WO2017085619A1 - Disc brake caliper, method for manufacturing a caliper and caliper spring - Google Patents

Disc brake caliper, method for manufacturing a caliper and caliper spring Download PDF

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Publication number
WO2017085619A1
WO2017085619A1 PCT/IB2016/056864 IB2016056864W WO2017085619A1 WO 2017085619 A1 WO2017085619 A1 WO 2017085619A1 IB 2016056864 W IB2016056864 W IB 2016056864W WO 2017085619 A1 WO2017085619 A1 WO 2017085619A1
Authority
WO
WIPO (PCT)
Prior art keywords
caliper
piston
proximal
distal
core
Prior art date
Application number
PCT/IB2016/056864
Other languages
French (fr)
Inventor
Fabio Scotti
Alessandro INSABATO
Andrea Teruzzi
Cristian Crippa
Original Assignee
Freni Brembo S.P.A.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Freni Brembo S.P.A. filed Critical Freni Brembo S.P.A.
Priority to JP2018524239A priority Critical patent/JP6875396B2/en
Priority to US15/776,829 priority patent/US11384804B2/en
Priority to CN201680066921.5A priority patent/CN108291595B/en
Priority to DE112016005268.5T priority patent/DE112016005268T5/en
Publication of WO2017085619A1 publication Critical patent/WO2017085619A1/en
Priority to US17/806,956 priority patent/US11994181B2/en

Links

Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/005—Components of axially engaging brakes not otherwise provided for
    • F16D65/0068—Brake calipers
    • F16D65/0075—Brake calipers assembled from a plurality of parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D55/00—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes
    • F16D55/02—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members
    • F16D55/22—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members by clamping an axially-located rotating disc between movable braking members, e.g. movable brake discs or brake pads
    • F16D55/228—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes with axially-movable discs or pads pressed against axially-located rotating members by clamping an axially-located rotating disc between movable braking members, e.g. movable brake discs or brake pads with a separate actuating member for each side
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/005—Components of axially engaging brakes not otherwise provided for
    • F16D65/0068—Brake calipers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D55/00—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes
    • F16D2055/0004—Parts or details of disc brakes
    • F16D2055/0016—Brake calipers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D55/00—Brakes with substantially-radial braking surfaces pressed together in axial direction, e.g. disc brakes
    • F16D2055/0075—Constructional features of axially engaged brakes
    • F16D2055/0091—Plural actuators arranged side by side on the same side of the rotor
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2200/00—Materials; Production methods therefor
    • F16D2200/0004—Materials; Production methods therefor metallic
    • F16D2200/0008—Ferro
    • F16D2200/0021—Steel
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00—Manufacturing; Assembly
    • F16D2250/0007—Casting
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00—Manufacturing; Assembly
    • F16D2250/0007—Casting
    • F16D2250/0015—Casting around inserts

