Disk brake

Abstract

The present invention relates to a disc brake having a brake actuation mechanism, the components of which are mounted in functional cooperation in the brake caliper by means of a rod, in which a brake lever is configured so that the clamping force from the actuator is substantially directed radially to the axis of the brake disc upon brake actuation, and in which the brake lever is further configured to be mounted at different angular positions around the axis of the rod.

Claims

1. A disc brake comprising a brake caliper, which overlaps at least one brake disc, and a brake actuation mechanism having an amplification mechanism comprising a brake lever being rotatable around a pivot bearing for introducing a clamping force from an actuator, the brake lever having an arm extending between its actuator connection means (6) and its transmission means, a thrust element in connection with said transmission means for transmitting the amplified clamping force onto the brake disc, in which the brake lever is configured and arranged in relation to the thrust element so that the clamping force from the actuator is substantially directed perpendicularly to the axis of the brake disc upon brake actuation, and in which the amplification mechanism and the thrust element are mounted in functional cooperation in the brake caliper by means of a rod, which rod is supported in the housing of the brake caliper so as to be not displaceable in axial direction, characterized in that the brake lever is configured to be mounted at different angular positions around the axis of the rod.

2. The disc brake of claim 1, in which the transmission means of the brake lever is configured to be decoupled from the thrust element so as to be rotatable with respect to the thrust element.

3. The disc brake of claim 1, in which the transmission means of the brake lever are configured to allow different angular positions in relation to the thrust element.

4. The disc brake of claim 1, in which the brake lever comprises a recess between its actuator connection means and its transmission means, which recess is traversed by the axis of said pivot bearing.

5. The disc brake of claim 4, in which the rod extends into said recess.

6. The disc brake of claim 5, further comprising a mounting brace having means for receiving said rod, said mounting brace traversing said recess.

7. The disc brake of claim 6, in which the means of the mounting brace are configured to allow a force-fit and/or form-fit with the rod.

8. The disc brake of claim 6, in which the mounting brace is releasably fixed in the brake caliper.

9. The disc brake of claim 8, in which the brake caliper comprises a recess for receiving one end of said mounting brace and opposite to said recess an opening for introducing the mounting brace.

10. The disc brake of claim 1, in which the brake caliper comprises an extended section for receiving the brake lever.

11. The disc brake of claim 10, in which the actuator connecting means cooperates with a transmission rod, the transmission rod being activated by a force-redirecting device transmitting an input force from an actuator.

12. The disc brake of claim 11, in which the force-redirecting device is supported in a swiveling manner inside a housing, the housing being attached to the extended section.

13. The disc brake of claim 12, in which angular connecting means are arranged between the extended section and the housing, which angular connecting means are configured to allow different angular positions of the housing in relation to the extended section.

14. The disc brake of claim 13, in which the angular connecting means comprise a flange ring, which is configured to enter into releasable pin connection with the housing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further advantages and features of the present invention do become apparent with respect to the embodiments shown in the attached drawings, in which

(2) FIG. 1 is a perspective, partially cut-out view of a brake caliper containing a brake actuation mechanism with a brake lever according to the invention;

(3) FIG. 2 is a perspective view of the brake caliper of FIG. 1 with an attached housing of a force-redirecting device;

(4) FIG. 3 is a further perspective, partially cut-out view of a brake caliper containing a brake actuation mechanism with a brake lever according to the invention showing a different angular position of the brake lever

(5) FIG. 4 is a perspective view of the brake caliper of FIG. 3 with an attached housing of a force-redirecting device and an actuator housing attached thereto;

(6) FIG. 5 is a perspective view of the brake actuation mechanism;

(7) FIG. 6 is a partial horizontal cross-sectional view of the brake actuation mechanism; and

(8) FIG. 7 is a cross-sectional view of the housing of the force-redirecting device.

DETAILED DESCRIPTION OF THE INVENTION

(9) FIG. 1 shows the disc brake according to the invention in perspective view with its substantial components, which are shown in their assembled state.

