WO2005106280A1

WO2005106280A1 - Probe of wear-indicator for brake pads

Info

Publication number: WO2005106280A1
Application number: PCT/IT2004/000238
Authority: WO
Inventors: Walter Canova; Alberto Bosis
Original assignee: Freni Brembo S.P.A.
Priority date: 2004-04-30
Filing date: 2004-04-30
Publication date: 2005-11-10
Also published as: EP1740846A1; ATE417213T1; ITMI20050758A1; ES2319528T3; EP1740846B1; DE602004018394D1

Abstract

The present invention relates to a probe (1) for an indicator of wear of the friction material (42) of the pads (4) of a brake. The probe comprises a conductor (3) capable of being connected to an indicator circuit and a block (2). This block has an engagement portion (20) capable of being fitted to a brake pad, a wear portion (22) capable of being turned towards the friction face of the brake, and a seating (23) made in the wear portion. The seating forms a path comprising an entrance (26a) and an exit (26b), and is formed in such a way that it can contain a wear segment (32) of the conductor (3). The wear portion (22) of the block comprises a groove (25) giving access to the seating (23); this groove connects the entrance to the exit of the path.

Description

DESCRIPTION "PROBE OF A WEAR-INDICATOR FOR BRAKE PADS" [0001] . The subject of the present invention is a probe for an indicator of wear of the friction material fitted to the pads of a brake, particularly to the pads of a disc brake.

[0002] . With reference to vehicles equipped with brakes, for example disc brakes, there is a particularly important requirement for the user to have available an indicator of the state of wear of the brake pad friction material .

[0003] . For this purpose, indicators comprising a probe and an indicator circuit are commonly used. The probe generally comprises a block having an aperture through it, within which a conductor wire is housed. The probe is housed in a recess made in the pad plate and in such a way that the wire is turned towards the brake disc. When the friction material of the pad fitted to the plate is consumed beyond a predetermined limit, the block of the probe also begins to be exposed to wear. In turn, the block, in becoming consumed, exposes the conductor wire to wear. When the conductor wire has worn until it breaks, a circuit is opened and this generates a warning signal directed to the user of the vehicle, relating to the state of wear of the brake pads. [0004] . As is known, however, indicators of the type outlined above are not free from disadvantages. For example, it is impossible for construction of the probe and its components to be completely automated. This is because the construction provides for the steps of cutting the conductor wire to the desired length, removing the insulating material from the ends of the wire, inserting the wire into the block having an aperture through it, crimping the terminals to the ends of the wire and moulding the connector which encases the terminals. The operation of inserting the conductor wire axially into the aperture in the block which constitutes its seating necessarily requires that the terminals should not yet have been crimped to the ends of the wire. Because this operation is rather complex, it is necessary to make provision for it to be carried but manually, interrupting an otherwise automated cycle, with an obvious increase in time and cost.

[0005] . From what has been stated above, it is clearly an important requirement to have an indicator of the state of brake pad wear which overcomes the disadvantages of the known technology.

[0006] . What is required is an indicator of the state of wear of the brake pads which can be easily produced in an automated manner. Specifically, there is a requirement for a probe the assembly of which does not require the conductor wire to be threaded into its seating by means of a movement along the axis of the seating. [0007] . There is also a requirement that this indicator should ensure that the conductor wire does not come out of its seating and that consequently it wears at the same rate as the friction material surrounding it. [0008] . The purpose of the present invention is to devise and make available an indicator of the state of wear of brake pads and an associated probe which meet the above-mentioned requirements and at the same time eliminate the disadvantages of the known technology. [0009] . This purpose is achieved by means of an indicator of the state of wear of brake pads according to claim 1 and by means of an indicator according to claim 6.

