Brake Caliper Device, Disc Brake Assembly, Use of a Brake Caliper Device and Method for Radially Retaining Air

Abstract

A brake caliper device for a disc brake assembly with a brake disc has a brake caliper support to be arranged stationarily relative to a vehicle. A brake caliper for holding at least one brake pad is provided, wherein the brake caliper can slide relative to the brake caliper support in an axial direction. A seal device is provided that seals a gap formed between the brake caliper and the brake caliper support. The seal device extends in the axial direction. The seal device has a brush, a sealing lip, and/or a loose sealing material projecting away from the brake caliper support in a direction toward the oppositely positioned brake caliper and/or projecting away from the brake caliper in a direction toward the oppositely positioned brake caliper support.

Claims

1. A brake caliper device for a disc brake assembly with a brake disc, the brake caliper device comprising: a brake caliper support configured to be arranged stationarily relative to a vehicle; a brake caliper configured to hold at least one brake pad, and to slide relative to the brake caliper support in an axial direction; and a seal device configured to seal a gap formed between the brake caliper and the brake caliper support, wherein the seal device extends in the axial direction, and wherein the seal device comprises a brush, a sealing lip, and/or a loose sealing material projecting away from the brake caliper support in a direction toward the oppositely positioned brake caliper and/or projecting away from the brake caliper in a direction toward the oppositely positioned brake caliper support.

2. The brake caliper device according to claim 1, wherein the brake caliper support comprises: at least two fastening sections configured to connect the brake caliper support to a steering knuckle of the vehicle; and a holding section extending from the at least two fastening sections in the axial direction, wherein the holding section, in a mounted state of the brake caliper device, at least partially surrounds the brake disc and comprises a receiving region for the brake caliper, wherein the brake caliper comprises: two brake caliper legs configured to fasten the at least one brake pad, respectively; and a brake caliper body connecting the brake caliper legs to each other and at least partially surrounding the brake disc in the mounted state of the brake caliper device, and wherein the gap sealed by the seal device is a gap formed between the holding section of the brake caliper support and the brake caliper body of the brake caliper.

3. The brake caliper device according to claim 1, wherein the seal device is configured to reduce a particle escape in a radial direction in relation to a rotation direction of the brake disc in the mounted state of the brake caliper device.

4. The brake caliper device according to claim 1, wherein the seal device comprises a caliper seal part disposed at the brake caliper, and an oppositely positioned support seal part disposed at the brake caliper support.

5. The brake caliper device according to claim 4, wherein the caliper seal part and the support seal part are arranged displaced relative to each other in a radial direction and at least partially overlap each other in a circumferential direction of the brake disc.

6. The brake caliper device according to claim 5, wherein the caliper seal part and the support seal part have mutually complementary and mutually engaging shapes, wherein the mutually complementary and mutually engaging shapes together form a labyrinth seal comprising a plurality of deflections in the gap along the radial direction, and wherein the brush, the sealing lip and/or the loose sealing material is present at the caliper seal part or at the support seal part.

7. The brake caliper device according to claim 4, wherein the caliper seal part comprises a guide channel extending along the axial direction wherein the support seal part comprises a projecting rib protruding into the guide channel, and wherein the brush, the sealing lip and/or the loose sealing material is present at the projecting rib.

8. The brake caliper device according to claim 4, wherein the support seal part comprises a guide channel extending along the axial direction, wherein the caliper seal part comprises a projecting rib protruding into the guide channel, and wherein the brush, the sealing lip and/or the loose sealing material is present at the projecting rib.

9. The brake caliper device according to claim 4, wherein the caliper seal part is formed as one part together with the brake caliper, and/or wherein the support seal part is formed as one part together with the brake caliper support.

10. The brake caliper device according to claim 4, wherein the caliper seal part is connected detachably to the brake caliper, and/or wherein the support seal part is connected detachably to the brake caliper support.

11. A disc brake assembly comprising: a brake disc; and a brake caliper device comprising: a brake caliper support configured to be arranged stationarily relative to a vehicle; a brake caliper configured to slide relative to the brake caliper support in an axial direction; at least one brake pad held at the brake caliper and configured to be pressed, by a movement of the brake caliper relative to the brake caliper support along the axial direction, against the brake disc; and a seal device configured to seal a gap formed between the brake caliper and the brake caliper support, wherein the seal device extends in the axial direction, and wherein the seal device comprises a brush, a sealing lip, and/or a loose sealing material projecting away from the brake caliper support in a direction toward the oppositely positioned brake caliper and/or projecting away from the brake caliper in a direction toward the oppositely positioned brake caliper support.

12. The disc brake assembly according to claim 11, wherein the seal device is configured to reduce a radial escape of brake dust-laden air, flowing along the brake disc when the brake disc is rotating, from the brake caliper device.