Definitions

  • the present invention relates to the field of braking systems for vehicles, and in particular the present invention relates to a disc brake caliper.
  • a disc brake consists of a disc, which is integral in rotation with the vehicle wheel, and a fixed caliper, in which a pair of pads carrying friction material are housed.
  • the caliper also holds pistons which, by being hydraulically operated, push the pads against the disc surfaces, thus obtaining the braking by virtue of the action of the friction material.
  • FIG. 1 shows a disc brake caliper according to an embodiment of the present invention
  • figure 2 shows a plan view of the caliper in figure
  • figure 3 shows a pad engaged with pistons of the caliper in figure 1;
  • figure 4 shows a rear front view of the pad with pistons in figure 3;
  • figure 5 shows a diagram highlighting the position of the center of gravity of the bridge portions and of the center of gravity of the piston areas in the caliper in figure 1;
  • figure 6 shows the pressure distribution in a pad of a caliper according to the present invention
  • figure 7 shows the pressure distribution in a pad of a caliper according to the prior art
  • FIG. 8 shows a lost core for making a caliper body of a caliper according to a further aspect of the present invention
  • figure 11 shows pads coupled with return springs according to another aspect of the present invention.
  • figure 12 shows a section of the pads with return springs in figure 11;
  • reference numeral 1 indicates a disc brake caliper according to an embodiment of the present invention, intended to be arranged straddling a disc rotatable about a rotation axis Z.
  • the expressions “axial direction” or “axially” will be used with reference to a direction parallel to the rotation axis Z of the disc
  • the expressions “radial direction” or “radially” will be used with reference to a radial direction with respect to said rotation axis
  • the expressions “circumferential direction” or “circumferentially” will be used with reference to a circumferential pattern about said rotation axis.
  • the caliper 1 comprises a caliper body 2, usually monolithic, preferably made by gravity casting.
  • the caliper body 2 consists of:
  • the upper portions 6a, 6b intersect in a central portion 8, making a cross body consisting of axial arms
  • each axial arm 6a', 6a'' is tapered from the respective side portion 2a, 2b towards the central portion 8.
  • Piston chambers accommodating therein a respective piston, which can be hydraulically actuated by means of pressurized oil fed by means of a hydraulic circuit, also prevalently obtained in the pump body, are obtained within the caliper body 2, and in particular in the side portions 2a, 2b thereof.
  • the caliper 1 further comprises a pair of pads 20, accommodated in the caliper body 2, supported in slidable manner so as to allow an axial sliding under the bias of said pistons.
  • the caliper according to the present invention has eight pistons, operating in fours on a respective pad.
  • the pad 20 can be biased by an intermediate distal piston 22a, by an intermediate proximal piston 22b, by a front side piston 24a and by a rear side piston 24b.
  • the pressure centers 24a', 24b' of the side pistons 24a, 24b lie on an imaginary circumference I centered on the rotation axis Z, at a predetermined angular distance A, while the pressure centers 22a' , 22b' of the intermediate pistons 22a, 22b are contained angularly in the angular region identified by said angular distance A.
  • the pressure center 22a' of the first intermediate piston 22a lies on the bisector B which bisects the angular region identified by the angular distance A, at a first radial distance Ra from the rotation axis Z; for example, the pressure center 22a' of the distal intermediate piston 22a lies on said imaginary circumference I .
  • the pressure center 22b' of the proximal intermediate piston 22b lies on said bisector B, at a second radial distance Rb from the rotation axis Z, smaller than the first radial distance Ra .
  • the pressure center 22a' of the distal intermediate piston 22a and the pressure center 22b' of the proximal intermediate piston 22b are distanced and radially aligned along a radial direction R.
  • the pressure centers 22a', 22b', 24a', 24b' fall within the contour of the pad, preferably at the vertexes of an imaginary rhombus for which the minor diagonal is arranged radially.
  • the entire sections of the pistons 22a, 22b, 24a, 24b fall within the contour of the pad.
  • the central portion 8 of the caliper body 2 intersects the radial direction R of the pressure centers 22a' , 22b' of the intermediate pistons 22a, 22b, preferably symmetrically, while the front bridge portion 4a and the rear bridge portion 4b are arranged circumferentially externally to the pressure centers 24a', 24b' of the side pistons 24a, 24b (figure 5) .
  • the center of gravity of the front bridge portion 4a, of the rear bridge portion 4b and of the central portion 8 is close to the center of gravity of the pistons 22a, 22b, 24a, 24b, thus resulting in a particularly rigid caliper, i.e. capable of developing a particularly prompt and vigorous braking.
  • the load distribution on the pad is particularly uniform (figure 6) with respect to the distribution of a usual pad of the prior art (figure 7) .
  • This allows, in the caliper according to the invention, to reduce the anomalous, non ⁇ uniform consumption of the friction material and to improve the braking action.
