Patent Application
20230095945
Embodiments concern a brake caliper support for a disc brake assembly, in particular for a motor vehicle. Furthermore, such a disc brake assembly is proposed. Moreover, use of the brake caliper support as well as a method for guiding air with a brake caliper support is proposed.
The configuration of a disc brake assembly with a brake disc, a brake caliper holder, and a brake caliper is known to a person of skill in the art. The brake caliper holder connects the brake caliper to a component fixed at the vehicle, for example, a steering knuckle, and serves for dissipating braking forces that are guided during the braking process from the brake pad through the brake caliper holder into the component fixed at the vehicle. The brake caliper itself does not participate in the force flow during the braking process but serves only for generating an axially oriented pressing force on the brake pads.
During a braking process, particles are produced due to abrasion at a brake disc and/or at brake pads. In order to retain these particles, for example, a brake dust particle filter is employed which is arranged downstream of a brake caliper device for a forward rotation direction.
Such a brake dust particle filter is known, for example, from WO 2019/048374 A1. The brake dust particle filter described therein is arranged downstream of the brake caliper support in a rotation direction.
It is an object of the embodiments to achieve a flow optimization in the region of the brake caliper or brake caliper support by means of which an improved reduction of brake dust emissions at the disc brake assemblies results, in particular in combination with a brake dust particle filter.
According to a first embodiment, a brake caliper support for holding a brake caliper of a disc brake assembly with a brake disc in a vehicle is proposed. The brake caliper support comprises:
a first brake caliper support bracket with at least two fastening sections for vehicle-side connection of the brake caliper support to a steering knuckle of the vehicle, wherein the first brake caliper support bracket in the mounted state is positioned opposite a brake disc friction surface of the brake disc;
a brake caliper support bridge which projects away from the first brake caliper support bracket in axial direction and at least partially circumferentially surrounds the brake disc in the mounted state; and
an arc-shaped air guiding element which is present at the first brake caliper support bracket and is positioned axially opposite the brake disc friction surface of the brake disc in the mounted state;
wherein the air guiding element is formed in axial direction in the manner of a protrusion or in the manner of a recess.
Herein, “positioned opposite” is understood as a mutual axial arrangement of the arc-shaped air guiding element and of the brake disc friction surface of the brake disc, wherein this feature however is intended to also expressly encompass embodiments in which the arc-shaped air guiding element is present radially beyond the actual friction surface and in particular is arranged radially inwardly displaced in relation to the friction surface.
The air guiding element can guide the brake dust particle-laden air which is produced during the braking process in such a way in circumferential direction of the brake disc that it is prevented that the air exits from the disc brake assembly in radial direction.
In particular, the air guiding element can guide the air in such a way that the air flow entering a brake dust particle filter arranged downstream of the brake caliper support is optimally oriented in order to be able to separate in this way a quantity of brake dust particles as large as possible.
In general, a larger quantity of particles can be guided into the brake dust particle filter arranged downstream of the disc brake assembly in forward rotation direction and can be separated thereat. In this way, a reduction of brake dust emissions at the disc brake assembly can be achieved.
The brake caliper support in the mounted state can be fastened stationarily at the vehicle or at a vehicle wheel, in particular at the steering knuckle. The steering knuckle is in particular a wheel support which is preferably pivotable. An attachment of the brake caliper support at the vehicle or vehicle wheel can be realized by means of the fastening sections. The fastening sections are configured in this context e.g. as openings through which bolts can be passed for connection to the steering knuckle.
The brake caliper support and the brake caliper can be part of the disc brake assembly. The brake caliper is in particular floatingly supported at the brake caliper support. This floating support enables an axial movement of the brake caliper relative to the brake caliper support and thus to the vehicle. The floating support is achieved in particular by pistons or pins which movably hold the brake caliper at the brake caliper support. The brake caliper comprises preferably at least one brake pad. In the mounted state, the brake caliper support can “frame” the brake caliper.
During a braking process, brake fluid is pressurized and forces by means of a piston of the brake caliper the brake pad of the brake caliper against the brake disc. In this way, a rotation of the brake disc can be slowed and/or stopped.
