Patent Application
20150377310
This patent application relates to a brake assembly having a bracket assembly that may be bonded with an adhesive.
A bracket for a vehicle brake assembly is disclosed in U.S. Pat. No. 5,649,612.
In at least one embodiment, a brake assembly is provided. The brake assembly may receive a camshaft for actuating a brake pad assembly. The bracket assembly may include a camshaft tube and a mounting flange. The camshaft tube may extend along an axis and may have a first tube end and a second tube end disposed opposite the first tube end. The mounting flange may be disposed proximate the first tube end. The mounting flange may be attached to the camshaft tube with an adhesive that may be disposed between the mounting flange and the camshaft tube. The mounting flange and the camshaft tube may cooperate to define a hole that receives the camshaft.
In at least one embodiment, a brake assembly is provided. The brake assembly may receive a camshaft for actuating a brake pad assembly. The bracket assembly may include a camshaft tube and a brake wing. The camshaft tube may extend along an axis and may have a first tube end and a second tube end disposed opposite the first tube end. The brake wing may be disposed proximate the second tube end. The brake wing may be attached to the camshaft tube with an adhesive that may be disposed between the brake wing and the camshaft tube. The brake wing and the camshaft tube may cooperate to define a hole that receives the camshaft.
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
Referring to
The brake assembly 10 may be a friction brake that may be configured to slow or inhibit rotation of at least one associated wheel. In
The spider 20 may support various components of the brake assembly 10. In addition, the spider 20 may facilitate mounting of the brake assembly 10 to the vehicle. For example, the spider 20 may be fixedly disposed on or fixedly positioned with respect to an axle assembly or a steering knuckle. In at least one embodiment, the spider 20 may include a hole 40 through which an axle and/or a spindle may extend. For example, a spindle may extend through the hole 40 and may support one or more wheel bearings that may support and facilitate rotation of a wheel assembly. The spider 20 may also include at least one anchor pin hole 42, at least one spider mounting hole 44, and a camshaft opening 46.
The anchor pin hole 42 may receive an anchor pin 50 that facilitates mounting and operation of a brake pad assembly 22 will be discussed in more detail below. In the embodiment shown, two anchor pin holes 42 are provided that are generally disposed opposite the bracket assembly 24. Each anchor pin hole 42 may receive a different anchor pin 50 and each anchor pin 50 may support a different brake pad assembly 22.
A spider mounting hole 44 may facilitate mounting of the spider 20 to the vehicle. In
The camshaft opening 46 may receive the camshaft 26 and optionally a portion of the bracket assembly 24. The camshaft 26 may extend through the camshaft opening 46 to engage one or more brake pad assemblies 22.
One or more brake pad assemblies 22 may be disposed proximate the spider 20. In
The brake shoe 60 may be a structural member of a brake pad assembly 22. The brake shoe 60 may be pivotally mounted to the spider 20 at a first end via the anchor pin 50. For example, the anchor pin 50 may be fixedly positioned with respect to the spider 20 and the brake shoe 60 may pivot about an outer surface or circumference of the anchor pin 50 when the brake pad assembly 22 is actuated. An opposite end of the brake shoe 60 may have a cam roller that may be configured to engage a cam of the camshaft 26.
The friction material 62, which may also be called a brake lining, may be disposed on an outer surface of the brake shoe 60 and may face toward the brake drum. The friction material 62 may engage the brake drum during vehicle braking and may be spaced apart from the brake drum when the friction braking is not being applied.
Referring to
The mounting flange 70 may facilitate mounting of the bracket assembly 24 to the spider 20. The mounting flange 70 may be spaced apart from the brake wing 72 and may be fixedly coupled to the camshaft tube 74 with an adhesive as will be discussed in more detail below. In at least one embodiment, the mounting flange 70 may have a mounting flange body 80 and a flange portion 82.