(10) The disc brake comprises a brake caliper 1 which is slideably guided on a carrier 2. The brake caliper 1 receives a brake actuation mechanism 3 preferably, but not exclusively, of that kind as it is described in WO 2011/113554 A2.

(11) The brake actuation mechanism 3 comprises a brake lever 4, which is arranged in an extended, neck-like rear housing section 5 of the brake caliper 1 such that the clamping force exerted by a not-shown actuator onto actuator connection means 6 of the brake lever 4 will be directed substantially perpendicularly with respect to the axis of a brake disc (not shown). The lever 4 thus swivels around some degrees horizontally in relation to the brake disc axis.

(12) The brake actuation mechanism 3 according to the invention is designed in such a way that it on the one hand enables a simple assembly in the brake caliper 1 and on the other hand realizes a faultless functioning with at the same time compact configuration due to the specific arrangement of the single components in relation to each other.

(13) In FIG. 1 the brake lever 4 is orientated lengthwise to the axis of the brake disc.

(14) As can be shown in FIG. 2, a housing 32 of a force-redirecting device is attached to the neck-like housing section 5 of the caliper 1 by means of angular connecting means 33. The angular connecting means in fact are configured to allow that the housing 32 of the force-redirecting device can be rotated around the neck of the housing section 5.

(15) FIG. 3 shows a perspective view in which the brake lever 4 is angularly offset, i.e. turned in relation to the axis of the brake disc. Accordingly, in FIG. 4 the position of an actuator 34, i.e. an air cylinder, is defined by the angular orientation of the brake lever 4, which is arranged in the corresponding angularly arranged extended housing section 5 of the caliper 1 and the further relative angular position of the angular connecting means 33 with respect thereto.

(16) The principle of the angular connecting means 33 will be described in connection with FIG. 7 further down below.

(17) In both FIG. 5 and FIG. 6 the brake actuation mechanism 3 according to the invention is shown as such.

(18) It comprises an amplification mechanism 7, which introduces the clamping force originating from the actuator 34, e.g. via further force-redirecting means, into the brake actuation mechanism 3 and thereby enforcing it in correspondence with a gear ratio being determined by its construction. This is achieved in that the brake lever 4 is pivotably supported against two cylindrical rollers 8, which rollers 8 are eccentrically arranged with respect to transmission means 9 of the brake lever 4, with which transmission means 9 the brake lever 4 is rotatably supported against a force-transmitting block 10, the force-transmitting block 10 being in attachment with a thrust element 11.

(19) The thrust element 11 itself is linearly axially guided in the brake caliper 1 so as to advance towards the brake disc upon rotation of the brake lever 4.

(20) The cylindrical rollers 8 are rotatably received in corresponding needle bearing cages 12, which are arranged in two support cups 13, thereby forming an eccentric pivot bearing 14 for the brake lever 4.

(21) The support cups 13 are supported against a traverse housing section 15 of the brake caliper 1, as can best be seen in FIG. 6.

(22) The brake lever 4 is designed and configured in relation to the eccentric pivot bearing 14 such that upon a pivoting movement around the rollers 8 an eccentric displacement of the lever 4, namely of its transmission means 9 in relation to the rollers 8 takes place, which eccentric displacement or offset results in an enforcement of the force being introduced from the actuator into the lever 4.

(23) Opposite to the rollers 8 the brake lever 4 is supported against the force-transmitting block 10 via further needle bearing cups 16. The force-transmitting block 10 is formed as one piece, preferably as a casted or forged component, and comprises on the side of the lever two substantially half cup-type recesses which serve for receiving the needle bearing cups 16. At the side of the brake disc the force-transmitting block 10 is formed with planar surfaces in order to abut against the thrust element 11 or any component of an adjuster mechanism (not shown) being received in the interior of the thrust element 11.

(24) According to the invention, as can be seen in particular in FIGS. 1, 3, and 5, the brake lever 4 comprises a recess 17, which recess 17 is arranged and extends between the actuator connection means 6 and the transmission means 9. The recess 17 is basically formed as a closed loop, which allows for certain strength capabilities of the lever performance.