The first brake caliper support bracket is in particular a section of the brake caliper support that comprises the fastening sections. In the mounted state, the first brake caliper support bracket extends in particular in such a way that it is positioned in parallel opposite the brake disc friction surface.
The brake caliper support bridge extends in particular at an angle to the first brake caliper support bracket. The brake caliper support bridge is projecting, for example, axially away from a radially extending section of the first brake caliper support bracket. That the brake caliper support bridge at least partially circumferentially surrounds the brake disc means in particular that the brake caliper support bridge is positioned opposite a circumferential edge of the brake disc. The brake caliper support bridge and the first brake caliper support bracket can be designed as one piece.
The terms “radial”, “axial”, and “tangential” relate in particular to an orientation in the mounted state (also “mounting state”) in which the brake caliper support is mounted at the steering knuckle. In this case, the orientations “radial”, “axial”, and “tangential” are to be understood in relation to the brake disc, i.e., to the rotation axis of the brake disc. In the unmounted state, “radial”, “axial”, and “tangential” refer to three orientations which differ from each other. Tangential means in particular along the circumferential direction.
The air guiding element is of an arc-shaped configuration. This means in particular that at least one section of the air guiding element does not extend straight. Arc-shaped can also be understood as curved. The air guiding element can extend e.g. along a circular segment section.
The air guiding element can be provided at a surface of the first brake caliper support bracket which is positioned opposite the brake disc in the mounted state. The air guiding element can be embodied as one piece together with the first brake caliper support bracket. When the air guiding element is configured as a protrusion, an axial distance (in the mounted state) between the first brake caliper support bracket and the brake disc can be reduced in the region of the air guiding element. When the air guiding element is embodied as a recess (also “cutout”), an axial distance (in the mounted state) between the first brake caliper support bracket and the brake disc can be increased in the region of the air guiding element.
According to an embodiment, the first brake caliper support bracket comprises a connection section which extends between the two fastening sections as well as a lateral section that connects the connection section to the brake caliper support bridge and extends with a radial orientation component in the mounted state.
The connection section can extend along the tangential direction. The lateral section can be provided at an angle to the connection section. The lateral section extends in particular along the radial direction.
According to a further embodiment, the brake caliper support comprises moreover a second brake caliper support bracket which is positioned opposite the first brake caliper support bracket, wherein the brake caliper support is suitable for receiving 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 and the second brake caliper support bracket to each other.
The brake caliper support can comprise a second brake caliper support bracket which is configured similar to the first brake caliper support bracket and, in the mounted state, is arranged at the other side of the brake disc than the first brake caliper support bracket. It is possible to provide one or a plurality of brake caliper support bridges which connect the brake caliper support brackets to each other.
According to a further embodiment, the air guiding element is arranged at the connection section and/or at the lateral section, wherein the air guiding element extends in particular along an extension direction of the connection section, preferably tangentially, and/or of the lateral section, preferably radially.
That the air guiding element extends along the extension direction of the connection section and/or of the lateral section means in particular that an extension direction of the air guiding element coincides with the extension direction of the connection section and/or of the lateral section.
According to a further embodiment, the air guiding element comprises a rib, which is protruding away from the connection section or away from the lateral section, or a channel-shaped groove in the connection section or in the lateral section.
The rib can be viewed as an example of a protrusion. The rib serves in particular for sealing as well as for guiding the flow. The groove can be an example of the recess. The channel-shaped groove can extend along the flow direction. The groove serves preferably for guiding the flow.
According to a further embodiment, the air guiding element of the connection section comprises a protruding rib and/or the air guiding element of the lateral section comprises a channel-type groove.
Fluidically, it has been found to be particularly advantageous when the air guiding element of the connection section is embodied as a protruding rib and the air guiding element of the lateral section as a channel-shaped groove.
According to a further embodiment, the protrusion is a protrusion away from a surface of the first brake caliper support bracket or the recess is a recess in a surface of the first brake caliper support bracket.
In particular, the protrusion or recess is not provided on a rim of the brake caliper support bracket but in an areal section of the first brake caliper support bracket.
According to a further embodiment, the air guiding element is configured as a protrusion and is arranged axially at a circumferential edge of the first brake caliper support bracket.
