This disclosure relates to a brake assembly that has a bridge.
A brake assembly having a bridge that lacks through holes near a retainer bracket mounting feature is disclosed in U.S. Pat. No. 8,857,575.
In at least one embodiment, a brake assembly is provided. The brake assembly may include a housing and a bridge. The housing and the bridge may cooperate to define an opening for receiving a brake pad assembly. The bridge may include a first arm and a second arm. The first arm may have a first inner mounting boss and a first outer mounting boss. The first inner mounting boss and the first outer mounting boss may be spaced apart from each other and may be coupled to the housing. The second arm may be spaced apart from the first arm. The second arm may have a second inner mounting boss and a second outer mounting boss. The second inner mounting boss and the second outer mounting boss may be spaced apart from each other and may be coupled to the housing.
The bridge may also include a connecting arm that may extend from the first arm to the second arm. The connecting arm may be spaced apart from the housing and may define a first through hole and a second through hole. The first through hole and the second through hole may be spaced apart from the opening.
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 carrier 20 may be configured to be fixedly mounted to the vehicle. For example, the brake carrier 20 may be mounted to an axle assembly or a steering knuckle, such as with an intermediate component like a torque plate in one or more embodiments. The brake carrier 20 may receive and may support the first brake pad assembly 24 and the second brake pad assembly 26 and may include a rotor opening 40 that may be configured to receive a rotor, also known as a brake disc. As such, the brake carrier 20 may straddle the rotor and help position the first brake pad assembly 24 and the second brake pad assembly 26 on opposite sides of the rotor.
The housing assembly 22 may receive various components of the brake assembly 10. In addition, the housing assembly 22 may facilitate positioning of the first brake pad assembly 24 and the second brake pad assembly 26 with respect to the rotor to facilitate braking of the vehicle. In at least one embodiment, the housing assembly 22 may include a housing 50 and a bridge 52. The housing 50 and the bridge 52 may cooperate to define an opening 54. The opening 54 may receive the first brake pad assembly 24, second brake pad assembly 26, brake pad springs 28, in a portion of the rotor.
The housing 50 may be moveably disposed on the brake carrier 20. For example, the housing 50 may be slidably disposed on a pair of guide pins that may be fixedly disposed on the brake carrier 20. The housing 50 may be associated with or may receive at least one actuator that may actuate the first brake pad assembly 24 and the second brake pad assembly 26 into engagement with the rotor. For example, the actuator may actuate the first brake pad assembly 24 into engagement with the rotor and then move the housing 50 and bridge 52 to actuate the second brake pad assembly 26 toward the rotor. The actuator may have any suitable configuration. For instance, the actuator may include a piston assembly that may be pneumatically, hydraulically, mechanically, electrically, or electromechanically actuated in one or more embodiments. The piston assembly may move along an axis toward or away from the rotor such that the piston assembly may exert force against a back side of the first brake pad assembly 24.
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The end surface 90 may be disposed at an end of the first inner mounting boss 80. The end surface 90 may face toward and may engage or contact the housing 50. Moreover, the end surface 90 may be the only surface of the first inner mounting boss 80 that engages or contacts the housing 50. The end surface 90 may be substantially planar in one or more embodiments.
The hole 92 may extend from the end surface 90 in a direction that extends toward the connecting arm 74. The hole 92 may receive a fastener, such as a bolt 110 as is best shown in
The outboard surface 94 may face away from the opening 54. In addition, the outboard surface 94 may extend from the first connecting surface 84 to the end surface 90.
The inboard surface 96 may be disposed opposite the outboard surface 94. As such, the inboard surface 96 may face toward the opening 54. The inboard surface 96 may extend from the end surface 90 and may at least partially define part of the opening 54.
The upper surface 98 may face away from the brake carrier 20. In addition, the upper surface 98 may extend from the outboard surface 94 to the inboard surface 96 and may be spaced apart from the first connecting surface 84.
The lower surface 100 may be disposed opposite the upper surface 98. As such, the lower surface 100 may face toward the brake carrier 20. The lower surface 100 may extend from the outboard surface 94 to the inboard surface 96 and may be spaced apart from the first connecting surface 84.
