DESCRIPTION

[0001] . Field of the invention

[0002] . The present invention relates to a caliper body, a brake caliper, a caliper body and caliper support assembly, as well as to a method of assembling a pad support pin in a caliper body .

[0003] . Background art

[0004] . In a disc brake of known type, the brake caliper is generally arranged astride a brake disc mounted on the hub of a vehicle wheel . The brake caliper usually comprises a caliper body which accommodates the brake pads and actuators for pushing the pads against the disc to achieve the braking action on the vehicle .

[0005] . In some known disc brake types , the pads are supported by support pins accommodated in appropriate caliper body seats made in the caliper body, in which each support pin passes through corresponding holes made in the support plate for the friction material of each brake pad . Such support pins have a longitudinal extension axis, a pin head, and a pin tip arranged at the opposite ends of the extension axis .

[0006] . The support pins are coupled with clearance with respect to the respective caliper body seat , and therefore elastic elements are used to axially constrain the pins to the caliper body seat s .

[0007] . In some cases, such elastic elements are coaxially preassembled to the pin body in an annular pin seat . The annular pin seat , in which the elastic element is accommodated, includes a usually cylindrical bottom wall with axial extension, axially delimited by at least a first seat wall substantially transverse to the bottom wall minus flared machining connectors .

[0008] . Such elastic elements are usually expanding elastic elements, and in a resting condition, have a larger radial dimension than the radial dimension of the first seat wall . When the support pin provided with the expanding elastic element is as sembled to the caliper body, the expanding elastic element is thus radially compressed by the walls of the caliper body seat in the direction of the support pin, and the expanding elastic element is constrained by friction to the caliper body seat . As a result , the expanding elastic element provides an axial constraint aimed at preventing the pin from coming out of it s seat .

[0009] . The expanding elastic element is inserted by sliding into the caliper body seat , e . g . , under a thrust action . Once the expanding elastic element is positioned inside the caliper body seat , and at least one pin abutment portion of the support pin axially abuts against the caliper body defining the maximum insertion position of the pin in the caliper body, the elastic element forms an axial constraint with respect to the pin, thus preventing the movement s of the pin in the extraction direction until the action in the axial direction applied by the first seat wall of the pin seat exceeds the static friction force between the elastic element and the caliper body, allowing the elastic element to slide with respect to the caliper body and therefore allowing the pin to come out of its seat . [0010] . For example, document EP1425520 to the Applicant shows a brake pad support pin coupled to a barrel-shaped expanding elastic element .

[0011] . The shape of the support pins and the respective expanding elastic elements is such as to meet the need to ensure an easy assembly of a brake caliper as sembly, as well as a simple replacement of the brake pads , e . g . , during maintenance, while meeting the need to ensure an axially constrained coupling between the support pins and the caliper body when the vehicle is used, while withstanding the operating biases .

[0012] . According to a further aspect , in order to ensure the correct axial positioning of the support pin and elastic element assembly, the pad support pins of known type are machined to have a pin abutment portion which, when the support pin has reached its maximum axial insertion position, axially abuts against the caliper body, and the expanding elastic element , forming a radial seal with the caliper body, prevents the unwanted release of the support pin from the caliper body .

[0013] . The pad support pins are machined in different manners to obtain different pin abutment portions according to the type of caliper body on which they must be mounted, e . g . , on monobloc caliper bodies or on caliper bodies having two caliper half-bodies assembled together . Consistently, the caliper body seat s in which the pin tip and the pin head are accommodated, respectively, have different shapes according to the type of caliper body .

[0014] . Some types of pad support pins have , at the pin tip end, a pin abutment portion, i . e . , a shoulder, having a larger radial dimension than a pin tip end portion with small diameter, so that it abut s against the caliper body when the pin is inserted into the caliper body, reaching it s maximum axial insertion position .

[0015] . In other types of pad support pins , the pin portion in which the annular seat is obtained, in which the elastic element is arranged, has a larger radial dimension than the rest of the pin and thus has, in the direction of the pin tip, a pin fitting shoulder shaped to abut against a caliper body seat shoulder so that it abuts against the caliper body when the pin is inserted into the caliper body, reaching its maximum axial insertion position . In such a case, the caliper body seat accommodating the pin portion in which the annular seat is obtained usually comprises a first cylindrical portion and a second cylindrical portion having different diameters , which are connected by the shoulder of the caliper body seat .

[0016] . Although such pad support pins and the corresponding elastic elements meet the needs of obtaining simple assembly and easy maintenance, it has been found that the mechanical operations for defining the pin abutment portions make the manufacturing of the support pins particularly complex and have a significant impact on the final cost and proces sing time .

