Brake Caliper Support, Disc Brake Assembly, Use of a Brake Caliper Support, and Method for Guiding Air

Abstract

A brake caliper support for a brake caliper of a disc brake assembly with a brake disc has a brake caliper support bracket provided with at least two fastening sections for connecting the brake caliper support to a steering knuckle of a vehicle. The brake caliper support bracket in a mounted state at the vehicle is positioned opposite a brake disc friction surface of the brake disc. A brake caliper support bridge projects away from the brake caliper support bracket in axial direction of the brake disc and circumferentially surrounds the brake disc at least partially in the mounted state. An arc-shaped air guiding element is disposed at the brake caliper support bracket. The air guiding element is positioned axially opposite the brake disc friction surface of the brake disc in the mounted state. The air guiding element is a protrusion or a recess extending axially, respectively.

Claims

1. A brake caliper support for a brake caliper of a disc brake assembly comprising a brake disc, the brake caliper support comprising: a first brake caliper support bracket comprising at least two fastening sections configured to connect the brake caliper support to a steering knuckle of a vehicle, wherein the first brake caliper support bracket is configured to be positioned opposite a brake disc friction surface of the brake disc of the disc brake assembly in a mounted state of the brake caliper support at the vehicle; a brake caliper support bridge disposed at the first brake caliper support bracket and projecting away from the first brake caliper support bracket in an axial direction of the brake disc in the mounted state, wherein the brake caliper support bridge is configured to circumferentially surrounds the brake disc at least partially in the mounted state; and an air guiding element which is arc-shaped and which is disposed at the first brake caliper support bracket, wherein the air guiding element is configured to be positioned axially opposite the brake disc friction surface of the brake disc in the mounted state, wherein the air guiding element is a protrusion or a recess extending in the axial direction, respectively.

2. The brake caliper support according to claim 1, further comprising a second brake caliper support bracket positioned opposite the first brake caliper support bracket, wherein the brake caliper support is configured to receive the brake disc between the first brake caliper support bracket and the second brake caliper support bracket in the mounted state, and wherein the brake caliper support bridge connects the first brake caliper support bracket and the second brake caliper support bracket to each other.

3. The brake caliper support according to claim 1, wherein the first brake caliper support bracket comprises a connection section extending between the at least two fastening sections, and wherein the first brake caliper support bracket further comprises a lateral section connecting the connection section to the brake caliper support bridge and extending with a radial direction component in relation to the axial direction in the mounted state.

4. The brake caliper support according to claim 3, wherein the air guiding element is arranged at the connection section and/or is arranged at the lateral section.

5. The brake caliper support according to claim 4, wherein the air guiding element extends along an extension direction of the connection section and/or extends along an extension direction of the lateral section.

6. The brake caliper support according to claim 4, wherein the air guiding element extends tangentially along an extension direction of the connection section and/or extends radially along an extension direction of the lateral section.

7. The brake caliper support according to claim 3, wherein the air guiding element comprises a rib, wherein the rib is arranged at the connection section and protrudes away from the connection section, or wherein the rib is arranged at the lateral section and protrudes away from the lateral section, or wherein the air guiding element comprises a channel-shaped groove in the connection section or in the lateral section.

8. The brake caliper support according to claim 3, wherein the air guiding element is arranged at the connection section and comprises a protruding rib, and/or wherein the air guiding element is arranged at the lateral section and comprises a channel-shaped groove.

9. The brake caliper support according to claim 1, wherein the first brake caliper support bracket has a surface, wherein the air guiding element is a protrusion protruding away from the surface of the first brake caliper support bracket, or wherein the air guiding element is a recess in the surface of the first brake caliper support bracket.

10. The brake caliper support according to claim 1, wherein the air guiding element is a protrusion arranged axially at a circumferential edge of the first brake caliper support bracket.

11. The brake caliper support according to claim 1, wherein the air guiding element is a protrusion and is detachably fastened to the first brake caliper support bracket.