The mounting flange body 80 may have a generally tubular configuration and may define a portion of the hole 76 through which the camshaft 26 may extend. The mounting flange body 80 may have an interior surface 84, which is best shown in
The flange portion 82 may be configured to be mounted to the spider 20. The flange portion 82 may extend outwardly from the mounting flange body 80 and may be integrally formed with the mounting flange body 80 in one or more embodiments. For example, the mounting flange body 80 and flange portion 82 may be cast as a unitary one-piece component. The flange portion 82 may include at least one mounting hole that may be aligned with a corresponding mounting hole on the spider 20. The mounting hole may receive a fastener 86 that may couple the mounting flange 70 to the spider 20 as is best shown in
The brake wing 72 may be coupled to the camshaft tube 74 and may support the actuator 30. The brake wing 72 may be spaced apart from the spider 20 and may be fixedly coupled to the camshaft tube 74 opposite the mounting flange 70. In at least one embodiment, the brake wing 72 may include a brake wing body 90 and a brake wing flange portion 92.
The brake wing body 90 may have a generally tubular configuration and may define a portion of the hole 76 through which the camshaft 26 may extend. The brake wing body 90 may have an interior surface 94, which is best shown in
The portion of the hole 76 in the brake wing body 90 may receive various components in addition to the camshaft 26. For example, the portion of the hole 76 in the brake wing body 90 may receive a bearing, bushing, and/or one or more seals like those previously described.
The brake wing flange portion 92 may be configured to support the actuator 30. The brake wing flange portion 92 may extend outwardly from the brake wing body 90 and may be integrally formed with the brake wing body 90 in one or more embodiments. For example, the brake wing body 90 and brake wing flange portion 92 may be cast as a unitary one-piece component. The brake wing flange portion 92 may include one or more actuator mounting holes and an actuator shaft opening. Each actuator mounting hole may receive a fastener that may couple the actuator 30 to the brake wing 72.
The camshaft tube 74 may extend from the mounting flange 70 to the brake wing 72. The camshaft tube 74 may have a generally tubular configuration and may define a portion of the hole 76 through which the camshaft 26 may extend. For instance, the camshaft tube 74 may extend along the axis 78 and may have an inner surface 100 and an outer surface 102 as is best shown in
The camshaft tube 74 may interconnect the mounting flange 70 and/or the brake wing 72 in various configurations as will be described in more detail below. Moreover, the mounting flange 70 or the brake wing 72 may be integrally formed with the camshaft tube 74 or may have a unitary one-piece configuration with the camshaft tube 74 in one or more embodiments.
Referring to
The slack adjuster 28 may be provided to compensate for brake wear or wear of the friction material 62. The slack adjuster 28 may be fixedly disposed near the second end of the camshaft 26. For example, the slack adjuster 28 may have a mounting hole that may receive the camshaft 26. The slack adjuster 28 may be coupled to the camshaft 26 in any suitable manner. For instance, the mounting hole of the slack adjuster 28 and the camshaft 26 may have mating splines that may help couple the slack adjuster 28 and a camshaft 26 together.
The actuator 30 may be provided to actuate the camshaft 26. The actuator 30 may be of any suitable type, such as a pneumatic, hydraulic, electrical, or electromechanical actuator. The actuator 30 may include an actuator shaft 110 that may extend toward or to the slack adjuster 28. For example, the actuator shaft 110 may extend through the actuator shaft opening in the brake wing 72. The actuator 30 may move between a retracted position and an extended position. In the retracted position, the camshaft 26 may be positioned such that a brake pad assembly 22 does not engage the brake drum to brake or inhibit rotation of an associated vehicle wheel assembly. In the extended position, the actuator 30 may rotate the camshaft 26 and actuate the brake pad assemblies 22 to move toward and engage the brake drum to inhibit rotation of an associated wheel hub assembly. The actuator 30 may be fixedly mounted to the brake wing 72. For example, the actuator 30 may include one or more mounting features 112, such as a threaded mounting stud that may extend through a mounting hole in the brake wing flange portion 92 and that may receive a washer and nut to fixedly couple the actuator 30 to the brake wing 72.