The first outer mounting boss 82 may also facilitate mounting of the first arm 70 to the housing 50. The first outer mounting boss 82 may be completely spaced apart from the first inner mounting boss 80. The first outer mounting boss 82 may be disposed further from the center plane 60 than the first inner mounting boss 80. In addition, the first outer mounting boss 82 may be disposed closer to the brake carrier 20 than the first inner mounting boss 80. The first outer mounting boss 82 may extend generally parallel to the center plane 60 and may include similar features as the first inner mounting boss 80. These features may include an end surface 120, a hole 122, an outboard surface 124, an inboard surface 126, an upper surface 128, and a lower surface 130.
The end surface 120 may be disposed at an end of the first outer mounting boss 82. The end surface 120 may face toward and may engage or contact the housing 50. Moreover, the end surface 120 may be the only surface of the first outer mounting boss 82 that engages or contacts the housing 50. The end surface 120 may be substantially planar and may be coplanar with the end surface 90 of the first inner mounting boss 80 in one or more embodiments.
The hole 122 may extend from the end surface 120 in a direction that extends toward the connecting arm 74. The hole 122 may receive a fastener, such as a bolt 110 as is best shown in
The outboard surface 124 may face away from the opening 54. In addition, the outboard surface 124 may extend from the end surface 120.
The inboard surface 126 may be disposed opposite the outboard surface 124. As such, the inboard surface 126 may face toward the opening 54. The inboard surface 126 may extend from the end surface 120 and may at least partially define part of the opening 54.
The upper surface 128 may face away from the brake carrier 20. The upper surface 128 may extend from the first connecting surface 84 to the end surface 120. In addition, the upper surface 128 may extend from the outboard surface 124 to the inboard surface 126. The upper surface 128 may also be disposed below the lower surface 100 of the first inner mounting boss 80.
The lower surface 130 may be disposed opposite the upper surface 128. As such, the lower surface 100 may face toward the brake carrier 20. The lower surface 130 may extend from the outboard surface 124 to the inboard surface 126 and may be spaced apart from the first connecting surface 84.
The first connecting surface 84 may extend from the first inner mounting boss 80 to the first outer mounting boss 82. The first connecting surface 84 may face toward the housing 50 and may be spaced apart from the housing 50. As such, a void or gap 132 may be provided between the first connecting surface 84 and the housing 50 and between the first inner mounting boss 80 and the first outer mounting boss 82 as is best shown with reference to
The second arm 72 may be disposed opposite the first arm 70. As such, the second arm 72 may extend from the housing 50 to the connecting arm 74. The second arm 72 may be disposed substantially perpendicular to the housing and may be spaced apart from the center plane 60 and the first arm 70. The second arm 72 may have mirror symmetry with the first arm 70. As such, the second arm 72 may include the same features as the first arm 70 in a mirrored arrangement. The main features of the second arm 72 are designated with the same reference numbers as those associated with the first arm 70, but with the addition of a prime symbol (′). For further clarity, features of the first arm 70 that were prefaced with the word “first” above will be prefaced with the word “second” when used in reference to features of the second arm 72. Accordingly, the second arm 72 may include a second inner mounting boss 80′, a second outer mounting boss 82′, and a second connecting surface 84′.
The second inner mounting boss 80′ may extend generally parallel to the center plane 60. The second inner mounting boss 80′ may include an end surface 90, a hole 92, an outboard surface 94, an inboard surface 96, an upper surface 98, and a lower surface 100 as previously discussed.
The second outer mounting boss 82′ may be spaced apart from the second inner mounting boss 80′. The second outer mounting boss 82′ may include an end surface 120, a hole 122, an outboard surface 124, an inboard surface 126, an upper surface 128, and a lower surface 130 as previously discussed.