  • a lost core 30 is used, consisting of a cross- shaped core body 31, intended to obtain in the caliper body the space for housing the pads, from which the intermediate chamber cores 32a, 32b for making the chambers for the intermediate pistons 22a, 22b, and the side chamber cores 34a, 34b for making the chambers for the side pistons 34a, 34b axially protrude, on one side and on the other (figure 8) .
  • the core 30 includes at least one circuit branch core which connects at least two piston chamber cores for making a circuit branch of the pressurized oil feeding circuit.
  • the core 30 has a proximal branch core 36 which protrudes from the proximal piston chamber core 32b and extends towards the distal piston chamber core 32a and a distal branch core 38 which protrudes from the distal piston chamber core 32a and extends towards the proximal piston chamber core 32b.
  • proximal branch core 36 and the distal branch core 38 terminate with a respective free end 40, 42 which are very close to each other but separated.
  • the proximal branch core 36 and the distal branch core 38 are separate from each other, also on the tip.
  • a semi-finished caliper body 50 is obtained, which is provided, in the side portion 2a, 2b, with the proximal piston chamber 52 and with the distal piston chamber 54 for housing the proximal intermediate piston 22b and the distal intermediate piston 22a, respectively, and with the front piston chamber 56 and with the rear piston chamber 58 for housing the front side piston 24a and the rear side piston 24b, respectively (figure 9) .
  • a proximal circuit branch 60 extends from the proximal piston chamber 52 towards the distal piston chamber 54 and a distal circuit branch 62 extends from the distal piston chamber 54 towards the proximal piston chamber 52.
  • the proximal circuit branch 60 does not intercept the distal circuit branch 62, i.e. said branches 60, 62 are separate, as the respective branch cores 36, 38 were.
  • the semi-finished caliper 50 is subjected to processing by material removal, in particular a first hole is made to remove the material from the caliper body which separates the proximal circuit branch 60 from the distal circuit branch 62, thus putting them into communication (figure 10) .
  • a second hole is further made to put the front piston chamber 56 into communication with the rear piston chamber 58, preferably at the same time as the first hole is made, along the same perforation axis F.
  • a semi-finished perforated caliper body 70 is thus obtained, in which the proximal piston chamber 52 is connected to the distal piston chamber 54 by means of the proximal branch 60 and the distal branch 62 obtained in the pump body 2, while the front piston chamber 56 is connected to the rear piston chamber 58 by means of a connection pipe 72 which also intercepts the proximal branch 60 and/or the distal branch 62.
  • the connection branch 72 leads onto the front portion 4a with a front gap 74 and onto the rear portion 4b with a rear gap 76, intended to be plugged.
  • the front gap 74 on one side of the caliper body 2 is instead intended to be connected to the front gap 74' of the other side of the caliper body through a bridge pipe 78, generally constituted by a tube, applied externally to the pump body 2 ( figure 1 ) .
  • the pads 20 are permanently biased towards the respective rest position by at least one spring 80, preferably by a pair of identical springs 80, preferably obtained by bending an appropriately shaped steel sheet.
  • a pad 20 comprises a supporting plate 21, having an outer surface 23 intended for the action of the pistons, and an opposite inner surface 25, and friction material 27 carried by the supporting plate 21 on the inner surface 25.
  • the supporting plate 21 has a proximal edge 27, at which eyelets 29 are obtained for supporting the pad 20 in sliding manner, sides 31, 33, and a distal edge 35, to which the spring 80 is applied.
  • the spring 80 which operates on both pads 20 at the same time, comprises a central strip 82 which extends axially, when the spring 80 is applied to the caliper body 2, between the pads 20, straddling the disc.
  • the central strip 82 is folded at the ends so as to form, for each end, a curl 84, which then extends on an abutment plane 86, intended to come into contact with the distal edge 35 of the pads 20.
  • the spring 80 further comprises a coupling portion 88 arranged centrally, comprising two pairs 90 of wings 92; the two pairs 90 are arranged side by side to the strip 82, in a stretch thereof which forms a recess 94.
  • the caliper according to the present invention is particularly rigid, and thus allows to apply prompt, vigorous braking; such a behavior is conferred, moreover, by the arrangement of the pistons, which determine a center of gravity very close to the center of gravity of the bridge portion sections.
  • the manufacturing process of the brake caliper is very reliable, and in particular the making of a hole on the semi-finished caliper body for forming the hydraulic connection between the piston chambers prevents the core from having weakened portions which could be easily subject to breakage during casting. It is apparent that a person skilled in the art may made changes to the caliper described above, all of which are contained within the scope of protection as defined in the following claims, in order to satisfy contingent needs .

