Disc brake caliper and a method of manufacturing a disc brake caliper

Abstract

A fixed type disc brake caliper (8, FIG. 1) has a body (10, FIG. 1) machined from at least one solid piece of material. The body comprises a pair of limbs (12, 14) interconnected by spaced bridging members (16, 18), each limb housing one or more hydraulic cylinders (26, 28, 30). The caliper has a cooling fluid passage (45, FIG. 1) for circulating cooling fluid through both limbs. In each of the limbs, the passage extends through both an upper peripheral wall region (42) between the cylinders and an upper face (38) and a lower peripheral wall region (44) between the cylinders and a lower face (40), so that the cooling fluid passage at least partially surrounds opposing side wall regions (54) of the, or each, cylinder in the limb. Advantageously, the passage (54) is formed by milling a channel (46) of varying depth around the pistons from an outer side face (48) of each limb. A cover plate (82, FIG. 6) is welded to the outer side face of each limb to close the open side of the channel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view from above of a body for a disc brake caliper in accordance with the invention;

FIG. 2 is a perspective view of the caliper body of FIG. 1 taken from below and to one side;

FIG. 3 is a side elevation of the caliper body of FIG. 1;

FIG. 4 is a cross sectional view of the caliper body of FIG. 1 taken on line A-A of FIG. 3;

FIG. 5 is a cross sectional view of the caliper body of FIG. 1 taken on line B-B of FIG. 3; and

FIG. 6 is a view similar to that of FIG. 5 but showing the body with blanking plates fitted.

DETAILED DESCRIPTION OF THE INVENTION

A disc brake caliper 8 has a caliper body 10 machined integrally from a single piece of material and includes a pair of limbs 12, 14 interconnected at either end by two spaced bridging members 16, 18. To provide for additional structural rigidity, the two limbs are further interconnected by a central support member 20 which extends laterally between the two limbs. A further support member 22 extends between the two bridging members 16, 18 longitudinally of the caliper body and merges with the central support member 20 where the two intersect. They body will typically be made from a solid billet of metal such as aluminium or aluminium alloy but could be made from any suitable material. Where the additional structural rigidity is not essential, one or both of the support members 20, 22 can be omitted.

In use, the caliper 8 straddles a brake disc (not shown) with a limb 12, 14 located on each side of the disc. A first limb 12 is connected in use to a torque reaction member e.g. a stub axle (not shown) by means of bolts or other fasteners (not shown) which engage in mounting holes 24.

The two limbs 12, 14 each have three hydraulic cylinders 26, 28, 30 spaced across the caliper body so that the cylinders 26, 28, 30 in the first limb 12 oppose the cylinders 26, 28, 30 in the second limb 14. The cylinders are arranged so that when the caliper is in use, the cylinders are spaced circumferentially with respect to the disc. In use, each of the cylinders 26, 28, houses a piston (not shown) which thrust friction pads (also not shown) against the opposing friction surfaces of the discs when the disc brake is actuated. The pads (not shown) may comprise a single arcuate pad on each side of the disc or may comprise a plurality of pads on each side of the disc so that there is provided a respective pad associated with each piston/cylinder assembly. Braking loads from the pads are transmitted to the caliper body 10 and via the fastenings to the torque reaction member.

The cylinders 26, 28, 30 are fluidly linked by means of fluid passages 31 in the caliper body to form a hydraulic brake fluid circuit in a known manner. Hydraulic brake actuating fluid is supplied to an inlet 32 of the hydraulic fluid circuit so that when the vehicle brakes are operated, hydraulic pressure in the piston and cylinder assemblies causes the brake pads to frictionally engage the brake disc. The hydraulic fluid circuit in the caliper also includes an outlet connection for a bleed nipple (not shown) to enable air to be bled from the hydraulic brake fluid circuit if required.

The cylinders 26, 28, 30 are machined into the limbs 12, 14 from their inner side faces 34, that is to say the side faces of the limbs which are directed towards the friction surfaces of the brake disc when the caliper is in use. To reduce the weight of the caliper body 10, grooves or recesses 36 are machined in the upper 38 and lower 40 faces of the limbs 12, 14. The area between the cylinders 26, 28, 30 and the upper face 38 can be considered an upper peripheral wall region 42 of the limb, whilst the area between the cylinders 26, 28, 30 and the lower face 40 can be considered an lower peripheral wall region 44.