Referring to
Referring to
The mounting flange 70 may have a conical mounting flange surface 132 that may be aligned with the conical surface 130. For example, the conical mounting flange surface 132 may be disposed substantially parallel to the conical surface 130 that is disposed at the first tube end 104 of the camshaft tube 74. As such, the conical surface 130 and the conical mounting flange surface 132 may both be disposed at a non-perpendicular angle with respect to the axis 78. Such angular positioning may help distribute load forces, such as normal load forces that may otherwise weaken or shear the adhesive 120 or chemical bonds between the adhesive 120 and the mounting flange 70 and/or the camshaft tube 74. As such, a more durable bracket assembly 24 may be provided as compared to a design in which the mounting flange 70 and camshaft tube 74 may mate and be adhered solely along flat parallel surfaces that extend substantially perpendicular to the axis 78.
The adhesive 120 may be disposed between the mounting flange 70 and the camshaft tube 74. In addition, the conical surface 130 and the conical mounting flange surface 132 may cooperate to define an adhesive channel 134. The adhesive channel 134 may extend continuously around the axis 78 and may receive the adhesive 120. The adhesive channel 134 may be configured as a groove or indentation that may be provided in the conical surface 130 and the conical mounting flange surface 132. The adhesive channel 134 may be filled with the adhesive 120 and may create a mechanical joint when the adhesive 120 solidifies in addition to the chemical bond provided by the adhesive 120. As such, the adhesive channel 134 may help retain the adhesive 120 and distribute load forces against the mounting flange 70 and camshaft tube 74 in a manner that inhibits shearing of the adhesive 120 or disengagement of the mounting flange 70 from the camshaft tube 74. In one or more embodiments, the adhesive 120 may be locally positioned in the adhesive channel 134 such that the adhesive 120 does not completely separate the mounting flange 70 from the camshaft tube 74. Alternatively, the adhesive 120 may be positioned in the adhesive channel 134 and may extend along regions of the conical surface 130 and the conical mounting flange surface 132 that are disposed adjacent to the adhesive channel 134. As such, the adhesive 120 may engage and bond to the conical surface 130 and the conical mounting flange surface 132 such that the adhesive 120 may be disposed between and may partially or completely separate the conical surface 130 from the conical mounting flange surface 132. It is also contemplated that the adhesive channel 134 may be omitted in one or more embodiments.
The brake wing 72 may have a conical brake wing surface 136 that may be aligned with a conical surface 130. For example, the conical brake wing surface 136 may be disposed substantially parallel to the conical surface 130 that is disposed at the second tube end 104 of the camshaft tube 74. As such, the conical surface 130 and the conical brake wing surface 136 may both be disposed at a non-perpendicular angle with respect to the axis 78. Such angular positioning may help distribute load forces, such as normal load forces that may otherwise shear the adhesive or chemical bonds between the adhesive and the mounting flange 70 and/or the camshaft tube 74 and improve durability as previously discussed.
The adhesive 120 may be disposed between the brake wing 72 and the camshaft tube 74. The conical surface 130 and the conical brake wing surface 136 may cooperate to define an adhesive channel 138. The adhesive channel 138 may continuously extend around the axis 78 and may receive the adhesive 120. The adhesive channel 138 may be configured as a groove or indentation that may be provided in the conical surface 130 and the conical brake wing surface 136. The adhesive channel 138 may be filled with the adhesive 120 and may create a mechanical joint when the adhesive 120 solidifies in addition to the chemical bond provided by the adhesive 120. As such, the adhesive channel 138 may help retain the adhesive 120 and distribute load forces against the brake wing 72 and camshaft tube 74 in a manner that inhibits shearing of the adhesive 120 or disengagement of the brake wing 72 from the camshaft tube 74. In one or more embodiments, the adhesive 120 may be locally positioned in the adhesive channel 138 such that the adhesive 120 does not completely separate the brake wing 72 from the camshaft tube 74. Alternatively, the adhesive 120 may be positioned in the adhesive channel 138 and may extend along regions of the conical surface 130 and the conical brake wing surface 136 that are disposed adjacent to the adhesive channel 138. As such, the adhesive 120 may engage and bond to the conical surface 130 and the conical brake wing surface 136 such that the adhesive 120 may be disposed between and may partially or completely separate the conical surface 130 from the conical brake wing surface 136. It is also contemplated that the adhesive channel 138 may be omitted in one or more embodiments.