[0010] . Other characteristics and advantages of the invention will become clear from the following description of a preferred example of embodiment, provided purely by way of non-limiting example with reference to the appended drawings, in which:

[0011] . - figure 1 shows in isometric projection a probe of a wear-indicator of the known type and a brake pad on which it may be mounted; [0012] . - figure la shows a detail of figure 1;

[0013] . - figure 2 shows in isometric projection a detail of the probe of the indicator according to the invention; [0014] . - figure 3 shows in isometric projection another detail of the probe of the indicator according to the invention;

[0015] . - figure 4 shows in isometric projection the detail in figure 3 inverted and reversed compared with figure 3;

[0016] . - figure 5 shows in isometric projection a probe according to the invention mounted on a brake pad;

[0017] . - figure 6 shows a section along the plane of symmetry in figure 5; [0018] . - figure 7a shows in section along the plane VII-VII in figure 6 a probe according to the invention in a first operating configuration;

[0019] . - figure 7b shows in section along the plane VII-VII in figure 6 a probe according to the invention in a second operating configuration;

[0020] . - figures 8a to 8d show four successive steps in the method of producing a probe according to the invention.

[0021] . With reference to the above-mentioned drawings, the number 1 indicates as a whole a probe for an indicator of wear of the friction material of the pads of a brake.

[0022] . The probe 1 comprises a block 2 and a conductor 3 which will be described in what follows. [0023] . In turn, the block 2 comprises an engagement portion 20 and a wear portion 22 opposite the engagement portion 20. The engagement portion 20 is capable of being inserted into a recess 41 and remaining firmly housed in it until an operator takes deliberate action to remove it.

[0024] . The recess 41 is typically made in a plate 40 of a brake disc 4.

[0025] . The block 2 is produced in such a way that, once the engagement portion 20 is inserted into the recess 41, the wear portion 22 is surrounded by the friction material 42 of the pad 4.

[0026] . The wear portion 22 in turn comprises one or more wear surfaces 24 facing towards the friction face 50 of the brake. In other words, the wear surfaces 24 are arranged in such a way that a half-line (for example s or s' in figure 7a) coming out perpendicularly from them meets the surface of the friction face 50.

[0027] . Inside the wear portion 22 there is a seating

23 shaped so that it can contain a wear segment 32 of the conductor 3 described in what follows. [0028] . The seating 23 forms a path into which the wear segment 32 of the conductor 3 must fit. This path may be characterised conventionally as having an entrance 26a and an exit 26b opposite to it. [0029] . The wear portion 22 also comprises a groove 25 providing access to the seating 23 and connecting the entrance 26a to the exit 26b. [0030] . This groove 25 is formed in such a way as to allow the wear segment 32 to be in inserted into the associated seating 23 by means of a movement in a transverse direction relative to the seating 23. [0031] . In accordance with a preferred form of embodiment, this groove 25 opens onto the wear surface 24. [0032] . The block 2 is preferably produced from a polymer material of the polyimide type (for example Meldin^® 7001 marketed by Saint-Gobain^®) capable of maintaining its own mechanical characteristics even at the high operating temperatures which are typically reached by the pad 4 during the braking action.

[0033] . The conductor 3 comprises means for electrical connection to an indicator circuit and a wear segment 32. [0034] . In accordance with a preferred form of embodiment, the means for electrical connection comprise a connector 30 of known type. [0035] . The wear segment 32 on the contrary is a length of the conductor 3 which provides electrical continuity of the circuit and which is designed to be exposed to wear together with the wear portion 22 of the block 2 within which the seating 23 is made and together with the friction material 42 which surrounds the wear portion 22. [0036] . From the above description, it will be clear how the type of probe according to the invention allows production to be automated completely. The reason is that it is no longer necessary to insert the conductor wire axially into the aperture in the block which constitutes the seating of the wire. [0037] . In accordance with a preferred form of embodiment of the method for producing the probe according to the invention, provision is made first of all for the steps of cutting the conductor 3 to the desired length (figure 8a) , removing the insulating material from the ends of the conductor (figure 8b) and crimping the terminals 31 to these ends (figure 8c) . These operations may be carried out in a continuous sequence, without the need for any manual intervention.

After this, provision may be made for the step of moulding the connector 30 which encases the terminals 31 (figure 8d) . [0038] . Finally, because of the innovative characteristics of the probe according to the invention, the conductor 3 can be inserted into its seating 23 inside the block 2, despite the presence of the terminals and the connector 30. [0039] . In what follows, a description is given of the operation of a probe for an indicator of wear of the friction material fitted to the pads of a brake in accordance with the present invention. [0040] . The probe 1 in accordance with the invention is inserted into the recess 41 made in the plate 40 of a pad 4. In this way, the wear portion 22 of the block 2 is sunk in the friction material 42 of the pad 4. [0041] . The braking action applied by the friction material 42 to the friction face 50, for example of a brake disc 5, causes wear of the friction material and consequent reduction in its thickness h.

