TWI752769B - Integrated disc brake caliper and method for producing same - Google Patents

Abstract

The invention relates to an integrated disc brake caliper and a method for producing the same. The invention involves integrally casting a caliper body from an alloy, and the caliper body includes a first section and a second section arranged symmetrically with an opening in-between. The first section includes an outer end surface and an inner end surface opposite to the outer end surface. The outer end surface is coaxially drilled through at an appropriate position to the second section by using a drill, thereby forming a through hole. A plug body is placed from the opening and fitted in the through hole. A cover is mounted on the first section to seal the through hole and keep it from being exposed through the outer end surface. The integrated disc brake caliper is finished by constructing a first oil duct, a second oil duct and a connecting duct. By virtue of the method disclosed herein, the caliper can be produced at an improved speed with an enhanced strength.

Description

One-piece caliper and method of making the same

The invention relates to a one-piece caliper which can be processed quickly and can improve strength and a manufacturing method thereof.

According to this, most vehicles currently use a disc brake system, which mainly includes a caliper body, a brake oil pipe and a brake pump. Wherein the caliper body is connected with the brake pump through the brake oil pipe, at least one piston is arranged inside the caliper body, and a brake pad is connected with the piston. When the braking action is to be performed, the brake pump pushes the brake oil inside the brake oil pipe, and the oil pressure is transmitted to the caliper body and the piston inside the caliper body through the brake oil pipe to act, so that the brake pad is clamped A brake disc is used to generate braking force to achieve the purpose of braking stop.

At present, the common brake calipers on the market include single-piston type and multi-piston type. As the name implies, the single-piston type has only a single piston, so its braking force is slightly insufficient, so it is mostly used in lighter weight vehicles such as locomotives or bicycles. on the vehicle. The multi-piston type brake caliper can greatly increase the clamping force of the brake disc due to the use of multiple pistons to act at the same time. Therefore, the general pursuit of high-performance vehicles mostly use multi-piston type brake calipers, such as: four-piston brake calipers or six-piston brake calipers Piston brake calipers, etc.

The multi-piston type brake calipers on the market are mostly multi-piece combined brake calipers, which are composed of two or more caliper bodies, which are less difficult to cut and assemble, and are also relatively cheap compared to manufacturing costs, so generally Manufacturers mostly use a multi-piece combined production method, but when the multi-piece combined brake caliper is actually used, because the caliper bodies are all assembled with screws, there are actually the following shortcomings: (1) conventional calipers the law must After the caliper is made into the front and rear half calipers, the drilling processing of the above-mentioned several hydraulic cylinder accommodating grooves is carried out. The separate processing is very slow, and additional screw holes are required before and after drilling, and the processing speed is slow. It goes without saying. (2) When the front and rear half calipers of the conventional calipers are assembled together, screws are inserted into the front and rear screw holes, and then they are pressed against each other, which increases the assembly time and reduces the production efficiency. Combination, its strength is weak, and it is easy to loosen, which can easily cause the lack of braking function and cause danger. (3) When assembling or disassembling and replacing with a new one, it is necessary to operate the screws one by one, which is troublesome and time-consuming, and the locking degree of the screws must be accurately set. (4) These screws may be subjected to shear stress due to excessive braking force, so their reliability is greatly questioned, and in the most serious cases, the safety of the user may be threatened. (5) This kind of structure composed of two cylinders is also easy to cause the structure to be loose. After a long time of use, the braking effect will gradually disappear. In actual use, the structure is unstable and the brake oil is very easy to seep out, resulting in The internal parts are contaminated by oil stains, which leads to the failure of the brakes, making the driving safety precarious.

Therefore, in view of the above-mentioned problems of conventional brake calipers, how to develop an innovative structure with a more stable structure and better braking effect is what consumers are eagerly looking forward to, and it is also the goal and direction that the relevant industry must strive to develop breakthroughs.

In view of this, the present invention relates to an integrally formed caliper body, which not only can be processed quickly and has a stable structure, but will not cause instability in the body structure due to prolonged use, and the integrated structure can reduce the possibility of oil leakage caused by assembly gaps. .

According to a first aspect of the present invention, there is provided an integrated caliper with a system connected to a brake pump for injecting a brake oil, which at least includes: a first block having relatively outer end faces and inner an end face, and has at least a through hole, an oil injection hole and a first oil passage, the through hole runs through the outer end face and the inner end face, and the first oil passage is connected with the through hole and the oil injection hole; a first oil passage Two blocks are arranged on one side of the inner end face and opposite to the first block to form an opening. The second block has at least one accommodating groove and a second oil passage, and one end of the accommodating groove is closed end, the other end The discharge end faces the through hole, the second oil passage is connected with the accommodating groove; a connecting oil passage is provided in the body for connecting the first and second oil passages; at least one inner plug body , which is disposed in the through hole; and an outer cover, which is fixed on the first block and closes the through hole exposed on the outer end surface.

In a preferred embodiment, the inside of the through hole is provided with a catch portion adjacent to the outer end surface, the inner plug system has a ring flange, and the ring flanges are respectively embedded in the catch portion to close the catch portion. through hole.