12. The brake caliper support according to claim 11, wherein the protrusion is detachably fastened by a screw connection and/or by a clamping connection to the first brake caliper support bracket.

13. The brake caliper support according to claim 1, wherein the brake caliper support forms a one-piece configuration together with the air guiding element.

14. The brake caliper support according to claim 13, wherein the one-piece configuration is a single cast part.

15. The brake caliper support according to claim 1, wherein the first brake caliper support bracket comprises a connection section extending between the at least two fastening sections and further comprises a lateral section connecting the connection section to the brake caliper support bridge, wherein the air guiding element extends as one piece along the connection section and along the lateral section, and wherein the air guiding element comprises a bend.

16. The brake caliper support according to claim 15, wherein the air guiding element comprises a first section extending tangentially in the mounted state and further comprises a directly or indirectly adjoining second section bent radially outwardly in the mounted state.

17. The brake caliper support according to claim 16, wherein the air guiding element comprises a third section arranged between the first section and the second section and forming a radially inwardly oriented bulge.

18. The brake caliper support according to claim 1, wherein the at least two fastening sections include a first fastening section and a second fastening section, wherein the first brake caliper support bracket comprises a connection section extending between the first fastening and second fastening section, and wherein the air guiding element extends continuously from the first fastening section to the second fastening section along the connection section.

19. The brake caliper support according to claim 1, wherein the first brake caliper support bracket comprises a connection section extending between the at least two fastening sections and further comprises a lateral section connecting the connection section to the brake caliper support bridge, wherein, in relation to the mounted state, the lateral section of the first brake caliper support bracket comprises an inner edge and an outer edge viewed in a circumferential direction of the brake disc, and wherein the air guiding element extends continuously from the inner edge all the way to the outer edge.

20. A disc brake assembly comprising: a brake caliper support according to claim 1; and a brake disc comprising a brake disc friction surface arranged opposite the air guiding element of the brake caliper support and opposite the first brake caliper support bracket of the brake caliper support.

21. The disc brake assembly according to claim 20, wherein the air guiding element is configured to deflect brake dust-laden air flowing along the brake disc when the brake disc is rotating.

22. The disc brake assembly according to claim 20, wherein the air guiding element is configured to prevent a radial exit of the brake dust-laden air from the brake caliper support.

23. The disc brake assembly according to claim 20, wherein the first brake caliper support bracket comprises a connection section extending between the at least two fastening sections, and wherein the air guiding element is arranged at the connection section of the first brake caliper support bracket and engages at least partially axially in a brake disc bell of the brake disc.

24. The disc brake assembly according to claim 20, further comprising a brake dust particle filter arranged downstream of the brake caliper support in a predetermined rotation direction of the brake disc.

25. A method of using the brake caliper support according to claim 1, the method comprising: targeted guiding of brake dust-laden air flowing along a rotating brake disc by the air guiding element of the brake caliper support into a brake dust particle filter arranged in a predetermined rotation direction of the brake disc downstream of the brake caliper support.

26. A method for guiding brake dust-laden air flowing along a rotating brake disc, the method comprising: deflecting the brake dust-laden air by the air guiding element of the brake caliper support according to claim 1; and after deflecting, guiding the brake dust-laden air along a forward rotation direction of the brake disc so that the brake dust-laden air exits through an exit region from the brake caliper support, wherein the exit region is arranged downstream of a lateral section and/or of a connection section of the first brake caliper support bracket in a predetermined rotation direction of the brake disc.

27. The method according to claim 26, further comprising: introducing the brake dust-laden air exiting from the exit region into a brake dust particle filter arranged downstream of the brake caliper support in the predetermined rotation direction of the brake disc.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0073] FIG. 1 shows a perspective view of an embodiment of a disc brake assembly.

[0074] FIG. 2 is a lateral plan view of the disc brake assembly according to FIG. 1.

[0075] FIG. 3 is a plan view (from above) of the disc brake assembly according to FIG. 1.