The terms “upper” and “lower” are used herein (including in the claims) in relation to a caliper when positioned in the orientation of the caliper 8 as shown in FIG. 3. However, it will be appreciated that a brake caliper in accordance with the invention may be used in other orientations and the terms should be construed according. For example, the caliper 8 may be fitted to a brake disc in a generally vertical orientation. In use, the upper faces 38 of the limbs will be directed generally away from the axis of rotation of the disc and so may also be considered as outer radial faces in the sense that they face outwardly in relation to the radius of the disc. Similarly, the upper peripheral wall regions 42 may be considered as radially outer peripheral wall regions. Whereas, the lower faces 40 of the limbs will be directed generally toward the axis of rotation of the disc and so can be considered as inner radial faces in the sense that they face generally inwardly in relation to the radius of the disc. By a similar analogy, the lower peripheral wall regions 44 may also be considered as radially inner peripheral wall regions.

The caliper 8 has a cooling fluid passageway, indicated generally at 45, through which cooling fluid, typically water, can be circulated to cool the caliper and the hydraulic brake fluid during use. To form part of the cooling fluid passageway 45, a groove or channel 46 is formed in the outer side face 48 of each of the limbs. The outer side face 48 being the face of each limb which is directed away from the respective friction surface of the disc in use.

As can be seen best in FIG. 3, each channel 46 substantially encircles the region of the limb 12, 14 in which the cylinders 26, 28, 30 are formed though the ends of the channel do not meet. The depth of each channel 46 varies along its length so that it has regions of greater depth 50 separated by regions of lesser depth 52. As shown in FIG. 5, the regions of greater depth 50 extend transversely into the limb so as to overlie the side wall region 54 of at least one of the cylinders. Whereas, the regions of lesser depth 52 do not extend transversely into the limb far enough to overlie the side wall regions of the cylinders, as is shown in FIG. 4. The regions of increased depth 50 create recesses or cooling pockets which surround significant areas of the side walls 54 of the cylinders through which the cooling water can flow. The relatively shallow regions are of a sufficient depth to enable the cooling fluid to pass from one pocket 50 to the next to create a flow path when the open outer sides of the channels 46 are closed off, as will be described in more detail later. At least one cooling pocket 50 is formed adjacent each cylinder in the upper peripheral wall region 42 and at least one cooling pocket 50 is formed adjacent each cylinder in the lower peripheral wall region 44. Thus each cylinder 26, 28, in each limb is at least partially surrounded on opposite circumferential sides by one or more cooling pockets 50. This provides for an even and more efficient cooling of the hydraulic fluid in the cylinders in use. In the present embodiment, at least two cooling pockets 50 are provided about the side wall of each of the cylinders in diametrically opposed positions.

Each channel 46 has a first end 60 which lies spaced from a first outer one of the cylinders 30 towards the adjacent bridging member 16. The channel 46 has a straight portion 62 which extends from the first end 60 towards the periphery of the cylinder 30 just to one side of a mid line of the cylinder as viewed in FIG. 3. The channel then follows the circumference of the first cylinder 30 over the apex of the cylinder, as shown in FIG. 3, where it is closest to the upper face 38 of the limb and part way down the other side of the cylinder 30. The channel then forms a cusp 64 and follows the contour of the middle cylinder 28 in a similar fashion. The channel 46 forms a further cusp 66 between the middle cylinder 28 and a second of the outer cylinders 26 and follows the circumference of the second outer cylinder 26 right around until it forms a further cusp 68 between the second outer cylinder 26 and the middle cylinder 28 in the lower peripheral wall region 44. The channel 46 then continues this fashion following the circumferences of the middle and first outer cylinders 28, 30 until it reaches a second end 70 which is spaced from the first end. The shallow regions 52 of the channel may be positioned where the side walls 54 of the cylinders are closest to the upper 38 and lower 40 faces of the limbs and so where the upper and lower peripheral wall regions 42, 44 are at their thinnest. As the channels 46 do not penetrate into the peripheral wall regions 52, 54 at these points, the structural integrity of the body is not compromised. Cooling pockets 50 are formed in the cusped regions of the channel between the middle 28 and outer cylinders 26, 30 and about outer circumferential regions of the outer cylinders 26, 30.