13. A system comprising: a disc brake assembly according to claim 11; and a brake dust particle filter, wherein the brake dust particle filter is arranged downstream of the brake caliper device in a predetermined rotation direction of the brake disc.

14. The system according to claim 13, wherein the predetermined rotation direction is a forward rotation direction.

15. A method comprising: using the brake caliper device according to claim 1 to radially retain in the brake caliper device brake dust-laden air flowing along the brake disc when the brake disc is rotating.

16. A method for radial retention of brake dust-laden air, flowing along a brake disc when the brake disc is rotating, with the brake caliper device according to claim 1, the method comprising: preventing by the seal device the brake dust-laden air from escaping radially from the brake caliper device.

17. The method according to claim 16, further comprising introducing the brake dust-laden air into a brake dust particle filter arranged downstream of the brake caliper support in a predetermined rotation direction of the brake disc.

18. The method according to claim 17, further comprising selecting the predetermined rotation direction to be a forward rotation direction.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0066] Further embodiments, features and advantages will become apparent from the subsequent description and dependent claims, taken in conjunction with the accompanying drawings.

[0067] FIG. 1 shows a perspective view of an embodiment of a system with a disc brake assembly and brake dust particle filter.

[0068] FIG. 2 shows a lateral plan view of the system according to FIG. 1.

[0069] FIG. 3 shows a section view of the system according to FIG. 1.

[0070] FIG. 4 shows a further section view of the system according to FIG. 1.

[0071] FIG. 5 shows a lateral plan view of an embodiment of a filter housing of a brake dust particle filter for a system according to FIGS. 1 to 4.

[0072] FIG. 6 shows a perspective view of the filter housing according to FIG. 5.

[0073] FIG. 7 shows a plan view of a brake caliper device.

[0074] FIG. 8 shows a lateral plan view of a disc brake assembly for the system according to FIGS. 1 to 4.

[0075] FIG. 9 shows a detail of the disc brake assembly according to FIG. 8.

[0076] FIG. 10 shows a section view of the disc brake assembly of FIG. 8 along A-A according to FIG. 7.

[0077] FIG. 11 shows a detail of the section view according to FIG. 10.

[0078] FIG. 12 shows an alternative embodiment of the seal device.

[0079] FIG. 13 shows a further alternative embodiment of the seal device.

DETAILED DESCRIPTION

[0080] In FIGS. 1, 2, 3, and 4, different views of an embodiment of a system 500 with a disc brake assembly 100, for example, for a motor vehicle, and a brake particle filter 1 are illustrated. In this context, in FIG. 1 a perspective view of the system 100, in FIG. 2 a lateral view and in FIGS. 3 and 4 section views parallel to the axis of rotation A are illustrated.

[0081] The disc brake assembly 100 comprises a brake disc 2 which is furnished with inner venting in the illustrated embodiment. The brake disc 2 has a radially inwardly positioned fastening plate 2E which comprises fastening openings 2F. In the Figures, only one opening 2F is provided with a reference character. By means of the fastening plate 2E and the fastening openings 2F, the brake disc 2 is fastened by means of suitable fasteners such as, for example, wheel bolts, to the wheel suspension so that a rotationally fixed coupling with the vehicle wheel, not illustrated here, or the rims is produced. At the circumferentially extending brake disc edge 2D (compare FIG. 3), one can see radially outwardly oriented outflow openings 2C. Air for cooling the brake disc 2 flows from the outflow openings 2C in operation of the brake which rotates in rotation direction R. For simplification, in the following a braking process for a forward travel will be considered. In principle, the rotation direction can also be reversed.

[0082] In the Figures, a forward rotation direction R opposite to the clockwise direction is indicated. 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. Due to the orientation of the brake disc 2, 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) are provided.

[0083] In FIG. 2, substantially an installation situation of the brake disc 2 and of a brake caliper 4 engaging around the brake disc 2 is indicated. The brake caliper 4 is coupled to a brake caliper holder 3 which engages also around the brake disc 2. At the brake caliper 4, brake pads 5 are arranged on both sides of the brake disc 2 and can be pushed against the friction surfaces 2A, 2B by means of brake hydraulics 8 (compare FIGS. 3 and 4) during the braking process. The brake caliper 4 and the brake caliper holder 3 form together a brake caliper device 400.

[0084] The brake caliper holder 3 as well as the brake caliper 4 are held by a floating support 9 by 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 is provided; the brake disc 2 is located between the gripping arms of the brake caliper 4 or the two brake pads 5. In the illustrated embodiment, the brake caliper 4 is arranged in forward travel direction F in front of the axis of rotation A. Variants are also conceivable in which the brake caliper 4 is provided behind the axis A. As illustrated in FIG. 7, the brake caliper 4 is held at the brake caliper support 6 so as to be slidable in axial direction AX. The brake caliper support 6 itself is stationarily fastened to a steering knuckle of the vehicle (not illustrated).