[0076] FIG. 4 is a plan view (in travel direction) of the disc brake assembly according to FIG. 1.

[0077] FIG. 5 is a lateral plan view of an embodiment of a filter housing of a brake dust particle filter for a disc brake assembly according to FIGS. 1-4.

[0078] FIG. 6 is a perspective view of the filter housing according to FIG. 5.

[0079] FIG. 7 is a lateral plan view of the disc brake assembly according to FIG. 1 without brake dust particle filter.

[0080] FIG. 8 is a perspective view of a brake caliper support.

[0081] FIG. 9 is a perspective view of a brake caliper device.

[0082] FIG. 10 is a perspective view of the brake caliper device according to FIG. 9 with a brake dust particle filter.

[0083] FIG. 11 is a perspective view of a further brake caliper device.

[0084] FIG. 12 is a section view of the brake caliper device of FIG. 11.

[0085] In the Figures, same or functionally the same elements, insofar as nothing to the contrary is indicated, are provided with the same reference characters.

DETAILED DESCRIPTION

[0086] In FIGS. 1, 2, 3, and 4, different views of an embodiment of a disc brake assembly, for example, for a motor vehicle, are illustrated. In this context, a perspective view of the disc brake assembly 100 is illustrated in FIG. 1, a lateral view in FIG. 2, and plan views parallel to the axis of rotation A in FIGS. 3 and 4.

[0087] The disc brake assembly 100 comprises a brake disc 2 which is provided with an internal venting action in the illustrated embodiment. The brake disc 2 has a radially inwardly positioned fastening plate 2E comprising fastener openings 2F. In the Figures, only one opening 2F is provided with a reference character, respectively. By means of the fastening plate 2E and the fastener openings 2F, the brake disc 2 is fastened by means of suitable fastener means, such as, for example, wheel bolts, at the wheel suspension so that a rotationally fixed coupling with the vehicle wheel, not illustrated here, or the wheel rims is produced. At the circumferentially extending brake disc edge 2D (compare FIG. 3), one can see radially outwardly oriented outflow openings 2C. In operation of the brake which is rotating in rotation direction R, air for cooling the brake disc 2 flows out of the outflow openings 2C. In the following, a braking process during forward travel is considered for simplification. In principle, the rotation direction can also be reversed.

[0088] In the Figures, a forward rotation direction R opposite to the clockwise direction is indicated (except in FIG. 7 which shows the brake from the interior of the vehicle). This is referred to in the following as forward rotation direction R. The axis of rotation A can be seen in FIGS. 2, 3, and 4. An axial extension direction AX (compare FIGS. 1, 3, and 4), a radial extension direction RX (compare FIG. 3), and a circumferential extension direction CX (compare FIG. 2) result based on the orientation of the brake disc 2.

[0089] In FIG. 2, an installation situation of the brake disc 2 and brake caliper 4 engaging around the brake disc 2 is indicated substantially. The brake caliper 4 is coupled to a brake caliper holder 3 which also engages around the brake disc 2. At both sides of the brake disc 2, brake pads 5 are arranged at the brake caliper 4 and are pressed against the friction surfaces 2A, 2B by means of brake hydraulics 8 (compare FIGS. 3 and 4) during the braking process.

[0090] The brake caliper holder 3 as well as the brake caliper 4 are held by a floating support 9 by means of a brake caliper support 6. Due to the floating support 9, an automatic centering of the brake caliper 4 with the brake pads 5 in relation to the brake disc 2, positioned between the gripper arms of the brake caliper 4 or the two brake pads 5, is provided. In the illustrated embodiment, the brake caliper 4 in forward direction F is arranged in front of the axis of rotation A. However, variants are also conceivable in which the brake caliper 4 is arranged behind the axis A.