As can be seen best in FIG. 2, the first end 60 of the channel 46 in the first limb 12 is connected to the corresponding first end 60 of the channel 46 in the other limb 14 by means of a bore 72 which extends through one of the bridging members 16. The second end 70 of the channel 46 in the first limb 12 is connected via a further bore 74 to a port 76 which serves as an inlet to the cooling fluid passage. The second end 70 of the channel 46 in the second limb 14 is connected by means of a yet further bore 78 to a further port 80 which serves as an outlet for the cooling fluid passage. Thus the channels 46 and bores 72, 74, 78 form a fluid circuit through which the cooling fluid may be circulated from the inlet port 76 to the outlet port 80. Means to enable the inlet and outlet ports 76, 80 to be connected with cooling fluid supply and return lines respectively may be provided. For ease of connection, both the inlet 76 and outlet 80 ports are positioned on the same side of the caliper adjacent the first limb 12. Thus the bore 78 which connects the second end 70 of the channel 46 in the second limb 14 to the outlet port 80 also extends through the bridging member 16. It will be appreciated that the cooling fluid could flow through the passageway 45 in the opposite direction in which case the port 80 becomes the inlet port and the port 76 becomes the outlet port.

After machining, the open outer sides of the channels or grooves 46 are closed by cover means such as blanking plates 82 that are fixed to the outer side faces 48 of the limbs. To accommodate the plates 82, the outer side faces 48 of the limbs are recessed as at 84. Preferably, the plates 82 are made of the same material as the caliper body and are welded in position to provide a fluid tight seal. The plates may be electron beam welded to the body, particularly where the body 10 and plates 82 are both made of aluminium or aluminium alloy. The plates 82 may be welded about their peripheries outside of the channels 46 but may also be welded to the outer side faces 48 in a central region within the channels 46. The recesses 84 preferably have a depth that is equal to the thickness of the cover plates 82 so that the sides of the caliper present a neat appearance after assembly.

Whilst welding the plates 82 is a preferred and advantageous arrangement, but alternative means of fixing the plates or other cover means to the body can be used such as bonding or by use of fastenings such as bolts or screws. A seal means may also be provided between the plates 82 and the body 10 of the caliper. Preferably, the plates 82 and any seal means provided should ensure that the cooling fluid is constrained to flow through the channels 46 without leaking across between the plates 82 and the bases of the recesses 84.

In use, cooling fluid is circulated through the cooling passage 45 by means of a pump which is connected to the inlet and outlet ports 76, 80 through feed and return pipes. The circulation of cooling fluid helps to cool the caliper and reduce the risk of the hydraulic fluid boiling. Whilst water is the preferred cooling fluid, other fluids may also be used such as antifreeze or a mixture of water and anti-freeze or any other suitable fluid.

The channels 46, the bores 72, 74, 78, the inlet and outlet ports 76, 80 and the recesses 84 for the blanking plates 82 can all be produced as part of the machining operations to produce the integral caliper body 10. Thus the recesses 84 can be milled into the side faces 48 of the limbs 12, 14 followed by the channels 46, which will typically be formed using an end mill. Preferably, the end mill has a radiused end so that the inner side face 44a of the channel is also radiused as shown in FIGS. 4 and 5. The bores 72, 74, 78 can then be formed using a drilling operation and the ports 76, 78 machined as required. The order in which the various machining process are carried out can be varied as appropriate. After machining of the caliper body, the blanking plates 82 are welded or otherwise fixed in position. The cooling fluid passage 45 can then be tested for integrity before the caliper is fully assembled.

When designing and manufacturing the caliper, the size of the cooling pockets 50 is determined in order to achieve the desired level of cooling. Thus, larger pockets 50 will tend to result in greater cooling of the caliper for a given flow rate of the coolant fluid. In contrast, reducing the size of the pockets will tend to decrease the cooling effect. Where maximum cooling is required, each groove or channel 46 may be produced with a constant depth so that the whole channel 46 forms a continuous cooling pocket overlying the side walls of the cylinders. However, care must be taken to ensure the structural rigidity of the body 10.