In a preferred embodiment, the through hole and the inner plug body are provided with a plurality of threads that are screwed with each other, and the inner plug body is provided with a tool slot near the outer end surface.

In a preferred embodiment, the ring flange is further provided with an annular recess for accommodating a ring.

In a preferred embodiment, the outer cover is fixed on the outer end surface of the first block by at least one fixing member.

In a preferred embodiment, the body is further provided with a mounting hole communicating with the first and second oil passages and the connecting oil passage, and a closure for closing the mounting hole.

According to the second aspect of the present invention, the manufacturing method for manufacturing the above-mentioned one-piece caliper at least sequentially includes the following steps: a caliper body is integrally formed by alloy casting, and the body has a first block and a second block symmetrically arranged a block, and an opening is formed therebetween, the first block has opposite outer and inner end surfaces; a drill bit is provided, which is coaxially drilled from the center of at least one predetermined position of the outer end surface to a preset appropriate position of the second block deep but not drilled through the second block to form at least a through hole and an accommodating groove; provide at least one inner plug body, which is inserted into the through hole through the opening; and provide an outer cover, which is fixed on the first A block closes the through hole exposed on the outer end face.

In a preferred embodiment, the axis lines of the through hole and the accommodating groove are in a collinear state, respectively.

1: Ontology

10: The first block

11: Outer end face

12: inner end face

13: Through hole

131: Latch Department

14: Oil filling hole

15: The first oil passage

20: Second block

21: accommodating slot

22: Second oil channel

31: Opening

32: Connect the oil passage

33: Mounting holes

34: Closures

40: Inner plug

41: Ring flange

42: Tool slot

43: Annular recess

44: Ring

50: Outer cover

51: Fixing parts

Figure 1 is a perspective view of the semi-finished caliper of the present invention; Figure 2 is a schematic cross-sectional view of the semi-finished caliper of the present invention; Figure 3 is a schematic cross-sectional view of the semi-finished caliper of the present invention from another perspective; Figure 4 shows an exploded perspective view of the caliper according to the present invention; Figure 5 shows a schematic cross-sectional view of the caliper according to the present invention; and Figure 6 shows a perspective view of the caliper according to the present invention.

Unless otherwise specified, the following terms used in the specification and scope of this application have the definitions given below. Please note that the singular term "a" used in the specification and scope of the application is intended to cover one and more than one stated items, such as at least one, at least two or at least three, rather than only having a single contained matter. In addition, open-ended conjunctions such as "comprising" and "having" used in the scope of the patent application mean that the combination of elements or components described in the claim does not exclude other components or components not specified in the claim. It should also be noted that the term "or" generally includes "and/or" in its sense unless the content clearly dictates otherwise. The term "about" used in the description of this application and the scope of the patent application is used to modify any error that may vary slightly, but such slight variation will not change its essence.

Please refer to FIG. 1 , the one-piece caliper of the present invention has a main body 1 connected to a brake pump (not shown) for injecting a brake oil, the main body 1 at least includes: a first block 10 and a second block 20 .

The first block 10 has opposite outer and inner end faces 11 and 12, and has at least a through hole 13, an oil injection hole 14 and a first oil passage 15. Please refer to FIGS. 2 and 3 at the same time. The hole 13 penetrates through the outer end surface 11 and the inner end surface 12 , and the first oil passage 15 is connected with the through hole 13 and the oil injection hole 14 .

The second block 20 is disposed on one side of the inner end face 12 and opposite to the first block 10 The second block 20 has at least one accommodating groove 21 and a second oil passage 22. One end of the accommodating groove 21 is a closed end, and the other end is an open end and faces the through hole 13. The second oil passage 22 is connected to the accommodating groove 21 .

In the present invention, the first block 10 and the second block 20 of the main body 1 are made in one piece, and the manufacturing method at least sequentially includes the following steps:

Step S01: A caliper body 1 is integrally formed by alloy casting, such as aluminum alloy gravity casting. The body 1 has a first block 10 and a second block 20 symmetrically arranged, as shown in FIG. 1, between which An opening 31 is formed, and the first block 10 has an opposite outer end surface 11 and an inner end surface 12 .

Step S02: Provide a drill bit (not shown in the figure), which coaxially drills through the center of at least one predetermined position of the outer end face 11 to a preset appropriate depth of the second block 20 but does not drill through the second block 20, Please also refer to FIG. 2 to form two through holes 13 located in the first block 10 and two accommodating grooves 21 located in the second block 20. One end of the accommodating groove 21 is a closed end. The other end is open and faces the through hole 13 , and the axis lines of the through hole 13 and the accommodating groove 21 are in a collinear state respectively. Further drilling is also performed from at least a predetermined position of the outer end face 11 to a predetermined appropriate depth of the second block 20, and drilling inward from the second block 20 to a predetermined appropriate depth, and An oil filling hole 14, first and second oil passages 15, 22 and a connecting oil passage 32 are respectively formed. Please refer to FIG. 3 at the same time. The connecting oil passage 32 is provided in the main body 1 for connecting the first and second oil passages. The second oil passages 15, 22, and the body 1 simultaneously forms a plurality of mounting holes 33 communicating with the first and second oil passages 15, 22 and the connecting oil passage 32, and the mounting holes 33 are processed by drilling Unnecessary machining holes generated when making the first and second oil passages 15, 22 and the connecting oil passage 32 must be closed with a plurality of sealing pieces 34 during use to prevent the first and second oil passages from being located in the first and second oil passages. The oil passages 15 and 22 and the liquid in the connecting oil passage 32 overflow.