[0091] Since the brake pads 5 press against the friction surfaces 2A, 2B of the brake disc 2 during the braking process, abrasion particles are produced at the brake pads 5 and in principle also at the brake disc 2. A portion of these brake dust particles are entrained by the rotation direction R of the brake disc in the circumferential direction CX. Therefore, for catching this brake dust or the brake dust particles, a brake dust particle filter 1 is provided in rotation direction R downstream of the brake caliper 4. Detailed side views and perspective illustrations of the filter housing 10 of the brake dust particle filter 1 are represented in FIGS. 5 and 6.

[0092] The housing 10 of the brake dust particle filter 1 engages around a region of the brake disc 2 substantially in a ring segment-shaped form. For this purpose, the brake dust particle filter 1 comprises a housing 10. The housing 10 has two oppositely positioned sidewalls 11A, 11B that are connected to each other by an outer circumferential wall 12 to a substantially U-shaped cross section. In the orientation of FIGS. 1, 3, and 4, an outer sidewall 11A results which is facing away from the vehicle in the mounted state. The oppositely positioned sidewall 11B (in the orientation of FIGS. 3 and 4 at the right side) is referred to as inner sidewall 11B because it is facing the interior of the vehicle. The brake disc 2 is thus partially enclosed between the two sidewalls 11A, 11B.

[0093] In radial direction opposite the circumferential wall 12, inner circumferential wall sections 13A, 13B are provided. The outwardly positioned, radially inwardly positioned, and axially outwardly positioned circumferential wall section is identified by 13A. The radially inwardly positioned and axially inwardly positioned circumferential section is identified by 13B.

[0094] Toward the brake caliper 4, the filter housing 10 has an edge with a connection contour 14 so that a gap 15 is present between the brake caliper 4 and the housing edge or connection contour 14. The connection contour 14 forms a brake caliper-side opening of the filter housing 10. In circumferential direction CX, the filter housing 10 extends from the connection contour 14 or an open side of the housing 10 all the way to an end wall 16. The end wall 16 connects the outer sidewall 11A, the outer circumferential wall 12, and the inner sidewall 11B to each other. Between the inner circumferential wall sections 13A, 13B there is a ring-shaped slot 17 provided into which the brake disc 2 with its brake disc edge 2D can be introduced. The housing walls 11A, 11B, 12, 13A, 13B, 16 enclose a housing interior 20. The brake disc 2 penetrates into the housing interior 20, or the filter housing 10 encloses or surrounds a ring segment of the brake disc 2. The filter housing 10 or installed parts in the brake dust particle filter 1 do not contact the brake disc 2.

[0095] In FIG. 5, possible dimensions of the filter housing 10 are illustrated. FIG. 5 shows a side view from the exterior side of the disc brake assembly 100 in axial direction. One can see that the sidewalls, in particular the outer sidewall 11A visible in FIG. 5, has a ring segment shape. The filter housing 10, viewed from the axis of rotation A, is delimited radially inwardly by the inner circumferential wall sections 13A, 13B (not illustrated) and radially outwardly by the outer circumferential wall 12. In this context, an inner radius RI can result from the distance of the inner circumferential wall sections 13A, 13B and an outer radius RO from the distance of the circumferential wall 12 relative to the axis of rotation A. The difference of the radii RO-RI can be referred to as height H of the filter housing 10. The length of the filter housing 10 results from the extension along the circumference between the open side or the connection contour 14 facing the brake caliper 4 and the end wall 16. A width W of the filter housing 10 in its axial extension results from the distance between the two sidewalls 11A, 11B (compare FIGS. 4 and 6).

[0096] In operation of the disc brake assembly 100 and of the brake dust particle filter 1, an air flow in circumferential direction CX through the filter housing 10 along the rotation direction R of the brake disc 2 is produced by the rotation direction R of the brake disc 2.

[0097] In the interior 20 of the filter housing 10, the particles can deposit due to adhesion forces at the inner walls along the flow path in the filter housing 10 or (not shown here) can be bonded by suitable filter materials.

[0098] The filter housing 10 or the brake dust particle filter 1 can be fastened at the brake caliper holder by a suitable fastener means, for example, a screw. In FIGS. 3 and 6, one can see fastener means 19 in the form of a nut. In this context, the brake dust particle filter 1 can be fastened, either directly or indirectly with intermediate positioning of a holder/adapter, at the brake caliper holder 3.