[0042] . Upon reaching a first predetermined level of wear of the friction material (h' in figure 7a) , the wear surface 24 facing towards the friction face 50 begins to come into contact with it.

[0043] . From this time onwards, any further wear of the friction material 42 involves simultaneous wear of the wear portion 22 of the block 2 of the probe 1. [0044] . Upon reaching a second predetermined level of wear of the friction material (h" in figure 7a) , the wear segment 32 of the conductor 3 begins to come into contact with the friction face 50.

[0045] . From this time onwards, any further wear of the friction material 42 involves simultaneous wear of the wear segment 32 of the conductor 3 of the probe 1. [0046] . Upon reaching a third predetermined level of wear of the friction material (h' " in figure 7a) , the wear segment 32 of the conductor 3 breaks or in any case is no longer capable of ensuring the electrical continuity of the indicator circuit. [0047] . When the electrical continuity which was ensured by the integrity of the conductor 3 fails, the indicator circuit generates a warning signal directed to the user of the vehicle and regarding the state of wear of the brake pads.

[0048] . Determination of the three successive levels h' , h" and h' " of wear of the f iction material 42 may vary depending on specific requirements. In accordance with a preferred form of embodiment, the third wear level which determines the generation of the warning signal will be determined so as to reconcile the opposing requirements of utilising the full thickness of the friction material 42 and allowing a remaining mileage such as to ensure that the vehicle can be driven safely to a maintenance facility. [0049] . From what has been stated above, it will be clear how the present invention overcomes the disadvantages of the state of the art. [0050] . In particular it will be clear how the present invention entirely meets the requirements of obtaining a probe which can be easily assembled in an automated manner. [0051] . Moreover, the probe 1 according to the invention ensures that there is no possibility of the conductor 3 escaping from the seating 23 and that it remains intact independently of the level of wear of the friction material 42. [0052] . Clearly, provision may be made for variants and/or additions to what has been described and illustrated above. For example, provision may be made for a different method of attaching the block 2 to the plate 40 of the pad 4. Or again, a different embodiment of the conductor 3 may be preferred, for example in the form of a metal strip or a portion of another conducting material. Finally, the connection of the probe 1 to the indicator circuit may be produced by any means suitable for providing electrical continuity of the circuit and considered adequate for the specific requirements. [0053] . Persons skilled in the art, for the purpose of meeting incidental and specific requirements, will be able to make numerous changes, adaptations and substitutions of components with other functionally equivalent ones without thereby departing from the scope of the following claims. *** * ***

Claims

1. A probe (1) for an indicator of wear of the friction material (42) of the pads (4) of a brake, comprising:

- a conductor (3) , capable of being connected to an indicator circuit, and having a wear segment (32) ; and

- a block (2) having an engagement portion (20) capable of being fitted to a brake pad (4) ; a wear portion (22) , capable of facing towards a friction face (50) of said brake; and a seating (23) made in said wear portion . (22) , said seating forming a path comprising an entrance (26a) and an exit (26b) , said seating being formed in such a way that it can contain said wear segment (32) of said conductor (3) ; in which said wear portion (22) comprises a groove (25) giving access to the seating (23) , said groove connecting said entrance (26a) to said exit (26b) ;

2. A probe (1) according to claim 1 in which said wear portion (22) comprises at least one wear surface (24) facing towards said friction face (50) of said brake (5) .

3. A probe (1) according to claim 2 in which said groove (25) giving access to the seating (23) opens onto said wear surface (24) .

4. A probe (1) according to claim 1 also comprising means (30) for electrical connection to an indicator circuit.

5. A probe (1) according to claim 4 in which said means comprise a connector (30) .

6. An indicator of wear of the friction material of the pads of a brake, comprising a probe according to any one of claims 1 to 5.

7. A method of production of a probe (1) for an indicator of the wear of the friction material (42) of the pads (4) of a brake, comprising the steps of: cutting said conductor (3) to a predefined length; removing the insulating material from the ends of said conductor; crimping terminals (31) to the ends of said conductor; moulding said connector (30) to encase said terminals (3) ; and - inserting said conductor (3) into said seating (23) in said block (2) .