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Braking Arrangements (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

A disc brake caliper (1) comprises a caliper body (2) and a pair of pads (20) and, in each side portion (2a, 2b) of the caliper body (2), a distal piston (22a) and a proximal piston (22b), having radially distanced and aligned pressure centers (22a', 22b').

Description

"DISC BRAKE CALIPER , ME THOD FOR MANUFACTURING A CALIPER
AND CALIPER SPRING"
DESCRIPTION
The present invention relates to the field of braking systems for vehicles, and in particular the present invention relates to a disc brake caliper.
Very briefly, a disc brake consists of a disc, which is integral in rotation with the vehicle wheel, and a fixed caliper, in which a pair of pads carrying friction material are housed. The caliper also holds pistons which, by being hydraulically operated, push the pads against the disc surfaces, thus obtaining the braking by virtue of the action of the friction material.
The number and relative position of the pistons considerably influence the action of the disc brake; for example, important factors depend on them, such as caliper rigidity, from which a more or less prompt braking derives, friction material consumption evenness, and the like.
It is the object of the present invention to obtain a disc brake caliper capable of obtaining a particularly prompt and immediate braking.
Such an object is achieved by a caliper made according to claim 1. The claims dependent thereon describe variant embodiments. The features and advantages of the caliper according to the present invention will be apparent from the following description, given by way of non-limiting example, according to the accompanying drawings, in which:
- figure 1 shows a disc brake caliper according to an embodiment of the present invention;
- figure 2 shows a plan view of the caliper in figure
1;
- figure 3 shows a pad engaged with pistons of the caliper in figure 1;
- figure 4 shows a rear front view of the pad with pistons in figure 3;
- figure 5 shows a diagram highlighting the position of the center of gravity of the bridge portions and of the center of gravity of the piston areas in the caliper in figure 1;
- figure 6 shows the pressure distribution in a pad of a caliper according to the present invention, while figure 7 shows the pressure distribution in a pad of a caliper according to the prior art;
- figure 8 shows a lost core for making a caliper body of a caliper according to a further aspect of the present invention;
- figures 9 and 10 show semi-finished caliper bodies according to the present invention;
figure 11 shows pads coupled with return springs according to another aspect of the present invention;
- figure 12 shows a section of the pads with return springs in figure 11; and
- figures 13 and 14 show the return spring in figure
11.
With reference to the accompanying figures, reference numeral 1 indicates a disc brake caliper according to an embodiment of the present invention, intended to be arranged straddling a disc rotatable about a rotation axis Z.
Hereinafter, the expressions "axial direction" or "axially" will be used with reference to a direction parallel to the rotation axis Z of the disc, the expressions "radial direction" or "radially" will be used with reference to a radial direction with respect to said rotation axis and the expressions "circumferential direction" or "circumferentially" will be used with reference to a circumferential pattern about said rotation axis.
The caliper 1 comprises a caliper body 2, usually monolithic, preferably made by gravity casting.
The caliper body 2 consists of:
- a first side portion 2a and a second side portion 2b, which when the caliper is coupled to the disc have prevailing extension along the circumferential direction and border the surfaces of the disc;
- a front bridge portion 4a and a rear bridge portion 4b, placed at circumferential ends of the side portions
2a, 2b and straddling the disc;
- an upper axial portion 6a, placed straddling the disc, which joins the first side portion 2a and the second side portion 2b, has predominantly axial extension and is placed in an intermediate position between the front portion 4a and the rear portion 4b; and
- an upper circumferential portion 6b, which joins the front portion 4a and the rear portion 4b, has predominantly circumferential extension and is placed in an intermediate position between the first side portion
4a and the second side portion 4b.
The upper portions 6a, 6b intersect in a central portion 8, making a cross body consisting of axial arms
6a', 6a'' and circumferential arms 6b', 6b''.