(25) The arrangement of the brake lever 4 inside the housing of the caliper 1, in particular inside its extended section 5 is such that the axis of the pivot bearing 14 traverses the recess 17, as well as the traverse housing section 15 of the brake caliper 1 supporting said pivot bearing 14 traverses said recess 17.

(26) This allows for a very compact design in particular for disc brakes of the radial type-actuation.

(27) The brake lever 4 being made preferably as one-piece itself is split into a part of a lever arm 18, which extends with a small width to the rear of the brake caliper 1 and which basically comprises the recess 17, and into the front, brake-disc side transmission means 9, which is substantially greater in lateral width than the lever arm part 18, as can best be seen in FIG. 6.

(28) To enable the desired compact design, the brake lever 4 of such design shall be introduced into the interior of the brake caliper 1 from the brake disc side. For that purpose, the traverse housing section 15 comprises an opening 19 through which the lever arm 18 can be inserted to swivel freely within said opening 19, while the wider transmission means 9 stay in front of the traverse housing section 15.

(29) The brake actuation mechanism 3 comprises a centrally arranged rod 20.

(30) As already explained above, according to the invention, in particular the rod 20 serves to keep the amplification mechanism 7 and/or a not-shown adjustment device and/or the thrust element 11 and/or a not-shown return device together as a self-supporting assembly unit, either all components as one single module or several components as separate sub-modules, each as pre-mounted self-supporting assembly units, for assembly purposes, while the central rod 2 0 is aligned coaxially to the axis of the brake disc.

(31) As it becomes apparent from the following the rod 20 serves as mounting means for the single assembly groups of the brake actuation mechanism 3 on the one hand and as fixation means for the brake actuation mechanism 3 in the housing of the brake caliper 1 on the other.

(32) As can be best seen in FIG. 6, for the passage of the central rod 20 the transmission means 9 of the lever 4 comprises an opening 21 and the force-transmitting block 10 comprises an opening 22, whereas the rollers 8 and the needle bearing cages 12 with the bearing cups 13 are arranged to both sides of the rod 20 at corresponding positions, respectively.

(33) Furthermore, the rod 20 freely traverses the opening 19 in the traverse housing section 15 of the brake caliper 1 and extends with its rear end into the recess 17 of the brake lever 4, as can best be seen in FIG. 2. Basically, the rod 20 is positioned in the plane being defined by said recess 17.

(34) At its rear end facing away from the brake disc the rod 20 comprises a thread 23.

(35) In the assembled state of the brake actuation mechanism 3, the threaded end 23 of the rod 20 is cooperating with a mounting brace 24.

(36) The mounting brace 24, which preferably comprises a rotationally symmetric shape, serves to fix the rod 20 and thereby the entire brake actuation mechanism 3 inside the housing of the brake caliper 1, while the mounting brace 24 traverses the recess 17 of the brake lever 4.

(37) For that purpose, the brake caliper 1 comprises at a corresponding position a lateral opening 25, through which the mounting brace 24 can be inserted upon assembly. Opposite to that lateral opening 25 and axially aligned thereto a rotationally symmetric recess 26 is provided at the inner wall of the brake caliper 1, as can best be seen in FIG. 6.

(38) In the final position of the mounting brace 24, a threaded passage 27 of it is aligned with the mounting orientation of the rod 20, so that the threaded end 23 of the rod 20 can be screwed into that threaded passage 27.

(39) In order to prevent that such threaded engagement could become loose, e.g. due to vibrations, a counter-screw 28 can be provided and axially inserted into a corresponding threaded axial opening in the mounting brace 24 so as to further block the threaded end 23 of the rod 20.

(40) The lateral opening 25 in the brake caliper 1 can be then closed by a corresponding sealing cup 29.