[0017] . Therefore, the need is strongly felt in the field to make pad support pins which are easy to manufacture and which allow reducing the production costs per piece, while allowing the standardization of the geometry of the pins for different types of calipers , thus further facilitating the processes of assembling such assemblies in respective caliper bodies .

[0018] . Therefore, the problem underlying the present invention is to devise a caliper body, pin and elastic element assembly, as well as a brake caliper, a pin as sembly, a caliper body, and a method for assembling a pad support pin in a caliper body of a vehicle, which have structural and functional features to meet the aforesaid needs while solving the drawbacks mentioned with reference to the prior art and meet the aforesaid needs .

[0019] . Solution

[0020] . It is the obj ect of the present invention to provide a caliper body, as well as a brake caliper, as well as a caliper and caliper support assembly, as well as a method of assembling a pad support pin in a caliper body of a vehicle, which are easy to manufacture and obtain while allowing easy maintenance and assembly, as well as the highest certainty for the pin not to accidentally come out of its seat when using the brake caliper .

[0021] . This and other obj ects and advantages are achieved by a caliper body according to claim 1 , as well as a brake caliper according to claim 9, as well as an assembly according to claim 8, as well as a caliper body according to claim 20, as well as a method of mounting a pad support pin in a caliper body of a vehicle according to claim 21 .

[0022] . Some advantageous embodiment s are the sub ject of the dependent claims .

[0023] . The analysis of this solution shows how the suggested solution allows simplifying the machining of the support pins while maintaining an easy, correct positioning of the support pin inside the caliper body .

[0024] . Moreover, the suggested solution reduces manufacturing cost s by reducing the pin portions which must be machined after drawing .

[0025] . Furthermore, the suggested solutions allow standardizing the different types of pins and the different types of pin seats made in the caliper body, further reducing manufacturing costs and simplifying the as sembly operations .

[0026] . Moreover, the suggested solutions allow ensuring the highest certainty for the pin not to be accidentally removed from its seat during use .

[0027] . Drawings

[0028] . Further features and advantages of the caliper body, brake caliper, assembly and assembly method are given by way of a nonlimiting example, with reference to the accompanying drawings , in which :

[0029] . - Figure 1 shows an axonometric view of a brake caliper mounted on a caliper support ;

[0030] . - Figure 2 shows an axonometric view, in separate parts, of the assembly in Figure 1 ;

[0031] . - Figure 3 shows an axonometric view, in separate parts, of the assembly in Figure 1 , according to a different point of view;

[0032] . - Figure 4 shows an axonometric view of a brake caliper according to the invention;

[0033] . - Figure 5 shows an axonometric view of a caliper body according to the invention;

[0034] . - Figure 6 shows a front view of the caliper body in Figure 5 ;

[0035] . - Figure 7 shows an axonometric view sectioned by a plane directed according to the radial and axial direction passing through the pin seat , of the brake caliper in Figure 4 in which a connecting screw is mounted;

[0036] . - Figure 8 shows an axonometric view, sectioned by a plane directed according to the radial and axial direction passing through the pin seat, of the brake caliper in Figure 4 in which the connecting screw is removed from its seat and the pin is removed from its seat ;

[0037] . - Figure 9 shows an axonometric view, sectioned by a plane passing through the circumferential and radial direction, of the caliper in Figure 4 in which a connecting screw is inserted;

[0038] . Figure 10 shows an axonometric view, sectioned by a plane passing through the circumferential and radial direction, of the caliper in Figure 4 in which a connecting screw is inserted, according to a dif ferent point of view;

[0039] . - Figure 11 shows an axonometric view of the as sembly of the brake pads , pad spring, brake-pad sliding and support pin and connecting screw depicted in operating position;

[0040] . - Figures 12 and 13 show an axonometric view of the caliper in Figure 4 , sectioned according to a plane pas sing through the radial and axial direction in which two pin disassembly steps are depicted, first removing the connecting screw and then removing the pin;

[0041] . - Figures 14 , 15 and 1 6 show an axonometric view of a portion of the caliper in Figure 4 , in three steps of mounting a pin, first including the insertion of the pin into its seat and then the insertion of the connecting screw into its seat so as to obstruct the removal path of the pin .

[0042] . Description of some preferred embodiments

[0043] . According to a general embodiment , a caliper body 1 of a brake caliper 2 is adapted to house thrust means 3 for urging opposing brake pads 4 against opposite braking surfaces 24 , 25 of a brake disc 26 on which said caliper body 1 is adapted to be arranged astride .

