Disc brake

Abstract

A disc brake having an actuation mechanism, a wear adjustment mechanism that includes a manual rewind apparatus having a manual adjuster shaft; a brake caliper having a housing cavity and an inboard wall, an inboard support interface, and an outboard support interface. The inboard support interface is located within the housing cavity, outboard of the inboard wall.

Claims

1. A disc brake comprising: an actuation mechanism that includes: a piston for applying an actuating force to a brake pad, an operating shaft for applying actuating force to the piston, a roller configured to pivotably support the operating shaft, the roller having at least one bearing surface configured to form a pivoting interface with the operating shaft, and a wear adjustment mechanism for adjusting extension of the piston to account for wear of the brake pad, the wear adjustment mechanism including a manual rewind apparatus having a manual adjuster shaft; a brake caliper having a housing cavity for at least partly accommodating the actuation mechanism, the housing cavity being partially defined by an inboard wall of the brake caliper; and an inboard support interface that supports the manual adjuster shaft and an outboard support interface that supports the manual adjuster shaft, wherein the inboard support interface is located within the housing cavity, outboard of the inboard wall, and wherein the manual adjuster shaft is not supported by the inboard wall, wherein the roller defines the inboard support interface.

2. The disc brake of claim 1 further comprising a seal in contact with the brake caliper and the manual adjuster shaft, wherein the seal is located at an interior face of the housing cavity.

3. The disc brake of claim 1 wherein the roller defines a first bearing surface and a second bearing surface, and wherein the inboard support interface is axially located between the first and second bearing surfaces of the roller.

4. The disc brake of claim 1 wherein the roller is secured to the brake caliper.

5. The disc brake of claim 4 wherein the brake caliper defines an aperture configured to receive an end of the roller, and wherein the roller is held in the aperture in an interference fit.

6. The disc brake of claim 4 wherein the roller is keyed to the brake caliper.

7. The disc brake of claim 4 further comprising a seal located between the roller and the brake caliper.

8. The disc brake of claim 1 wherein the inboard support interface further comprises a bore configured to receive the manual adjuster shaft.

9. The disc brake of claim 8 wherein the bore has a constant diameter.

10. The disc brake of claim 8 wherein the bore has a closed profile.

11. The disc brake of claim 10 wherein the bore has a substantially circular profile.

12. The disc brake of claim 8 wherein the bore has an open-sided recess.

13. The disc brake of claim 12 wherein the open-sided recess is a curved recess.

14. The disc brake of claim 12 wherein the bore has a substantially semi-circular profile.

15. The disc brake of claim 1 wherein the manual rewind apparatus is located within the piston.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is an isometric view of an example disc brake;

(2) FIG. 2 is a plan view of the brake of FIG. 1, with a brake rotor in situ;

(3) FIG. 3 is an isometric view of the brake of FIG. 1 from an inboard direction, with the inboard and outboard brake pads omitted for clarity;

(4) FIG. 4 is an isometric view of the brake of FIG. 1 from an inboard direction, with the outboard brake pad and a caliper housing of the brake omitted for clarity;

(5) FIG. 5 is an isometric view showing an actuator arrangement of the brake of FIG. 1;

(6) FIG. 6 is an isometric cross-sectional view through an inboard-outboard horizontal plane 6-6 of the actuator arrangement of the brake of FIG. 1;

(7) FIG. 7 is a plan view of the isometric cross-sectional view of FIG. 6;

(8) FIG. 8 is an isometric view of a brake according to an embodiment of the present invention;

(9) FIG. 9 is a further isometric view of the brake of FIG. 8;

(10) FIG. 10 is an isometric view of the brake of FIG. 8 with the brake caliper omitted for clarity;

(11) FIG. 11 is a cross-sectional view through the brake of FIG. 8 on a horizontal plane 11-11, as shown on FIG. 10, aligned with the axis of the manual adjuster shaft;

(12) FIG. 12 is an isometric view of a roller of the brake of FIG. 8; and

(13) FIG. 13 is an isometric view of an alternative roller of the brake of FIG. 8.

DETAILED DESCRIPTION

(14) As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

(15) Actuation

(16) FIGS. 1, 2 and 3 illustrate an example of a disc brake 2 of a type that may be adapted to incorporate the present invention. The Figures and associated description below are included to explain the function of the actuation mechanism. The disc brake incorporates an actuating mechanism comprising a single piston suitable for a commercial vehicle. This type of brake is particularly, but not exclusively, suitable for lighter duty heavy vehicles, for example smaller trucks, or a trailer of a tractor-trailer combination.