(41) According to the invention, in order to adapt to spatial needs resulting from constraints in the surroundings of the disc brake, in particular with respect to the arrangement of the external actuator, the lateral opening 25 and the inner recess 26, in aligned orientation, could be arranged angularly offset both with respect to the horizontal and vertical plane, which planes being defined in relation to the axis of the brake disc. By that the brake lever 4 can be also arranged at corresponding angular positions, as this is indicated in FIG. 3.

(42) Thus, the brake lever 4 thereby is also angularly offset in relation to the axis or longitudinal extension of the rod 20 and to the orientation of the thrust element 11.

(43) This is particularly enabled in that the entire brake actuation mechanism 3 according to the invention is, by the majority, rotationally symmetrically orientated around the central rod 20. Since furthermore the force-transmitting block 10 does abut against the thrust element 11 (or against components thereof) in a planar way, but rotatably decoupled therefrom, it is enabled to rotate the brake lever 4 with the single components of the amplification mechanism 7 with respect to the rod 20 and with respect to the axially linearly guided thrust element 11 and fix the brake lever 4 with the amplification mechanism 7 in the desired angular position, namely via the mounting brace 24 upon assembly of the brake actuation mechanism 3.

(44) FIG. 7 shows a force-redirecting device being supported inside the housing 32 in a swiveling manner.

(45) The force-redirecting device is basically configured as a triangular shaped lever 35, the one end 36 of which is adapted to attach to a piston (not shown) of an actuator, while the other end 37 of it is fixedly, but relatively movably connected to a transmission rod 38 by means of a holding clamp 39. The holding clamp 39 holds the ball-shaped end 40 of the transmission rod 38 freely rotatably in a correspondingly concave reception of the end 37 of the triangular shaped lever 35.

(46) The transmission rod 38 shall attach to the actuator connection means 6 of the brake lever 4.

(47) The triangular shaped lever 35 is pivotably supported in the housing 32 by means of a pivot bearing 41.

(48) The angular connecting means 33, with which the housing 32 of the force-redirecting device 35 will be attached to the flange-like end of the housing section 5 of the caliper, comprises a flange ring 42.

(49) The flange ring 42 comprises a circular series of recesses or bores 43, as best can be seen in FIG. 2.

(50) A corresponding series of recesses or bores 44 is circularly arranged around a pipe section 45 of the housing 32, the pipe section 45 being traversed by the transmission rod 38.

(51) Pins 46 can be placed at and inserted into corresponding bores 44 of the housing 32, so as to define connection means for the flange ring 42, the latter will then be fixed in a particular angular position in that bores 43 of the flange ring 42 receive the pins 46.

(52) A nut ring 47 is provided, which will be screwed onto an outer thread 48 of the pipe section 45 and inside a circular groove of the flange ring 42, thereby fixing the latter in a previously selected relative position as defined by the pin connection between the housing 32 and the flange ring 42. Furthermore, a sealing ring 49 is provided to seal the housing 32 in relation to the brake caliper 1.

LIST OF REFERENCE NUMERALS

(53) 1 Brake caliper 2 Carrier 3 Brake actuation mechanism 4 Brake lever 5 Rear extending housing section 6 Actuator connection means 7 Amplification mechanism 8 Rollers 9 Transmission means 10 Force-transmitting block 11 Thrust element 12 Needle bearing cage 13 Support cups 14 Eccentric pivot bearing 15 Traverse housing section 16 Needle bearing cup 17 Recess of lever 18 Lever arm part 19 Opening in traverse housing section 20 Rod 21 Opening 22 Opening 23 Threaded end of rod 24 Mounting brace 25 Lateral opening in caliper 26 Lateral recess in caliper 27 Threaded passage in mounting brace 28 Counter-screw 29 Sealing plug 30 31 32 Housing force-redirecting device 33 Angular connecting means 34 Actuator 35 Triangular lever/force-redirecting device 36 End to actuator 37 End to transmission rod 38 Transmission rod 39 Holding clamp 40 Ball-shaped end 41 Pivot bearing 42 Flange ring 43 Bores of flange ring 44 Bores of pipe section 45 Pipe section 46 Pins 47 Nut ring 48 Thread 49 Sealing