Preferably, each axial arm 6a', 6a'' is tapered from the respective side portion 2a, 2b towards the central portion 8.
Piston chambers, accommodating therein a respective piston, which can be hydraulically actuated by means of pressurized oil fed by means of a hydraulic circuit, also prevalently obtained in the pump body, are obtained within the caliper body 2, and in particular in the side portions 2a, 2b thereof.
The caliper 1 further comprises a pair of pads 20, accommodated in the caliper body 2, supported in slidable manner so as to allow an axial sliding under the bias of said pistons.
Preferably, the caliper according to the present invention has eight pistons, operating in fours on a respective pad.
In particular, the pad 20 can be biased by an intermediate distal piston 22a, by an intermediate proximal piston 22b, by a front side piston 24a and by a rear side piston 24b.
Having identified the rotation axis Z of the disc, the pressure centers 24a', 24b' of the side pistons 24a, 24b lie on an imaginary circumference I centered on the rotation axis Z, at a predetermined angular distance A, while the pressure centers 22a' , 22b' of the intermediate pistons 22a, 22b are contained angularly in the angular region identified by said angular distance A.
Preferably, the pressure center 22a' of the first intermediate piston 22a lies on the bisector B which bisects the angular region identified by the angular distance A, at a first radial distance Ra from the rotation axis Z; for example, the pressure center 22a' of the distal intermediate piston 22a lies on said imaginary circumference I .
Furthermore, according to the invention, the pressure center 22b' of the proximal intermediate piston 22b lies on said bisector B, at a second radial distance Rb from the rotation axis Z, smaller than the first radial distance Ra .
In other words, the pressure center 22a' of the distal intermediate piston 22a and the pressure center 22b' of the proximal intermediate piston 22b are distanced and radially aligned along a radial direction R.
With respect to the pad 20, the pressure centers 22a', 22b', 24a', 24b' fall within the contour of the pad, preferably at the vertexes of an imaginary rhombus for which the minor diagonal is arranged radially. Preferably, the entire sections of the pistons 22a, 22b, 24a, 24b fall within the contour of the pad.
Having positioned the pad 20 in the pump body 2, the central portion 8 of the caliper body 2 intersects the radial direction R of the pressure centers 22a' , 22b' of the intermediate pistons 22a, 22b, preferably symmetrically, while the front bridge portion 4a and the rear bridge portion 4b are arranged circumferentially externally to the pressure centers 24a', 24b' of the side pistons 24a, 24b (figure 5) .
Advantageously, the center of gravity of the front bridge portion 4a, of the rear bridge portion 4b and of the central portion 8 is close to the center of gravity of the pistons 22a, 22b, 24a, 24b, thus resulting in a particularly rigid caliper, i.e. capable of developing a particularly prompt and vigorous braking.
Furthermore, advantageously during braking, the load distribution on the pad is particularly uniform (figure 6) with respect to the distribution of a usual pad of the prior art (figure 7) . This allows, in the caliper according to the invention, to reduce the anomalous, non¬ uniform consumption of the friction material and to improve the braking action.
According to a further aspect of the invention, during the casting of the caliper body according to the present invention, a lost core 30 is used, consisting of a cross- shaped core body 31, intended to obtain in the caliper body the space for housing the pads, from which the intermediate chamber cores 32a, 32b for making the chambers for the intermediate pistons 22a, 22b, and the side chamber cores 34a, 34b for making the chambers for the side pistons 34a, 34b axially protrude, on one side and on the other (figure 8) .
Preferably, the core 30 includes at least one circuit branch core which connects at least two piston chamber cores for making a circuit branch of the pressurized oil feeding circuit.
In particular, the core 30 has a proximal branch core 36 which protrudes from the proximal piston chamber core 32b and extends towards the distal piston chamber core 32a and a distal branch core 38 which protrudes from the distal piston chamber core 32a and extends towards the proximal piston chamber core 32b.
The proximal branch core 36 and the distal branch core
38 terminate with a respective free end 40, 42 which are very close to each other but separated. In other words, the proximal branch core 36 and the distal branch core 38 are separate from each other, also on the tip.