(17) Various orientations of the disc brake are described. In particular the directions inboard and outboard refer to the typical orientation of the disc brake when fitted to a vehicle. In this orientation, the brake pad closest to the center of the vehicle is the brake pad directly actuated by an actuation mechanism, and being the inboard brake pad, and the outboard brake pad being the brake pad mounted to a bridge or frame portion of the caliper. Thus, inboard can be equated with an actuating side of the disc brake, and outboard with a reaction side. The terms radial, circumferential, tangential and chordal describe orientations with respect to the brake rotor. The terms vertical and horizontal describe orientations with the disc brake mounted uppermost on an axle, though it will be appreciated that in use such a disc brake may adopt any axle orientation depending upon packaging requirements of the vehicle.

(18) The disc brake 2 comprises a caliper 3 having a housing 6 to accommodate the actuation mechanism, and which is slidably mounted on a carrier 4 for movement in an inboard-outboard direction.

(19) As can be seen from the view in FIG. 4 with the housing 6 omitted, the caliper 3 can slide on the carrier 4, by way of first and second guide pins 3a, 3b. In this embodiment, the first guide pin 3a is longer than the second guide pin 3b.

(20) With reference to the cut-away view of FIG. 5 in particular, the inboard actuation mechanism comprises a single brake piston 15, slidable in the direction of arrow 14 (i.e., inboard-outboard) relative to the rotor 10 (not shown in FIG. 5, for clarity).

(21) In order to urge the piston assembly in the direction of arrow 14, the operating shaft 21 is pivoted about rollers 23 which are located along a transverse axis 28. In this embodiment, there are two rollers 23, which are spaced from one another laterally. Each roller 23 is located on a single bearing surface (not shown), each bearing surface being curved to accept the roller 23. Convex surfaces 21a of the operating shaft 21 are located opposite the roller 23. The operating shaft has an axis 22, being the radial center of the arc defined by the convex surfaces 21a, which is parallel and offset from the transverse axis 28. The convex surfaces 21a locate in a semi-circular recess of a yoke 20. A surface of the yoke 20 opposite the recess is in contact with an inboard end face of the piston 15. The operating shaft 21 further comprises a lever 24 having a pocket 25 adapted to receive an output push rod (not shown) of a brake actuator (e.g., an air chamber). The lever 24 is, in this embodiment, shaped as an inverted U (see FIG. 4 in particular) and the line of action of the brake actuator (from pocket 25) is substantially over the line of action of the piston 15.

(22) In other embodiments, another form of cam surface instead of the convex surfaces 21a of the operating shaft 21 may be employed (e.g., a plain bearing) and/or the arrangement may be reversed with the rollers 23 being in contact with the yoke 20, and the convex surfaces 21a being located in the recess of the caliper housing 6.

(23) Application of a force in the direction of arrow 26 (FIG. 5) causes pivoting movement of the operating shaft 21 about the rollers 23, and the convex surfaces 21a bear on the yoke 20. The offset axes 28 and 22 cause the yoke 20 to move in the direction of the piston 15, contacting the piston 15 and causing the piston 15 to urge the friction material of an inboard brake pad 11a directly against the rotor 10. A reaction force from the operating shaft 21 is transmitted to the bearing surface of the caliper 3 via the rollers 23 and is then transmitted to an outboard brake pad 11b via the bridge 5, with the friction material of the outboard pad being urged against the rotor 10, such that the brake pads clamp the rotor and effect braking through a frictional brake force.

(24) The actuation mechanism further incorporates a wear adjustment mechanism of a suitable type to maintain an appropriate running clearance between the brake pads 11a, 11b and the rotor 10 as the friction material wears.

(25) Once the friction material has worn to its design limit, it is necessary for the brake pads 11a and 11b to be replaced. In order to accommodate the extra depths of unworn new pads as compared to worn old pads, it is necessary for the piston 15 to be rewound back to its retracted position.

(26) To this end, a manual rewind apparatus incorporating an elongate manual adjuster shaft 51 is provided (see FIGS. 6 and 7). A hex head 53 or other suitable interface is provided at the outer (user accessible) longitudinal end of the manual adjuster shaft 51. The hex head 53 has a cover 54, which is located on the hex head 53. In this embodiment, the cover 54 is a rubber cap. The cover 54 can be removed by a user when access to the hex head 53 is required. A spanner, wrench or other suitable tool may be attached to the hex head 53 to affect the rewinding operation.