Referring to
The mounting flange 70 may be configured to mate with the first tube end 104 of the camshaft tube 74. For example, the conical mounting flange surface 132 may be aligned with and may be disposed substantially parallel to the conical surface 130 that is disposed at the first tube end 104. As such, the conical surface 130 and the conical mounting flange surface 132 may both be disposed at a non-perpendicular angle with respect to the axis 78. The mounting flange 70 may also have a first mounting flange step surface 150 and a second mounting flange step surface 152. The first mounting flange step surface 150 may extend from the interior surface 84 to a first end of the conical mounting flange surface 132 and may be disposed substantially perpendicular to the axis 78. The second mounting flange step surface 152 may extend from a second end of the conical mounting flange surface 132 to or toward an outer surface of the mounting flange 70. The second mounting flange step surface 152 may be disposed substantially perpendicular to the axis 78 and may be offset from the first mounting flange step surface 150 such that the first mounting flange step surface 150 and the second mounting flange step surface 152 are not coplanar.
The adhesive 120 may be disposed between the mounting flange 70 and the camshaft tube 74. The conical surface 130 and the conical mounting flange surface 132 may cooperate to define an adhesive channel 134 as previously described. The adhesive 120 may be locally positioned in the adhesive channel 134 such that the adhesive 120 does not completely separate the mounting flange 70 from the camshaft tube 74. Alternatively, the adhesive 120 may be positioned in the adhesive channel 134 and may extend along regions of the conical surface 130 and the conical mounting flange surface 132 that are disposed adjacent to the adhesive channel 134 and/or along the first mounting flange step surface 150 and the second mounting flange step surface 152 and may partially or completely separate the mounting flange 70 from the camshaft tube 74. It is also contemplated that the adhesive channel 134 may be omitted in one or more embodiments.
The brake wing 72 may be configured to mate with the second tube end 104 of the camshaft tube 74. For example, the conical brake wing surface 136 may be aligned with and may be disposed substantially parallel to the conical surface 130 that is disposed at the second tube end 104. As such, the conical surface 130 and the conical brake wing surface 136 may both be disposed at a non-perpendicular angle with respect to the axis 78. The brake wing 72 may also have a first brake wing step surface 160 and a second brake wing step surface 162. The first brake wing step surface 160 may extend from the interior surface 94 to a first end of the conical brake wing surface 136 and may be disposed substantially perpendicular to the axis 78. The second brake wing step surface 162 may extend from a second end of the conical brake wing surface 136 to or toward an outer surface of the brake wing 72. The second brake wing step surface 162 may be disposed substantially perpendicular to the axis 78 and may be offset from the first brake wing step surface 160 such that the first brake wing step surface 160 and the second brake wing step surface 162 are not coplanar.
The adhesive 120 may be disposed between the brake wing 72 and the camshaft tube 74. The conical surface 130 and the conical brake wing surface 136 may cooperate to define an adhesive channel 138 as previously described. The adhesive 120 may be locally positioned in the adhesive channel 138 such that the adhesive 120 does not completely separate the brake wing 72 from the camshaft tube 74. Alternatively, the adhesive 120 may be positioned in the adhesive channel 138 and may extend along regions of the conical surface 130 and the conical brake wing surface 136 that are disposed adjacent to the adhesive channel 138 and/or along the first brake wing step surface 160 and the second brake wing step surface 162 and may partially or completely separate the brake wing 72 from the camshaft tube 74. It is also contemplated that the adhesive channel 138 may be omitted in one or more embodiments.