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The connecting arm mounting boss 140 may facilitate mounting of the retainer bracket 30 as is best shown in
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The first recess bottom surface 160 may be disposed at the bottom of the first recess 142. As is best shown in
The first through hole 144 may be spaced apart from the center plane 60 and the connecting arm mounting boss 140. The first through hole 144 may extend from the first recess bottom surface 160 in a direction that extends away from the first recess 142 to a bottom side of the connecting arm 74. The first through hole 144 may cooperate with the first recess 142 to reduce the weight of the bridge 52, thereby reducing the weight of the brake assembly 10 which may help improve fuel economy. In addition, the first through hole 144 may facilitate drainage from the first recess 142 and may enhance airflow to components of the brake assembly 10. The first through hole 144 may be a feature that is formed in the bridge 52 during casting and may not undergo material removal or machining operations, thereby helping reduce manufacturing costs.
The second recess 142′ may have mirror symmetry about the center plane 60 with respect to the first recess 142. As such, the second recess 142′ may be spaced apart from the center plane 60 and may extend from an opposite side of the connecting arm mounting boss 140 from the first recess 142. Like the first recess 142, the second recess 142′ may extend in a downward direction from the perspective shown in
The second recess bottom surface 160′ may be disposed at the bottom of the second recess 142′. As is best shown in
The second through hole 144′ may have mirror symmetry about the center plane 60 with respect to the first through hole 144. As such, the second through hole 144′ may be spaced apart from the center plane 60 and the connecting arm mounting boss 140. In addition, the second through hole 144′ and the first through hole 144 may be disposed on opposite sides of the center plane 60. The second through hole 144′ may extend from the second recess bottom surface 160′ in a direction that extends away from the second recess 142′ to a bottom side of the connecting arm 74. The second through hole 144′ may cooperate with the second recess 142′ to reduce the weight of the bridge 52, thereby reducing the weight of the brake assembly 10 which may help improve fuel economy. In addition, the second through hole 144′ may facilitate drainage from the second recess 142′ and may enhance airflow to components of the brake assembly 10. The second through hole 144′ may be a feature that is formed in the bridge 52 during casting and may not undergo material removal of machining operations, thereby helping reduce manufacturing costs.
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The backing plate 170 may be a structural member of a brake pad assembly 24, 26. The backing plate 170 may be made of any suitable material, such as a metal or metal alloy. In at least one configuration, the backing plate 170 may include one or more tabs 174. The tabs 174 may facilitate positioning of a corresponding brake pad spring 28. For instance, the tabs 174 may extend through one or more openings in a corresponding brake pad spring 28.
The friction material 172 may be disposed on the backing plate 170. The friction material 172 may face toward the rotor and may engage the rotor during vehicle braking.
A brake pad spring 28 may be provided with the first brake pad assembly 24 and the second brake pad assembly 26. For example, a first brake pad spring 28 may be disposed between the first brake pad assembly 24 and the retainer bracket 30 or between the first brake pad assembly 24 and a pad shield that may be disposed under the retainer bracket 30. As such, the first brake pad spring 28 may extend from the first brake pad assembly 24 to the retainer bracket 30 or the pad shield. A second brake pad spring 28 may be spaced apart from the first brake pad spring 28 and may be disposed between the second brake pad assembly 26 and the retainer bracket 30 or between the retainer bracket 30 and a pad shield. As such, the second brake pad spring 28 may extend from the second brake pad assembly 26 to the retainer bracket or the pad shield. A brake pad spring 28 may exert a biasing force on a corresponding brake pad assembly that may the brake pad assembly against the brake carrier 20 to help position the brake pad assembly.
The retainer bracket 30 may help hold the first brake pad assembly 24 and the second brake pad assembly 26 in the brake carrier 20. The retainer bracket 30 may extend across the opening from the housing 50 to the bridge 52. For example, the retainer bracket 30 may have a first end that may hook onto or may be coupled to the housing 50 and a second end that may be coupled fastened to the bridge 52. The retainer bracket 30 may contact and exert force upon one or more brake pad springs 28 in one or more configurations. Alternatively, retainer bracket 30 may extend across a pad shield that may be disposed in the opening and may be located between the retainer bracket 30 and the first brake pad assembly 24 and the second brake pad assembly 26.
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.