[0099] The installation space in the region of the disc brake assembly 100, in particular in case of a steered front axle of a vehicle, can have an effect on the housing shape of the brake dust particle filter 1. For example, the filter housing 10 has axially inwardly a region 18 which is recessed in the direction toward the interior 20 of the filter housing 10 and arranged between the end wall 16 and the connection contour 14. Thus, a changing width of the cross section of the filter housing 10 results along the circumferential direction CX.

[0100] Based on FIGS. 7 to 12, different embodiments of the brake caliper support 6 will be described. All of the brake caliper supports 6 described with the aid of FIGS. 7 to 12 can be used in the disc brake assembly 100 of FIGS. 1 to 4.

[0101] FIG. 7 shows a lateral plan view of the disc brake assembly 100 according to FIG. 1 without brake dust particle filter 1. In the illustration of FIG. 7, one looks onto a first brake caliper support bracket 62 which, in plan view, has substantially a C-shape. The first brake caliper support bracket 62 comprises a connection section 63 as well as two lateral sections 65. The connection section 63 extends between two fastening sections 60, 61 that are embodied as axial holes and serve to attach the brake caliper support 6 to the steering knuckle of the vehicle.

[0102] The first brake caliper bracket 62 extends in the mounted state (FIG. 7) opposite the brake disc 2. As illustrated in FIG. 8, the connection section 63 extends substantially along the circumferential direction CX. The lateral sections 65 are positioned perpendicularly to the connection section 63 and extend substantially along the radial direction RX.

[0103] As illustrated in FIG. 8, the brake caliper support 6 comprises moreover a second brake caliper support bracket 66 that has a shape similar to the first brake caliper support bracket 62 but comprises no fastening sections 60, 61. In the mounted state, the brake disc 2 extends between the two brake caliper support brackets 62, 66.

[0104] The brake caliper support brackets 62, 66 are axially connected to each other at their lateral sections 65 by two brake caliper support bridges 64. They are positioned in the mounted state opposite the circumferential edge 2D of the brake disc 2. As illustrated in FIG. 7, the brake caliper support 6 engages around the brake disc 2 and frames the brake caliper 4 in doing so.

[0105] FIGS. 9 and 10 show a brake caliper device 101 with the brake caliper support 6 and the brake caliper 4 as well as the particle filter 1. As illustrated in FIGS. 9 and 10, the brake caliper support 6 comprises two air guiding elements 70 at an inner side of the brake caliper support 6, which is positioned opposite the brake disc 2 in the mounted state. Both air guiding elements 70 are formed as one piece together with the brake caliper support 6 and are provided at the first brake caliper support bracket 62.

[0106] The first air guiding element 70 is formed as a protrusion 71 (rib). It extends along the circumferential direction CX at the connection section 63. The protrusion 71 is arc-shaped. The protrusion 71 extends in this context in axial direction AX in the direction toward the brake disc 2. The protrusion 71 reduces a distance between the brake disc 2 and the brake caliper support 6 and prevents thus that the brake dust-laden air which circulates along the brake disc 2 exits radially from the brake caliper support 6. Moreover, the protrusion 71 is oriented such that it guides the air into the interior 20 of the brake dust particle filter 1 (see FIG. 10). The protrusion 71 guides the air in this context in the direction toward an exit region 73 which borders the brake dust particle filter 1. In this way, a degree of separation is increased.

[0107] The second air guiding element 70 is formed as a recess 72 (channel-shaped groove). It extends substantially along the circumferential direction CX at the lateral section 65 which is arranged at the side of the brake dust particle filter 1. As can be seen in FIG. 9, the recess 72 extends in circumferential direction CX continuously from an inner edge 65A of the lateral section 65 all the way to an outer edge 65B of the lateral section 65. The recess 72 is arc-shaped in this context. In the region of the recess 72, the lateral section 65 is recessed in axial direction AX away from the brake disc 2. The recess 72 increases a distance between the brake disc 2 and the brake caliper support 6 and forms thus a channel through which the particle-laden air is guided into the interior 20 of the brake dust particle filter 1 (see FIG. 10). The channel enlarges in this context the exit region 73. In this way, the degree of separation is increased.