Referring to
The mounting flange 70 may be configured to mate with the first tube end 104 of the camshaft tube 74. The mounting flange 70 may have a first mounting flange step surface 150, a second mounting flange step surface 152, and a mounting flange connecting surface 172. The first mounting flange step surface 150 may extend from the interior surface 84 to a first end of the mounting flange connecting surface 172 and may be disposed substantially perpendicular to the axis 78. The second mounting flange step surface 152 may extend from a second end of the mounting flange connecting surface 172 to or toward an outer surface of the mounting flange 70. The second mounting flange step surface 152 may be disposed substantially perpendicular to the axis 78 and may be offset from the first mounting flange step surface 150 as previously discussed. The mounting flange connecting surface 172 may be disposed substantially parallel to the axis 78 in one or more embodiments. In addition, the mounting flange connecting surface 172 may be disposed substantially parallel to the connecting surface 170.
The adhesive 120 may be disposed between the mounting flange 70 and the camshaft tube 74. The connecting surface 170 and the mounting flange connecting surface 172 may cooperate to define an adhesive channel 134 as previously described. The adhesive 120 may be locally positioned in the adhesive channel 134 such that the adhesive 120 does not completely separate the mounting flange 70 from the camshaft tube 74. Alternatively, the adhesive 120 may be positioned in the adhesive channel 134 and may extend along regions of the connecting surface 170 and the mounting flange connecting surface 172 that are disposed adjacent to the adhesive channel 134 and/or along the first mounting flange step surface 150 and the second mounting flange step surface 152 and may completely separate the mounting flange 70 from the camshaft tube 74. It is also contemplated that the adhesive channel 134 may be omitted in one or more embodiments.
The brake wing 72 may be configured to mate with the second tube end 104 of the camshaft tube 74. The brake wing 72 may have a first brake wing step surface 160, a second brake wing step surface 162, and a brake wing connecting surface 174. The first brake wing step surface 160 may extend from the interior surface 94 to a first end of the brake wing connecting surface 174 and may be disposed substantially perpendicular to the axis 78. The second brake wing step surface 162 may extend from a second end of the brake wing connecting surface 174 to or toward an outer surface of the brake wing 72. The second brake wing step surface 162 may be disposed substantially perpendicular to the axis 78 and may be offset from the first brake wing step surface 160 as previously discussed. The brake wing connecting surface 174 may be disposed substantially parallel to the axis 78 in one or more embodiments. In addition, the brake wing connecting surface 174 may be disposed substantially parallel to the connecting surface 170.
The adhesive 120 may be disposed between the brake wing 72 and the camshaft tube 74. The connecting surface 170 and the brake wing connecting surface 174 may cooperate to define an adhesive channel 138 as previously described. The adhesive 120 may be locally positioned in the adhesive channel 138 such that the adhesive 120 does not completely separate the brake wing 72 from the camshaft tube 74. Alternatively, the adhesive 120 may be positioned in the adhesive channel 138 and may extend along regions of the connecting surface 170 and the brake wing connecting surface 174 that are disposed adjacent to the adhesive channel 138 and/or along the first brake wing step surface 160 and the second brake wing step surface 162 and may completely separate the brake wing 72 from the camshaft tube 74. It is also contemplated that the adhesive channel 138 may be omitted in one or more embodiments.
Referring to
The mounting flange 70 may be configured to mate with the first tube end 104 of the camshaft tube 74. The mounting flange 70 may have a first mounting flange step surface 150 and a mounting flange connecting surface 172. The first mounting flange step surface 150 may extend from the interior surface 84 to a first end of the mounting flange connecting surface 172 and may be disposed substantially perpendicular to the axis 78. The mounting flange connecting surface 172 may be disposed substantially parallel to the axis 78 and the outer surface 102. As such, the mounting flange connecting surface 172 may extend continuously around the outer surface 102 and may be configured as a socket that may receive the first tube end 104 of the camshaft tube 74. As such, the mounting flange connecting surface 172 may be disposed outward from the outer surface 102 or further from the axis 78 than the outer surface 102 in one or more embodiments.