[0044] . Said brake disc 26 defines an axial direction A-A parallel to or coincident with a rotation axis X-X of said brake disc 26, a radial direction R-R orthogonal to said rotation axis X-X, and a circumferential direction C-C which, in each intersection point between said axial direction A-A and said radial direction R-R, is orthogonal to both said axial direction A-A and said radial direction R-R.

[0045] . Said caliper body 1 comprises at least one screw seat 5 to accommodate a connecting screw 6 for connecting the caliper body 1 to a caliper support 7 .

[0046] . Said screw seat 5 extends along a screw seat direction S- S .

[0047] . Said connecting screw 6 comprises a screw head 8 to support and tighten the connecting screw 6 and connect said caliper body 1 to said caliper support 7 .

[0048] . Said at least one screw seat 5 is surrounded by a screw head support surface 9 adapted to support said screw head 8 and tighten said connecting screw 6 .

[0049] . Said screw head support surface 9 defines a first screw head support surface extension 12 directed along said screw seat direction S-S .

[0050] . Said caliper body 1 comprises at least one pin seat 10 adapted to accommodate a brake-pad sliding and support pin 11 . Said pin 11 is adapted to support and allow the sliding of opposing brake pads 4 . Said pin 11 is extractable to allow the disassembly and replacement of the brake pads 4 when they are worn, for example .

[0051] . Said at least one pin seat 10 extends along a pin seat direction P-P .

[0052] . Said at least one pin seat 10 defines a second pin seat extension 13 directed along said pin seat direction P-P .

[0053] . Said first screw head support surface extension 12 intersects said second pin seat extension 13 .

[0054] . By virtue of the intersection between the first screw head support surface extension 12 and the second pin seat extension 13, certainty can be doubled and it is possible to ensure that the pin 11 does not to come out of its pin seat 10 during the operation of the brake caliper 2 . In particular, the invention provides that the function of ensuring that the pin 11 does not come out of its seat 10 is performed by the connecting screw 6 connecting the caliper body 1 to the vehicle . [0055] . According to an embodiment, the pin seat 10 , on the side opposite to the connecting screw 6, includes a narrowing to allow a widened portion of said pin 11 to abut in its seat and prevent it from coming out of the side of the caliper body opposite to said connecting screw 6 .

[0056] . According to an embodiment , said at least one pin seat 10 opens towards and seamlessly faces said first screw head support surface extension 12 so that when said connecting screw 6 is not accommodated in said at least one screw seat 5 , said at least one pin seat 10 can be freely accessed.

[0057] . According to an embodiment, said at least one screw seat 5 defines a third screw seat extension 14 directed along said screw seat direction S-S .

[0058] . Said third screw seat extension 14 intersects said second pin seat extension 13 .

[0059] . According to an embodiment , said at least one pin seat 10 is an at least partially cylindrical seat .

[0060] . Said at least one screw seat 5 is an at least partially cylindrical seat .

[0061] . According to an embodiment , said screw head support surface 9 is an annular crown .

[0062] . According to an embodiment , said screw head support surface 9 is obtained in a flattened caliper body portion 15 formed in said caliper body 1 and which forms at least one flattened portion side wall 16, for example resting on a cylindrical extension, which at least partially surrounds said screw head support surface 9 .

[0063] . According to an embodiment , looking transversely to a circumferential C-C and radial R-R plane ( see Figure 6) , the mouth of said at least one pin seat 10 is completely visible without obstructions of portions or component s of the caliper body 1 . Access to the pin seat 10 is thus free for said pin 11 when the connecting screw 6 is removed, but is impossible when the connecting screw 6 is in its screw seat 5, thus blocking the pin 11 in its pin seat 10 .

[0064] . According to an embodiment , said caliper body 1 is a body made in one piece forming three connection bridges 30 , 31 , 32 which connect two opposite elongated elements 35 , 36, in each of which two seat s 22 , 23 for thrust means 3 are obtained .

[0065] . According to an embodiment , said screw seat direction S-S is a radial direction R-R or a direction parallel to a radial direction R-R, preferably the radial direction R-R passing through the centerline of the caliper body 1 or through the thrust center of one of the brake pads 4 .

[0066] . Said pin seat direction P-P is an axial direction A-A or a direction parallel to an axial direction A-A.

[0067] . The present invention also relates to a brake caliper 2 comprising a caliper body 1 according to any one of the embodiments described above . Opposing brake pads 4 elastically biased by at least one pad spring 17 are accommodated in said brake caliper 2 .

[0068] . Said pads are supported by and slide on at least one brake-pad sliding and support pin 11 .