The air guiding element is arranged, for example, along the circumferential edge of the first brake caliper support bracket. In this context, the circumferential edge of the first brake caliper support bracket can be an edge of the connection section which is farthest removed from the brake caliper support bridge.
According to a further embodiment, the air guiding element is formed as a protrusion and is fastened detachably at the first brake caliper support bracket, in particular by means of a screw connection and/or a clamping connection.
Providing the air guiding element so as to be detachable is particularly advantageous because in this way retrofitting of a brake caliper support which originally does not comprise an air guiding element is enabled.
According to a further embodiment, the brake caliper support is of a one-piece configuration, in particular a single cast part, wherein the air guiding element is present as one piece together with the brake caliper support.
In particular, one-piece means a one-part component. The air guiding element can be cast integrally with the first brake caliper support bracket.
According to a further embodiment, the air guiding element extends as one piece along the connection section and the lateral section, and the air guiding element comprises a bend.
The bend in the air guiding element refers in particular to a change of the extension direction of the air guiding element. The bend is located, for example, at the boundary between the connection section and the lateral section. Due to this angled course, a deflection of the air flow into the brake dust particle filter can be optimized.
According to a further embodiment, the air guiding element comprises a first section which extends tangentially in the mounted state and comprises an indirectly or directly adjoining second section which is bent radially outwardly in the mounted state, wherein preferably the air guiding element comprises a third section between the first section and the second section which forms a radially inwardly oriented bulge.
Due to this angled course and optionally due to the bulge, a deflection of the air flow into the brake dust particle filter can be optimized. This embodiment is in particular advantageous in connection with the internally vented brake disc described in the following.
According to a further embodiment, the air guiding element extends continuously from one fastening section to the other fastening section along the connection section.
In other words, the air guiding element can extend along a total (in particular tangential) extension direction of the connection section. In other embodiments, the air guiding element extends only along a section (for example, along half) of the connection section. The section of the connection section along which the air guiding element extends is in particular at the side of the brake caliper support which borders the brake dust particle filter.
According to a further embodiment, the lateral section, in relation to the mounted state, comprises an inner edge and an outer edge in circumferential direction wherein the air guiding element extends continuously from the inner edge all the way to the outer edge.
According to a second aspect, a disc brake assembly with a brake disc and the brake caliper support according to the first aspect or according to an embodiment of the first aspect is proposed, wherein a brake disc friction surface of the brake disc is arranged opposite the air guiding element and the first brake caliper support bracket.
In this context, the brake caliper support and the brake caliper cover at least in sections a friction surface of the brake disc in radial direction along the circumferential direction. One or a plurality of brake pads can be arranged moreover at the brake caliper.
During the braking process, brake dust particles are produced substantially at the friction surface and at the brake pads acting thereon. Therefore, the brake dust particle filter with its filter housing is arranged as close as possible at the brake caliper.
In embodiments, the disc brake assembly is embodied with an internally vented brake disc. An internally vented brake disc comprises a brake disc edge with radial outflow openings. In the interior of the brake disc, air channels for cooling the brake disc extend so that the heated cooling air exits substantially radially at the outflow openings. It can be advantageous to embody the circumferential wall opposite the brake disc edge (for externally vented brake discs) or opposite the radial outflow openings to be air-tight.
The air guiding element deflects the air in particular in the direction of an intake region of the inner venting action. In this way, the particles are in particular not deflected into the environment but reach the brake disc particle filter through the internal venting action of the brake disc. Here, the particles can be separated at the filter medium by the corresponding flow conditions.
According to an embodiment, the air guiding element is configured to deflect brake dust-laden air flowing along the rotating brake disc. Deflection means here in particular that the air guiding element changes a flow direction of the brake dust-laden air.
According to a further embodiment, the air guiding element is suitable to prevent the brake dust-laden air from radially exiting the brake caliper support. In this way, a greater number of particles is deflected into the brake dust particle filter.
According to a further embodiment, the air guiding element is arranged at the connection section and engages at least partially axially in a brake disc bell of the brake disc. In this way, escape of particles radially through a gap between the brake disc bell and the brake caliper support can be reduced.