[0085] The brake caliper support 6 comprises two fastening sections 6A, 6B for vehicle-side connection of the brake caliper support 6 to the vehicle. The fastening sections 6A, 6B are located at an inner side of the vehicle. Two holding sections 6C, 6D extend away from the fastening sections 6A, 6B in axial direction and, in the mounted state, bridge the brake disc edge 2D at a distance, as illustrated in FIG. 7. The two holding sections 6C, 6D are connected to each other, in turn, by a connection arc 6E (FIG. 2). The holding sections 6C, 6D as well as the connection arc 6E define a receiving region 6F for the brake disc 2. The brake caliper support 6 engages around a region of the brake disc 2 substantially in a ring segment shape.

[0086] The brake caliper 4 comprises two brake caliper legs 4A for attachment of a brake pad 5, respectively. The brake caliper legs 4A extend substantially parallel to the brake disc 2. The brake disc 2 extends in this context between the two brake caliper legs 4A. The brake caliper legs 4A are connected to each other by a brake caliper body 4C (FIG. 7). The latter extends in axial direction AX and bridges in the mounted state the brake disc edge 2D. The brake caliper 4 engages about a region of the brake disc 2 substantially in a ring segment shape. The brake caliper support 6 forms in this context substantially a frame about the brake caliper 4.

[0087] A gap 15 is provided between the brake caliper 4 and the brake caliper support 6. It is required so that the brake caliper 4 is movable relative to the brake caliper support 6 in axial direction AX.

[0088] Since during the braking process the brake pads 5 are acting on the friction surfaces 2A, 2B of the brake disc 2, abrasion at the brake pads 5 and in principle also at the brake disc 2 is produced. A portion of these brake dust particles are entrained by the rotation R of the brake disc in circumferential direction CX. Therefore, for catching this brake dust or the brake dust particles, a brake dust particle filter 1 is provided downstream of the brake caliper 4 in rotation direction R. 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.

[0089] The housing 10 of the brake dust particle filter 1 engages around a region of the brake disc 2 substantially in a ring segment shape. For this purpose, the brake dust particle filter 1 comprises a housing 10. The housing 10 has two oppositely positioned sidewalls 11A, 11B which are connected to each other by an outer circumferential wall 12 to an approximately U-shaped cross section. In the orientation of FIGS. 1, 3, and 4, an outer sidewall 11A is provided which in the mounted state is facing away from the vehicle. 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 toward the vehicle interior. The brake disc 2 between the two sidewalls 11A, 11B is thus partially enclosed.

[0090] Inner circumferential wall sections 13A, 13B extend opposite the circumferential wall 12 in radial direction. 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 wall section is identified by 13B.

[0091] The housing edge 14 forms an opening of the filter housing 10 at the brake caliper side. The filter housing 10 extends in circumferential direction CX from the connection contour or an open side 14 of the housing 10 up 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, an annular slot 17 is present into which the brake disc 2 can be inserted with its brake disc edge 2D. 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 engages around 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.

[0092] 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 as the distance of the inner circumferential wall sections 13A, 13B and an outer radius RO as the distance of the circumferential wall 12 from 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 results from the extension along the circumference between the open side 14 facing the brake caliper 4 and the end face 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).

[0093] 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 R of the brake disc 2.

[0094] In the interior 20 of the filter housing 10, the particles can deposit along the flow path in the filter housing 10 by adhesion forces at the inner walls or (not illustrated here) can be bonded by suitable filter materials.

[0095] The filter housing 10 or the brake dust particle filter 1 is fastened with a suitable fastener, for example, a screw, at the brake caliper holder 3. One can see fastener 19 in FIGS. 3 and 6.

[0096] FIG. 8 shows a lateral plan view of a disc brake assembly 100 for the system 500 according to FIGS. 1-4. The illustration of FIG. 8 corresponds in this context to that of FIG. 2, wherein the brake dust particle filter 1 has been omitted. FIG. 9 shows a detail Y of the disc brake assembly 100 according to FIG. 8.

[0097] As can be seen in FIG. 9, a seal device 50 is provided in the region of the gap 15 between the brake caliper 4 and the brake caliper support 6. It enables a sealing action of the gap 15 in radial direction RX. The seal device 50 extends axially along the entire length of the gap 15. As illustrated in FIG. 7, the gap 15 is covered with the aid of the seal device 50 in radial direction RX.