From the casting, after having eliminated the core 30, a semi-finished caliper body 50 is obtained, which is provided, in the side portion 2a, 2b, with the proximal piston chamber 52 and with the distal piston chamber 54 for housing the proximal intermediate piston 22b and the distal intermediate piston 22a, respectively, and with the front piston chamber 56 and with the rear piston chamber 58 for housing the front side piston 24a and the rear side piston 24b, respectively (figure 9) .
Furthermore, a proximal circuit branch 60 extends from the proximal piston chamber 52 towards the distal piston chamber 54 and a distal circuit branch 62 extends from the distal piston chamber 54 towards the proximal piston chamber 52.
In the semi-finished caliper 50, the proximal circuit branch 60 does not intercept the distal circuit branch 62, i.e. said branches 60, 62 are separate, as the respective branch cores 36, 38 were.
The semi-finished caliper 50 is subjected to processing by material removal, in particular a first hole is made to remove the material from the caliper body which separates the proximal circuit branch 60 from the distal circuit branch 62, thus putting them into communication (figure 10) .
Preferably, a second hole is further made to put the front piston chamber 56 into communication with the rear piston chamber 58, preferably at the same time as the first hole is made, along the same perforation axis F.
A semi-finished perforated caliper body 70 is thus obtained, in which the proximal piston chamber 52 is connected to the distal piston chamber 54 by means of the proximal branch 60 and the distal branch 62 obtained in the pump body 2, while the front piston chamber 56 is connected to the rear piston chamber 58 by means of a connection pipe 72 which also intercepts the proximal branch 60 and/or the distal branch 62. The connection branch 72 leads onto the front portion 4a with a front gap 74 and onto the rear portion 4b with a rear gap 76, intended to be plugged. The front gap 74 on one side of the caliper body 2 is instead intended to be connected to the front gap 74' of the other side of the caliper body through a bridge pipe 78, generally constituted by a tube, applied externally to the pump body 2 ( figure 1 ) .
According to another aspect of the present invention, the pads 20 are permanently biased towards the respective rest position by at least one spring 80, preferably by a pair of identical springs 80, preferably obtained by bending an appropriately shaped steel sheet.
A pad 20 comprises a supporting plate 21, having an outer surface 23 intended for the action of the pistons, and an opposite inner surface 25, and friction material 27 carried by the supporting plate 21 on the inner surface 25.
The supporting plate 21 has a proximal edge 27, at which eyelets 29 are obtained for supporting the pad 20 in sliding manner, sides 31, 33, and a distal edge 35, to which the spring 80 is applied.
The spring 80, which operates on both pads 20 at the same time, comprises a central strip 82 which extends axially, when the spring 80 is applied to the caliper body 2, between the pads 20, straddling the disc.
The central strip 82 is folded at the ends so as to form, for each end, a curl 84, which then extends on an abutment plane 86, intended to come into contact with the distal edge 35 of the pads 20.
The spring 80 further comprises a coupling portion 88 arranged centrally, comprising two pairs 90 of wings 92; the two pairs 90 are arranged side by side to the strip 82, in a stretch thereof which forms a recess 94.
Innovatively, the caliper according to the present invention is particularly rigid, and thus allows to apply prompt, vigorous braking; such a behavior is conferred, moreover, by the arrangement of the pistons, which determine a center of gravity very close to the center of gravity of the bridge portion sections.
Furthermore, the consumption of friction material, as well as the pressure distribution on the braking band, is advantageously even.
According to a further advantageous aspect, the manufacturing process of the brake caliper is very reliable, and in particular the making of a hole on the semi-finished caliper body for forming the hydraulic connection between the piston chambers prevents the core from having weakened portions which could be easily subject to breakage during casting. It is apparent that a person skilled in the art may made changes to the caliper described above, all of which are contained within the scope of protection as defined in the following claims, in order to satisfy contingent needs .