Step S03 : providing at least one inner plug body 40 , as shown in FIG. 4 , which is inserted into the through hole 13 through the opening 31 to form a setting for closing the through holes 13 ; wherein, please also Referring to FIG. 5 , a latching portion 131 is provided inside the through hole 13 adjacent to the outer end surface 11 , and the inner plug body 40 has an annular flange 41 , and the annular flanges 41 are respectively embedded in the latches The stopper 131 closes the through hole 13 , and a plurality of threads are provided between the through hole 13 and the inner plug body 40 , and the inner plug body 40 is provided with a tool slot 42 near the outer end surface 11 . , during assembly, a tool (such as a hexagonal wrench) can be used to extend from the outer end surface 11 into the tool slot 42 (for example, a hexagonal slot), and the tool can be operated to drive the inner plug body 40 to rotate The ring flange 41 is further provided with an annular recess 43 for accommodating a ring 44, the ring 44 can be pre-sleeved in the annular recess 43, the inner plug body 40 is then fixed in the through hole 13 , so that the ring 44 can be tightly disposed between the inner plug body 40 and the through hole 13 .

Step S04 : providing an outer cover 50 which is fixed on the first block 10 and closes the through hole 13 exposed on the outer end surface 11 . In the embodiment shown in the figure, the outer cover 50 is fixed to the outer end surface 11 of the first block 10 by at least one fixing member 51 (such as screws or bolts), and the inner plug body 40 and the outer cover are used. 50 The through hole 13 is more securely closed, and an integrated caliper of the present invention is formed, as shown in FIG. 6 .

The manufacturing method of the present invention can complete a one-piece caliper, which not only increases the molding speed but also improves the strength of the caliper, and improves the conventional two-piece or multi-piece assembled caliper body, which has the problems of difficult assembly and low reliability. It is not easy to use for a long time and the main body structure is unstable, and the integrated structure can reduce the possibility of oil leakage caused by the assembly gap.

The above embodiments are only used to illustrate the present invention, but not to limit the present invention. Those skilled in the relevant art, various transformations or changes made without departing from the technical scope of the present invention should also belong to the protection category of the present invention.

10: The first block

11: Outer end face

12: inner end face

13: Through hole

14: Oil filling hole

15: The first oil passage

20: Second block

21: accommodating slot

22: Second oil channel

32: Connect the oil passage

Claims (8)

An integrated caliper has a system connected with a brake pump for injecting a brake oil, which at least includes: A first block has opposite outer and inner end surfaces, and has at least a through hole, an oil injection hole and a first oil passage, the through hole runs through the outer end face and the inner end face, and the first oil passage is connected with the through hole and the oil filling hole; A second block, disposed on one side of the inner end face and opposite to the first block to form an opening, the second block has at least one accommodating groove and a second oil passage, one end of the accommodating groove It is a closed end, and the other end is an open end and faces the through hole, and the second oil passage is connected with the accommodating groove; a connecting oil passage, which is provided in the main body for connecting the first and second oil passages; At least one inner plug body is disposed in the through hole; and An outer cover is fixed on the first block and closes the through hole exposed on the outer end surface. The one-piece caliper as claimed in claim 1, wherein a catch portion is provided inside the through hole adjacent to the outer end surface, the inner plug system has a ring flange, and the ring flanges are respectively embedded in the catches part to close the through hole. The one-piece caliper as claimed in claim 2, wherein a plurality of threads are arranged between the through hole and the inner plug body, and the inner plug body is provided with a tool slot close to the outer end surface. The one-piece caliper of claim 2, wherein the ring flange is further provided with an annular recess for accommodating a ring. The one-piece caliper according to any one of claims 1 to 4, wherein the outer cover is fixed to the outer end surface of the first block by at least one fixing member. The one-piece caliper according to any one of claims 1 to 4, wherein the body is further provided with a mounting hole communicating with the first and second oil passages and the connecting oil passage, and a mounting hole for closing the mounting hole closure. A method for manufacturing the one-piece caliper according to any one of claims 1 to 4, comprising at least the following steps in sequence: A caliper body is integrally formed by alloy casting, the body has a first block and a second block symmetrically arranged, an opening is formed therebetween, and the first block has opposite outer end faces and inner end faces; providing a drill bit, which coaxially drills through the center of at least a predetermined position of the outer end face to a preset appropriate depth of the second block but does not drill through the second block, so as to form at least a through hole and an accommodating groove; providing at least one inner plug body, which is inserted into the through hole through the opening; and An outer cover is provided, which is fixed on the first block and closes the through hole exposed on the outer end surface. The manufacturing method of the one-piece caliper according to claim 7, wherein the axis lines of the through hole and the accommodating groove are in a collinear state, respectively.

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