[0108] FIGS. 11 and 12 show a further brake caliper device 102 with a brake caliper support 6, the brake caliper 4, and the particle filter 1. As illustrated in FIGS. 11 and 12, the brake caliper support 6 comprises at its inner side an air guiding element 70. The air guiding element 70 is provided detachably at the first brake caliper support bracket 62.

[0109] The air guiding element 70 of FIGS. 11 and 12 is provided as a protrusion 71 and is fastened to an outer circumferential edge 67 of the connection section 63. The air guiding element 70 extends substantially along the outer edge 67. The air guiding element 70 comprises a first section 69A which extends in the mounted state tangentially and a second section 69B adjoining it and bent radially outwardly in the mounted state. The air guiding element 70 comprises a third section 69C between the first section 69A and the second section 69B which forms a radially inwardly oriented bulge or bend 68.

[0110] The air guiding element 70 deflects the air flowing about the brake disc 2 in particular in the direction of an intake region of an internal venting action of the brake disc 2. In this way, the particles in particular are not deflected into the environment but pass through the internal venting action of the brake disc 2 into the brake dust particle filter 1. Here, the particles can be separated at the filter medium due to the corresponding flow conditions.

[0111] The embodiments can be modified in many ways. It is e.g. conceivable to provide recesses 72 where the protrusions 71 are illustrated, and vice versa. In the example of FIGS. 9 and 10, the protrusion 71 and/or the recess 72 can be omitted. The geometry of the guiding elements 70 can be modified at will in order to optimize the air flow into the brake dust particle filter 1. Moreover, the shape of the brake caliper support 6 can be modified. It is e.g. conceivable to use a brake caliper support 6 that has only one brake caliper support bracket 62 and/or only one brake caliper support bridge 64 and/or only one lateral section 65.

REFERENCE CHARACTERS

[0112] 1 brake dust particle filter [0113] 2 brake disc [0114] 2A, 2B brake disc friction surface [0115] 2C outflow opening [0116] 2D brake disc edge [0117] 2E fastening plate [0118] 2F fastener opening [0119] 3 brake caliper holder [0120] 4 brake caliper [0121] 5 brake pad [0122] 6 brake caliper support [0123] 7 brake line connector [0124] 8 brake hydraulics [0125] 9 floating support [0126] 10 filter housing [0127] 11A (outer) sidewall [0128] 11B (inner) sidewall [0129] 12 (outer) circumferential wall section [0130] 13A (inner outwardly positioned) inner circumferential wall section [0131] 13B (inner inwardly positioned) inner circumferential wall section [0132] 14 connection contour [0133] 15 gap [0134] 16 end wall [0135] 17 slot [0136] 18 inwardly recessed housing region [0137] 19 filter fastener [0138] 20 housing interior [0139] 60, 61 fastening section [0140] 62 first brake caliper support bracket [0141] 63 connection section [0142] 64 brake caliper support bridge [0143] 65 lateral section [0144] 65A inner edge [0145] 65B outer edge [0146] 66 second brake caliper support bracket [0147] 67 circumferential edge [0148] 68 bend [0149] 69A first section [0150] 69B second section [0151] 69C third section [0152] 70 air guiding element [0153] 71 protrusion [0154] 72 recess [0155] 73 exit region [0156] 100 disc brake assembly [0157] 101 brake caliper device [0158] 102 brake caliper device [0159] A axis of rotation [0160] AX axial extension direction [0161] CX circumferential extension direction [0162] F forward travel direction [0163] H height [0164] R forward rotation direction [0165] RI inner radius [0166] RO outer radius [0167] RX radial extension direction [0168] W width