[0069] . According to an embodiment, said pad spring 17 elastically biases said brake-pad sliding and support pin 11 with an elastic action, for example, an elastic action directed in the radial R-R and/or circumferential C-C direction .

[0070] . According to an embodiment , said brake-pad sliding and support pin 11 comprises an annular pin seat 18 .

[0071] . Said pad spring 17 comprises a spring portion 19, or tab, at least partially inserted into said annular pin seat 18 so as to counteract exces sive movements of said brake-pad sliding and support pin 11 along the axial direction A-A.

[0072] . According to an embodiment , at least one connecting screw 6 connects said caliper body 1 to a caliper support 7 .

[0073] . According to an embodiment, said connecting screw 6 is a screw stud .

[0074] . According to an embodiment , said connecting screw 6 comprises a screw head 8 .

[0075] . Said screw head 8 comprises a screw head support and tightening surface 21 which rests against said screw head support surface 9 when the screw is tightened . The screw head 8 thus at least partially intersect s said second pin seat extension 13 .

[0076] . According to an embodiment, said screw head 8 comprises grip surfaces 22 for maneuvering said connecting screw 6 .

[0077] . According to an embodiment , said connecting screw 6 comprises a screw shank 20 for the connection with said screw seat 5 and with a caliper support screw seat 23 provided in said caliper support 7 .

[0078] . According to an embodiment, said pad spring 17 is connected to the caliper body 1 and biases said brake pads resting on said caliper body 1 in a circumferential direction C-C and away from the brake disc 26 in the axial direction A-A.

[0079] . According to an embodiment , said brake pads 4 each comprise a support plate 27 .

[0080] . Said support plate 27 comprises a support arm 28 for supporting said support plate 27 on the pad surface 2 9 provided in said caliper body 1 .

[0081] . According to an embodiment , said pad surface 2 9 faces said brake pads 4 and protrudes from an end bridge 30 .

[0082] . According to an embodiment , said brake pads 4 each comprise a support plate 27 .

[0083] . Said support plate 27 comprises a support fork 33 placed astride said brake-pad sliding and support pin 11 .

[0084] . According to an embodiment , said caliper body 1 comprises plate support elements 34 which are directed radially R-R or according to a direction parallel to a radial direction R-R, for example, passing through the centerline or pressure center of the brake pad 4 , adapted to support the support plates 27 and to react to the braking action .

[0085] . The present invention also relates to a brake caliper assembly comprising a brake caliper 2 according to any one of the embodiments described above, and to a caliper support 7 .

[0086] . Said caliper support 7 comprises at least one caliper support screw seat 23 for accommodating a screw shank 20 of a connecting screw 6 which connects said caliper body 1 to said caliper support 7 .

[0087] . The present invention also relates to a method of mounting brake pads 4 in a caliper body 1 .

[0088] . This method comprises at least the following steps :

[0089] . - providing a brake caliper 2 as defined in any one of the embodiments described above ;

[0090] . - with the caliper body 1 disassembled, connecting said pad spring 17 to said caliper body 1 ;

[0091] . - with the caliper body 1 disassembled, inserting the brake pads 4 into the caliper body 1 so as to engage the support arm 28 thereof to said pad surface 29 ;

[0092] . - inserting said brake-pad sliding and support pin 11 into said pin seat 10 by positioning the support forks 33 astride said pin 11 and at least partially inserting said spring portion 1 9 into said annular pin seat 18 ;

[0093] . - inserting said connecting screw 6 into said screw seat

5 , thus at least partially obstructing access to said pin 18 so that the screw head 8 at least partially intersects said second pin seat extension 13 .

LIST OF REFERENCE SIGNS

1 caliper body

2 brake caliper

3 thrust means

4 brake pad

5 screw seat

6 connecting screw

7 caliper support

8 screw head

9 screw head support surface

10 pin seat

11 brake-pad sliding and support pin

12 first screw head support surface extension

13 second pin seat extension

14 third screw seat extension

15 flattened caliper body portion

16 flattened portion side wall

17 pad spring

18 annular pin seat

19 spring portion or tab

20 screw shank

21 screw head support and tightening surface

22 grip surfaces

23 caliper support screw seat

24 braking surface

25 braking surface

26 brake disc

27 support plate

28 support arm

29 pad surface

30 end bridge

31 intermediate bridge

32 end bridge 33 support fork

34 plate support element

35 elongated caliper body element

36 elongated caliper body element

A-A axial direction

X-X rotation axis

R-R radial direction

C-C circumferential direction

P-P pin seat direction

S-S screw seat direction