The adhesive 120 may be disposed between the outer surface 102 and the mounting flange connecting surface 172. In addition, the outer surface 102 and the mounting flange connecting surface 172 may cooperate to define an adhesive channel 134. The adhesive 120 may be locally positioned in the adhesive channel 134 such that the adhesive 120 does not completely separate the mounting flange 70 from the camshaft tube 74. Alternatively, the adhesive 120 may be positioned in the adhesive channel 134 and may extend along regions of the outer surface 102 and the mounting flange connecting surface 172 that are disposed adjacent to the adhesive channel 134 and/or between the first mounting flange step surface 150 and the first tube end surface 180. As such, the adhesive 120 may partially or completely separate the mounting flange 70 from the camshaft tube 74. It is also contemplated that the adhesive channel 134 may be omitted in one or more embodiments.
The brake wing 72 may be configured to mate with the second tube end 104 of the camshaft tube 74. The brake wing 72 may have a first brake wing step surface 160 and a brake wing connecting surface 174. The first brake wing step surface 160 may extend from the interior surface 94 to a first end of the brake wing connecting surface 174 and may be disposed substantially perpendicular to the axis 78. The brake wing connecting surface 174 may be disposed substantially parallel to the axis 78 and the outer surface 102. As such, the brake wing connecting surface 174 may extend continuously around the outer surface 102 and may be configured as a socket that may receive the second tube end 104 of the camshaft tube 74. As such, the brake wing connecting surface 174 may be disposed outward from the outer surface 102 or further from the axis 78 than the outer surface 102 in one or more embodiments.
The adhesive 120 may be disposed between the outer surface 102 and the brake wing connecting surface 174. In addition, the outer surface 102 and the brake wing connecting surface 174 may cooperate to define an adhesive channel 138. The adhesive 120 may be locally positioned in the adhesive channel 138 such that the adhesive 120 does not completely separate the brake wing 72 from the camshaft tube 74. Alternatively, the adhesive 120 may be positioned in the adhesive channel 138 and may extend along regions of the outer surface 102 and the brake wing connecting surface 174 that are disposed adjacent to the adhesive channel 138 and/or between the first brake wing step surface 160 and the second tube end surface 182. As such, the adhesive 120 may partially or completely separate the brake wing 72 from the camshaft tube 74. It is also contemplated that the adhesive channel 138 may be omitted in one or more embodiments.
The bracket assembly may be manufactured in the following manner. First, the components of the bracket assembly may be provided and the mating surfaces may be machined as needed to provide compatible mating surfaces. The bracket assembly components, such as the mounting flange, the brake wing, and the camshaft tube may be made of an aluminum alloy using any suitable technique, such as casting, extruding, or forging. Providing components made of an aluminum alloy may provide significant weight savings as compared to other materials like steel, thereby helping reduce vehicle weight and improve vehicle fuel economy. Unfortunately, components made from aluminum alloys may be difficult to weld together and the heat that is applied during welding may reduce the strength of the aluminum alloy proximate the weld, thereby reducing the strength and durability of the assembly. Next, the adhesive may be applied to at least one part, such as by spraying or applying a bead of adhesive to at least one mating surface. The use of an adhesive may eliminate welding and the associated reduction in strength caused by high welding temperatures. The parts may then be aligned and assembled such that the adhesive may bond the individual parts together and form the brake assembly. In addition, the parts may be held together under pressure and the adhesive may be allowed to cure or harden to join the individual parts. The bracket assembly may then undergo subsequent manufacturing and assembly steps with other components to help create the brake assembly.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.