(27) Located outboard of the cover 54 is a sealing arrangement in the form of a collar 56. The collar 56 is generally annular and is configured to locate on the manual adjuster shaft 51 adjacent the cover 54. The manual adjuster shaft 51 is configured such that it can freely rotate within the collar 56 e.g., by use of one or more of suitable lubrication, coatings such as PTFE, or by the collar incorporating a lip seal that minimizes the contact areas between the collar and shaft. In this embodiment, the collar 56 includes a circumferential recess 56a facing inboard. Within the recess 56a are first and second sealing members 56b and 56c. The base of the sealing member engages with the collar 56 to substantially seal lubricant within the housing 6 of the brake and help prevent foreign material from contaminating the housing 6 of the brake. In this embodiment, the second sealing member 56c is a spring energized sealing ring that engages a slot in an internal surface of the recess 56a of the collar 56, to further help seal lubricant within the housing 6 of the brake and help prevent foreign material from contaminating the housing 6 of the brake.

(28) When the brake is assembled, the manual adjuster shaft 51, collar 56, and cover 54 are located within a through bore, extending from an inboard surface of the caliper 3. The cover 54 is retained within the housing with a retaining member 54b, which locates within a circumferential slot 54a on the external surface of the cover 54, between the cover 54 and the bore of the caliper 3. In this embodiment, the retaining member 54b is an annular retainer with an inner surface that engages the outer surface of the cover 54, and circumferential protrusion projecting radially inwardly and engaging the slot 54a. Preferably, the retaining member 54b is metal.

(29) The manual adjuster shaft 51 is mounted concentrically and radially inwardly with respect to the components of the adjustment mechanism 30. At the outboard end longitudinally opposite the hex head 53, a piston engaging end piece 55 is mounted on the manual adjuster shaft 51. In this embodiment, the end piece 55 is circular in profile, with two diametrically opposed projections 57. The end piece 55 and the projections are dimensioned such that the projections locate within channels of the inner piston 15b. The channels allow the inner piston 15b to advance during a braking operation, whilst the manual adjuster shaft 51 is axially fixed.

(30) In use during manual adjustment, therefore, a user rotates the hex head 53 to rotate the manual adjuster shaft 51. Due to the engagement between the projections 57 of the end piece 55 and the channels of the inner piston 15b, the inner piston 15b is caused to rotate, rewinding the piston 15 back to its original retracted position.

(31) Brake Caliper and Wear Adjustment Mechanism

(32) Referring now to FIGS. 8 and 9, a disc brake according to an embodiment of the invention is indicated generally at 102. The disc brake 102 is similar to that described above, having an actuation mechanism 104 (see FIG. 10) housed at least partially in a brake caliper housing cavity 106. The brake caliper 103 has an inboard side 103c, an outboard side 103d, and opposing ends 103a, 103b, as indicated in FIG. 9. The housing cavity 106 is defined at the inboard side 103c of the caliper by an inboard wall 115. The actuation mechanism 104 includes a wear adjustment mechanism 108 having a manual rewind apparatus with a manual adjuster shaft 110.

(33) Rather than a through bore 118 of the caliper acting as a plain bearing to rotationally support the manual adjuster shaft, as in the example disc brake described above, the manual adjuster shaft 110 of this embodiment is supported at an inboard support interface located within the housing cavity 106 of the caliper 103, with the inboard support interface providing a surface acting as a plain bearing. The manual adjuster shaft 110 is additionally supported by an outboard support interface. The outboard support interface of this embodiment is an end piece 113 similar to that described in the above example and which is itself supported within the piston. In alternative embodiments, the outboard support interface is provided by other suitable arrangements.

(34) As the manual adjuster shaft 110 is supported by the inboard support interface within the housing cavity 106, sealing between the manual adjuster shaft 110 and the caliper 103 can take place at an interior of the caliper, rather than at an exterior of the caliper as in the example disc brake described above. That is, sealing takes place at an internal face of the caliper 103, i.e., a face that is not exposed to the exterior environment. There is no requirement for sealing at, for example, an exterior face of the inboard wall 115 adjacent to a bore of the caliper. The manual adjuster shaft 110 does not therefore need to extend beyond the outside of the caliper 103 to allow sealing to take place and extends beyond the outside of the caliper 103 less than the shaft of the example disc brake of FIGS. 1 to 7. Space is saved by the shorter manual adjuster shaft 110, giving more room for maintenance of, for example, the pneumatic actuator, or to allow the pneumatic actuator to be fitted at a wider range of orientations with respect to the housing without obscuring or impinging on the end of the shaft.

(35) A sealing arrangement 114, substantially the same as the sealing arrangement described above is provided, as shown in FIG. 11. However, in this embodiment, the sealing arrangement 114 forms a seal with an internal face 120 of the caliper 103. In this embodiment, the sealing arrangement 114 is located within the inboard wall 115. The manual adjuster shaft 110 is rotatable within the sealing arrangement 114. Advantageously, the actuation mechanism 104 can be installed in the caliper 103 from a single side, i.e., the outboard side, of the disc brake 102. Further, since the through-bore 118 is not used as a bearing, a greater clearance between it and the manual adjuster shaft 110 can be provided. As a result, any corrosion inboard of the seal is unlikely to result in seizing of the shaft.