[0098] The contours of the seal device 50 can be seen particularly well in FIGS. 10 and 11. FIG. 10 shows a section view of the disc brake assembly of FIG. 8 along A-A according to FIG. 7, while in FIG. 11 a detail Z of the section view according to FIG. 10 is shown.

[0099] The seal device 50 is of a two-part configuration. It comprises a caliper seal part 51 which is formed as one part together with the brake caliper 4 and a support seal part 52 which is formed as one part together with the brake caliper support 6. The caliper seal part 51 in this context is configured as a projecting part (rib) of the brake caliper body 4C and the support seal part 52 is embodied as a projecting part (rib) of the holding section 6D of the brake caliper support 6. Radially viewed, the caliper seal part 51 and the support seal part 52 overlap each other so that in the gap 15 a plurality of deflections 53 are provided. Deflections mean in this context that air which escapes through the gap 15 from the brake caliper device 400 is deflected several times, which has the result that the escape of the air through the gap 15 is made significantly more difficult. The caliper seal part 51 and the support seal part 52 however do not close the gap 15 completely but serve for radial sealing of the gap 15. Due to the seal device 50, a radial escape of brake dust particles through the gap 15 is prevented.

[0100] FIG. 12 shows a seal device 60 which can be used as an alternative to the seal device 50. The seal device 60 is also of a two-part configuration and comprises a caliper seal part 61 which is formed as one piece together with the brake caliper 4 and a support seal part 62 which is formed as one piece together with the brake caliper support 6. The caliper seal part 61 is a channel extending along the axial direction AX. The support seal part 62 is embodied as a projecting rib of the holding section 6D of the brake caliper support 6. The rib 62 protrudes in the illustrated mounted state into the channel 61. Viewed radially, the caliper seal part 61 and the support seal part 62 form a plurality of deflections 63 in the gap 15 so that the gap 15 is radially sealed.

[0101] FIG. 13 shows a seal device 70 which can be used as an alternative to the seal device 50, 60. The seal device 70 is also of a two-part configuration and comprises a caliper seal part 71 which is formed as one part together with the brake caliper 4 and a support seal part 72 which is formed as one part together with the brake caliper support 6. The caliper seal part 71 is a rib with a shape which is curved in section and protrudes radially inwardly. The support seal part 72 has a complementary shape and is embodied as a rib which comprises in section a curved shape and protrudes radially outwardly. The caliper seal part 71 and the support seal part 72 protrude in this context into each other such that a labyrinth seal 70 is formed. Due to the seal device 70, a radial escape of particles is reduced because a plurality of deflections 73 are provided in the gap 15.

[0102] The embodiments can be modified in multiple ways. In particular, the shape of the seal device 50, 60, 70 can be varied at will as long as it has an axial extension direction AX and enables a radial sealing action. The seal device can be provided, for example, as a separate component which is attached to the brake caliper and/or to the brake caliper support. The seal device can also be embodied, for example, as a brush seal or the like. Instead of the seal device 60 of FIG. 12, the channel 61 could also be part of the brake caliper support 6 and the rib 62 part of the brake caliper 4.

REFERENCE NUMBERS

[0103] 1 brake dust particle filter [0104] 2 brake disc [0105] 2A, 2B brake disc friction surface [0106] 2C outflow opening [0107] 2D brake disc edge [0108] 2E fastening plate [0109] 2F fastening opening [0110] 3 brake caliper holder [0111] 4 brake caliper [0112] 4A brake caliper leg [0113] 4C brake caliper body [0114] 5 brake pad [0115] 6 brake caliper support [0116] 6A, 6B fastening section [0117] 6C, 6D holding section [0118] 6E connection arc [0119] 6F receiving region [0120] 8 brake hydraulics [0121] 9 floating support [0122] 10 filter housing [0123] 11A (outer) sidewall [0124] 11B (inner) sidewall [0125] 12 (outer) circumferential wall [0126] 13A (inner outwardly positioned) circumferential wall section [0127] 13B (inner inwardly positioned) circumferential wall section [0128] 14 connection contour [0129] 15 gap [0130] 16 end wall [0131] 17 slot [0132] 19 fastener [0133] 20 housing interior [0134] 50 seal device [0135] 51 caliper seal part [0136] 52 support seal part [0137] 53 deflection [0138] 60 seal device [0139] 61 caliper seal part [0140] 62 support seal part [0141] 63 deflection [0142] 70 seal device [0143] 71 caliper seal part [0144] 72 support seal part [0145] 73 deflection [0146] 100 disc brake assembly [0147] 400 brake caliper device [0148] 500 system [0149] A axis of rotation [0150] AX axial extension direction [0151] CX circumferential extension direction [0152] F forward travel direction [0153] R forward rotation direction [0154] RI inner radius [0155] RO outer radius [0156] RX radial extension direction [0157] Y detail [0158] Z detail