Claims

1. Caliper (1) for disc brake applicable to a disc rotatable about a rotation axis (Z), comprising:
- a caliper body (2) consisting of a first side portion (2a) and a second side portion (2b) , having prevailing extension in a circumferential direction, and a front bridge portion (4a) and a rear bridge portion (4b), circumferentially spaced and placed at circumferential ends of the side portions (2a, 2b) to join them;
- a pair of pads (20) having friction material (27) supported by the caliper body (2) to be arranged on one side and the other side of the disc, in an axially slidable manner;
- in each side portion (2a, 2b), a distal piston (22a) and a proximal piston (22b) , supported by the caliper body
(2) for influencing the pad (20), having pressure centers (22a', 22b') radially spaced and aligned, i.e. placed on a same radial direction (R) .
2 . Caliper according to claim 1, comprising, in each side portion (2a, 2b), a front side piston (24a) and a rear side piston (24b), having pressure centers (24a', 24b') lying on an imaginary circumference (I) centered on the rotation axis (Z), at a defined angular distance (A), and the pressure centers (22a', 22b') of the proximal and distal pistons (22a, 22b) are angularly contained in an angular region identified by said angular distance (A) .
3 . Caliper according to claim 2, wherein the pressure center (22a') of the distal piston (22a) and the pressure center (22b') of the proximal piston (22b) lie on the bisector (B) bisecting the angular region identified by the angular distance (A) .
4. Caliper according to claim 2 or 3, wherein the pressure centers (22a' , 22b' , 24a' , 24b' ) fall within the peripheral contour of the pad (20) .
5. Caliper according to claim 2, 3 or 4, wherein the pressure centers (22a' , 22b' , 24a' , 24b' ) fall at the vertexes of an imaginary rhombus for which the minor diagonal is disposed radially.
6. Caliper according to any of claims 2 to 5, wherein the entire sections of the pistons (22a, 22b, 24a, 24b) fall within the peripheral contour of the pad.
7. Caliper according to any of the preceding claims, wherein the caliper body (2) comprises:
- an upper axial portion (6a) that joins the first side portion (2a) and the second side portion (2b) , has predominantly axial extension and is placed in an intermediate position between the front portion (4a) and the rear portion (4b) ; and
- an upper circumferential portion (6b), which joins the front portion (4a) and the rear (4b), has predominantly circumferential extension and is placed in an intermediate position between the first side portion (4a) and the second side portion (4b) ;
wherein the upper portions (6a, 6b) intersect in a central portion (8), realizing a cross body consisting of axial arms (6a', 6a'') and circumferential arms (6b', 6b'') .
8. Caliper according to claim 7, wherein each axial arm (6a', 6a'') has a shape tapered from the respective side portion (2a, 2b) towards the central portion (8) .
9. Caliper according to claim 7 or 8, wherein the central portion (8) of the caliper body (2) symmetrically intersects the radial direction (R) of the pressure centers (22a', 22b') of the distal (22a) and proximal (22b) pistons.
10. Caliper according to any of claims 7 to 9, wherein the front bridge portion (4a) and the rear bridge portion (4b) are placed circumferentially externally to the pressure centers (24a', 24b') of the side pistons (24a, 24b) .
11. Method of manufacturing of a caliper (1) for disc brake, comprising
- the step of realizing a semi-finished caliper body (50) by means of gravity casting, wherein said caliper body (2) is provided with separate piston chambers;
- the step of making a hole to put at two of said piston chambers in communication.
12. Lost core (30) for the realization by means of gravity casting of a caliper body (2), comprising:
- a core body (31) intended to obtain the space in the caliper body for housing the pads;
intermediate chamber cores (32a, 32b), projecting axially from the core body (31) from one side and the other, for the realization on each side of a proximal piston chamber (54) and a distal piston chamber (56) ;
- a proximal branch core (36) that protrudes from the proximal piston chamber core (32b) and extends towards the distal piston chamber core (32a) and a distal branch core (38) that protrudes from the distal piston chamber core (32a) and extends towards the proximal piston chamber core (32b) ;
wherein the proximal branch core (36) and the distal branch core (38) terminate with a respective free end (40,42) separated from each other.
13. Spring (80) applicable to the caliper body (2) of a caliper (1) for disc brake, suitable to permanently influence pads (20) of said caliper towards a rest position .
PCT/IB2016/056864 2015-11-17 2016-11-15 Disc brake caliper, method for manufacturing a caliper and caliper spring WO2017085619A1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
JP2018524239A JP6875396B2 (en) 2015-11-17 2016-11-15 Disc brake calipers, caliper manufacturing methods, and caliper springs
US15/776,829 US11384804B2 (en) 2015-11-17 2016-11-15 Disc brake caliper, method for manufacturing a caliper and caliper spring
CN201680066921.5A CN108291595B (en) 2015-11-17 2016-11-15 Disc brake caliper, method for manufacturing caliper and caliper spring
DE112016005268.5T DE112016005268T5 (en) 2015-11-17 2016-11-15 Disc brake caliper, method for making a saddle and saddle spring
US17/806,956 US11994181B2 (en) 2015-11-17 2022-06-15 Disc brake caliper, method for manufacturing a caliper and caliper spring

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
ITUB2015A005653A ITUB20155653A1 (en) 2015-11-17 2015-11-17 CALIPER FOR DISC BRAKE, METHOD OF MANUFACTURING OF A CALIPER AND SPRING FOR CALIPER
IT102015000073426 2015-11-17

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US15/776,829 A-371-Of-International US11384804B2 (en) 2015-11-17 2016-11-15 Disc brake caliper, method for manufacturing a caliper and caliper spring
US17/806,956 Division US11994181B2 (en) 2015-11-17 2022-06-15 Disc brake caliper, method for manufacturing a caliper and caliper spring

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JP (1) JP6875396B2 (en)
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US20180328427A1 (en) 2018-11-15
DE112016005268T5 (en) 2018-08-02
CN108291595A (en) 2018-07-17
JP6875396B2 (en) 2021-05-26
US20220356921A1 (en) 2022-11-10
CN108291595B (en) 2020-03-20
US11384804B2 (en) 2022-07-12
ITUB20155653A1 (en) 2017-05-17
US11994181B2 (en) 2024-05-28
JP2019501339A (en) 2019-01-17

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