(36) A cover, in this embodiment in the form of a rubber cap 116 protects the exposed end of the manual adjuster shaft 110. The cap 116 can be fitted to the manual adjuster shaft 110 prior to installation, allowing installation of the adjustment mechanism from the outboard side.

(37) In contrast to the above-described example, in this embodiment a single roller 126 (see FIG. 10) pivotably supports the operating shaft 124. The roller 126 provides a bearing surface or surfaces 122 where the operating shaft 124 is pivotably supported. In this embodiment, the roller provides two bearing surfaces 122 where the operating shaft 124 is pivotably supported.

(38) In this embodiment, the inboard support interface is provided by the roller 126. The location of the roller 126 within the housing cavity 106 enables the roller 126 to provide a suitable location for the inboard support interface within the housing cavity 106. Advantageously, the roller 126 providing the inboard support interface removes the need for an additional supporting component.

(39) The inboard support interface is in this embodiment located between the two bearing surfaces 122 along a longitudinal axis x of the roller 126. In this embodiment, the inboard support interface is provided in the form of a bore. As shown in FIG. 12, in this embodiment, the bore is an open-sided, curved recess 112, with a substantially semi-circular profile. In an alternative embodiment, the recess is deeper, or may be shallower. The open-sided recess 112 improves ease of installation of the manual adjuster shaft 110.

(40) A roller 226 of an alternative embodiment is shown in FIG. 13. The inboard support interface of the roller 226 is a closed bore 212, with a substantially circular profile. The closed bore 212 locates the manual adjuster shaft 110, improving ease of installation of the manual adjuster shaft 110 through the bore 118.

(41) The roller 226 provides a bearing surface or surfaces 222 where the operating shaft is pivotably supported. In this embodiment, the roller provides two bearing surfaces 222 where the operating shaft is pivotably supported.

(42) The roller 126 of this embodiment is secured to the caliper 103, in order to prevent unwanted rotation of the roller 126, and so to prevent the roller 126 affecting rotation of the manual adjuster shaft 110. Opposing ends 103a, 103b of the caliper 103 each define an aperture 128a, 128b configured to receive respective ends 126a, 126b of the roller 126 in an interference fit. In an alternative embodiment, rather than an interference fit, the roller ends are keyed to the caliper to prevent rotation. In a further alternative embodiment, the roller ends and the caliper apertures have a corresponding non-circular shape in order to prevent rotation of the roller. Seals 130a, 130b are provided at each of the roller ends to prevent the ingress of contaminants.

(43) In production, the caliper 103 is cast. The apertures 128a, 128b are machined into the caliper 103, for example by milling from one end 103a, 103b of the caliper 103. A curved support surface (not shown) for the roller 126, 226 is milled from the caliper 103. The milling tool is supported at an end of the caliper 103. Where the inboard support interface is provided by the roller, milling of the entire roller support surface of the caliper 103 can advantageously take place from a single end of the caliper 103. This is because in such an embodiment, there is no need for a protruding abutment to control axial movement of a roller that would otherwise prevent milling from a single end. A block of excess material is cast along the roller support surface in the intended path of the milling tool when the caliper casting is produced. This excess is then milled away during machining. Advantageously, it has been found that such an arrangement reduces transverse loads on the milling tool during machining when it is cantilevered to this extent, in comparison to milling away a few millimeters of material with a side portion of the tool only.

(44) The roller 126, 226 is machined, then is case-hardened after machining.

(45) On installation of the actuation mechanism 104 and the roller 126, 226 within the disc brake 102, the sealing arrangement 114 is first assembled and fitted to the caliper 103. The roller 126, 226 is inserted from one of the ends 103a, 103b of the caliper 103. The manual adjuster shaft 110 and the remainder of the manual rewind apparatus are then installed.

(46) Although the above embodiments are described in relation to a single piston disc brake, the invention could be used with a twin piston disc brake, or alternative suitable types of brake. For example, the invention could be fitted to a twin piston disc brake with a central manual adjuster shaft. Alternatively, the roller could extend further to one side or another to support an offset manual adjuster shaft. In an alternative embodiment, the inboard support interface is not provided by a single extended roller. For example, in one embodiment, the inboard support interface is provided by a support component provided with a bearing surface and fitted to a pocket milled into the caliper, for example between first and second rollers.

(47) While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.