11 and the second piston 21 are arranged in an oblique manner with respect to the first surface 31 of the brake disc 30 and the second surface 32 of the brake disc 30 . The movement of each piston 11, 21 towards the brake disc 30 includes movement in the radially outward direction R. The deviation of the movement of each piston 11, 21 from the normal direction (corresponding to the axial direction A) of the friction surfaces 31, 32 of the brake disc is at least 1° or at least 2° or at least 3° and /or it can be up to 20° or up to 15°.

Taking into account the tilted orientation of the pistons 11, 12, the friction materials 14, 24 of the two brake pads 12, 22 have a thickness that varies along the radial direction R, radially outward. Both friction materials 14, 24 with directionally increasing thickness align the friction surfaces of the brake pads 12, 22 parallel to the surfaces 31, 32 of the brake disc.

Figure 10 shows a solution that can be provided additionally or alternatively to the solution of Figure 9 if the pistons 11, 12 are aligned in an oblique manner. Here, this inclination of the pistons 11, 12 is taken into account by having a varying thickness in the backplates 13, 23 of both brake pads 12, 22, the backplates 13, 23 has a thickness that increases in the radially outward direction.

Figure 11 shows a disc brake system in which, similar to the embodiments of Figures 9 and 10, the pistons 11, 21 move non-orthogonally to the surfaces 31, 32 of the brake disc. In the case of Figure 11 this is established by having a tapered brake disc 30, where the movement of the pistons 11, 21 takes place along the axial direction A. The first surface 31 and the second surface 32 of the brake disc 30 are at a non-zero angle with respect to each other such that the first surface 31 and the second surface 32 are oriented in a radially outward direction (R). approach each other. It is emphasized once again that this can be combined with an oblique arrangement of pistons as shown in Figures 9 and 10. The angle of the surfaces 31 , 32 of the brake disc 30 with respect to the axial direction A may be at least 1° or at least 2° or at least 3° and/or at most 20° or at most 15°.

In the case of the embodiment of Figure 11, the first piston 11 and the second piston 21 have the shape of a cylinder cut at an angle to take into account the tapering of the brake disc 30.

Additionally or alternatively, varying thicknesses of the backplates 13 , 23 and/or friction materials 14 , 24 may be provided and, conversely, here with cut pistons 11 , 21 It should be noted that the solution presented in can be provided for the radially outwardly moving pistons 11, 21 of FIGS. 9 and 10.

12 and 13 relate to embodiments of a disc brake system provided with a dust collector 70. The dust collector 70 is, in each case, arranged radially outward from the housings 10 , 20 . Here, the space made available by omitting the bridge portion is used to mount the dust collector 70. The dust collector may include magnetic inserts and/or an adhesive coating to capture and retain brake dust.

Figure 12 shows a two-piece dust collector 70, each piece attached to one of the housings 10, 20, an individual brake pad 12, 22 and an individual surface 31 of the brake disc 30. , 32) and are arranged on the slot between the brake pads 12 and 22.

Figure 13 shows a one-piece dust collector extending between the two housings 10, 20 and around the circumferential outer edge 33 of the brake disc 30. A one-piece dust collector 70 is connected to both housings.

10 first housing
11 1st piston
11a Pressure surface of first piston
12 First brake pad
13 First back plate
14 First friction material
15 First brake fluid supply unit
16 first cavity
17 1st rear wall
18 First main seal
19 First auxiliary seal
20 Second housing
21 2nd piston
21a Pressure surface of the second piston
22 Second brake pad
23 Second back plate
24 Second friction material
25 Second brake fluid supply unit
26 second cavity
27 2nd rear wall
28 Second main seal
29 Second auxiliary seal
30 brake disc
31 first surface
32 second surface
33 Circumferential outer edge
40 rim
50 carrier
60 knuckles
70 dust collector
R Radially outward direction
A Axial outward direction

Claims (16)

A disc brake system for a vehicle, comprising:
- brake disc,
A first housing having at least one first piston for actuating a first brake pad, wherein the first brake pad is configured to press against the first surface of the brake disc,
A second housing having at least one second piston for actuating a second brake pad, wherein the second brake pad is configured to press against a second surface of the brake disc opposite the first surface. It includes a second housing,
The first housing and the second housing form separate, individual units. According to paragraph 1,
A disc brake system, wherein each of the first housing and the second housing has its own brake fluid supply. According to paragraph 1,
The first housing or the second housing is connected to at least one of a carrier and a knuckle. According to paragraph 1,
A disc brake system, wherein the distance between the circumferential outer edge of the brake disc and the inner side of the rim is less than 3 cm. According to paragraph 1,
A first cavity of the first housing for retaining the first piston has a rear wall opposite the first brake pad at an angle with respect to the first surface of the brake disc or the pressure surface of the first piston. have; or
A second cavity of the second housing for retaining the second piston has a rear wall opposite the second brake pad at an angle with respect to the second surface of the brake disc or the pressure surface of the second piston. Having a disc brake system. According to clause 5,
A radially inner side of the rear wall of the first housing or the rear wall of the second housing is inclined away from the brake disc relative to the respective radial outer side. According to paragraph 1,
The movement of the first piston towards the first surface of the brake disc for braking has a non-orthogonal component with respect to the first surface or the movement of the second piston towards the second surface of the brake disc for braking A disc brake system, wherein movement of the piston has a non-orthogonal component with respect to the second surface. In clause 7,
the first piston is arranged obliquely with respect to the first surface or axial direction of the brake disc; or
A disc brake system, wherein the second piston is arranged obliquely with respect to the axial direction or the second surface of the brake disc. According to clause 8,
A disc brake system, wherein the first piston or the second piston is arranged obliquely such that the movement of the first piston or the second piston towards the brake disc for braking has a radially outward component. According to paragraph 1,
A disc brake system, wherein the first surface and the second surface of the brake disc are at a non-parallel angle to each other. According to clause 10,
The brake disc is tapered so that the first surface and the second surface approach each other in a radially outward direction. According to paragraph 1,
A disc brake system, wherein the first piston or the second piston has the shape of an obliquely cut cylinder. According to paragraph 1,
The backplate or friction material of the first brake pad has a thickness that varies along a radial direction. According to paragraph 1,
The backplate or friction material of the second brake pad has a thickness that varies along a radial direction. According to paragraph 1,
The first housing includes a main seal and a secondary seal for the first piston, or
and the second housing includes a main seal and a secondary seal for the second piston. According to paragraph 1,
A disc brake system further comprising a dust collector.

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