According to a further embodiment, the disc brake assembly comprises furthermore a brake dust particle filter which, in a predetermined rotation direction of the brake disc, in particular the forward rotation direction, is arranged downstream of the brake caliper support.
In embodiments, a filter housing used for the brake dust particle filter can be a ring segment-shaped, for example, banana-shaped or helmet-shaped, filter housing. The interior of the filter housing is facing the brake disc in this context. It is conceivable to provide in the filter housing a filter medium which is made of a material which can withstand the relatively high temperatures during a disc braking process. The filter medium is suitable to bind or retain the brake dust particles.
In embodiments, the filter medium comprises an areal material with metal fibers, glass fibers, ceramic fibers and/or temperature-resistant plastic materials. Preferably, the employed filter material is resistant at typical operating temperatures of disc brake assemblies, for example, between −20° C. and 700° C. Known are metal fiber nonwovens that can be used as filter material. Tests by the applicant have shown that filter materials which are used in filter assemblies for crankcase venting devices are suitable as filter material in brake dust particle filters.
The filter housing and/or the brake caliper support are preferably also manufactured of a material that is resistant at temperatures between −20° C. and 700° C.
The brake dust particle filter is suitable for arbitrary applications in disc brakes. In this context, the brake dust particle filter can be used for stationary or mobile applications. As mobile applications, for example, motor vehicles such as passenger cars, trucks, buses, rail vehicles or the like are conceivable. Stationary, shaft brakes as they are used in wind or water power plants can be provided with corresponding brake dust particle filters.
The embodiments and features that have been described for the proposed brake caliper support apply likewise to the proposed disc brake assembly.
According to a third aspect, use of the brake caliper support according to the first aspect or according to an embodiment of the first aspect is proposed for targeted guiding by the air guiding element of brake dust-laden air flowing along a rotating brake disc into a brake disc particle filter which is arranged downstream of the brake caliper support in a predetermined rotation direction of the brake disc, in particular the forward rotation direction.
The embodiments and features described for the proposed brake caliper support and the disc brake assembly apply likewise to the proposed use.
According to a fourth aspect, a method for guiding brake-dust laden air flowing along a rotating brake disc is proposed with a brake caliper support according to the first aspect or according to an embodiment of the first aspect which holds the brake caliper of the brake disc. The method comprises:
deflecting the brake dust-laden air by the air guiding element of the brake caliper support; and
guiding the deflected air along a forward rotation direction of the brake disc so that it exits through an exit region from the brake caliper support, wherein the exit region is arranged downstream of the lateral section and/or of the connection section of the brake caliper support, in a predetermined rotation direction of the brake disc, in particular in the forward rotation direction.
According to an embodiment, the method comprises moreover:
introducing the air exiting from the exit region into a brake dust particle filter which is arranged downstream of the brake caliper support in the predetermined rotation direction of the brake disc.
The embodiments and features described for the proposed brake caliper support and the disc brake assembly apply likewise to the proposed method.
Further possible implementations comprise also combinations, not explicitly mentioned, of features or embodiments described above or in the following in relation to the embodiments. In this context, a person of skill in the art will also add individual aspects as improvements or supplements to the respective basic form of the embodiments.
Further advantageous embodiments and aspects are subject matter of the dependent claims as well as of the embodiments described in the following. In the following, the embodiments will be explained in more detail with reference to the attached Figures.
In the Figures, same or functionally the same elements, insofar as nothing to the contrary is indicated, are provided with the same reference characters.
In
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
In the Figures, a forward rotation direction R opposite to the clockwise direction is indicated (except in
In
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.
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
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
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.
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.
In
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.
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.
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
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.
Based on
The first brake caliper bracket 62 extends in the mounted state (
As illustrated in
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
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
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
The air guiding element 70 of
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.
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
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2020 118 880.3 | Jul 2020 | DE | national |
This application is a continuation application of International Application No. PCT/EP2021/066483 filed on Jun. 17, 2021, which claims the benefit of German Application No. 10 2020 118 880.3 filed on Jul. 16, 2020, the entire disclosures of which are incorporated herein by reference for all purposes.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/EP2021/066483 | Jun 2021 | US |
| Child | 18075432 | US |