Whilst a continuous groove or channel 46 of varying depth is the preferred method of creating a series of linked cooling pockets 50 other methods of machining a cooling fluid passage from the outer side face 48 of each limb 12, 14 can be used. For example, the cooling pockets 50 in each limb could each be machined separately and fluidly interconnected by means of bores drilled or otherwise formed between them. Furthermore, whilst milling is the preferred method of forming the channels 46, other methods could also be used. For example, the channels 46 or pockets 50 could be formed using spark erosion or any other suitable method.

Whilst in the preferred embodiment, the caliper body 10 is machined from a single piece of metal as a mono-block unit, the invention can be equally applied to disc brake callipers having a two-piece machined caliper body. In a two-piece body, the channels 46 in either limb may be fluidly interconnected by means of external pipes. Alternatively, the channels 46 may be fluidly interconnected by means of passageways through the bridging members, provided seal means are used at the interface of the two pieces to ensure that the no leakage takes place. It will also be appreciated that the term body applies to the main structural component of the caliper and does not include the cover plates 82 or other parts which may be affixed during assembly of the caliper. Thus when referring to a caliper with a mono-block body 10, the main part of the body is machined from a single piece of metal to which the plates 82 are affixed along with any other required parts such as fluid connectors, pipes, pistons and seals.

It can be seen that a machined caliper 8 constructed and manufactured in accordance with the invention has a cooling fluid passage that extends around large areas of the side walls of the cylinders to provide improved cooling. It is a particular advantage that the cooling fluid passage can be arranged to provide cooling pockets that are positioned generally symmetrically about each cylinder to ensure an even cooling. Thus the cooling fluid passage 45 extends over at least two regions of the side walls of each cylinder 26, 28, 30 that are diametrically opposed.

Whereas the invention has been described in relation to what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not limited to the disclosed arrangements but rather is intended to cover various modifications and equivalent constructions included within the spirit and scope of the invention.

Where the terms “comprise”, “comprises”, “comprised” or “comprising” are used in this specification, they are to be interpreted as specifying the presence of the stated features, integers, steps or components referred to, but not to preclude the presence or addition of one or more other feature, integer, step, component or group thereof.

Claims

1. A fixed type disc brake caliper having a machined from solid body, the body comprising a pair of limbs interconnected by spaced bridging members, wherein each limb houses at least one hydraulic cylinder, the caliper having a cooling fluid passage for circulating cooling fluid through both limbs, in which, in each limb, the passage extends at least partially through both an upper peripheral wall region of the limb between the at least one cylinder and an upper face of the limb and a lower peripheral wall region of the limb between the at least one cylinder and a lower face of the limb, so that the cooling fluid passage at least partially surrounds opposing side wall regions of each cylinder in the limb.

2. The fixed type disc brake caliper of claim 1, in which the cooling fluid passage substantially encircles the at least one cylinder in each limb.

3. The fixed type disc brake caliper of claim 1, in which the cooling fluid passage comprises a channel in an outer side face of each limb, the caliper further comprising a cover mounted to the outer side face of each limb to close an open side face of the channel.

4. The fixed type disc brake caliper of claim 3, in which the depth of the channel in each limb varies along its length, the channel comprising regions of greater depth separated by regions of lesser depth.

5. The fixed type disc brake caliper of claim 4, in which at least some of the regions of greater depth extend into a peripheral wall region of the respective limb so as to overlap a side wall region of at least one cylinder.

6. The fixed type disc brake caliper of claim 5, in which there are at least two cylinders in each limb and at least one region of greater depth of the channel overlaps side wall regions of two adjacent cylinders in the respective limb.

7. The fixed type disc brake caliper of claim 3, in which the channel in each limb has a first end and a second end, the first end of the channel in one limb being fluidly connected to the first end of the channel in the other limb by means of a bore which extends through one of the bridging members.

8. The fixed type disc brake caliper of claim 7, in which the caliper has inlet port and an outlet port for the cooling fluid passage, the second end of the channel in each limb being connected with a respective one of the ports by means of a further bore.

9. The fixed type disc brake caliper of claim 3, in which the cover comprises a cover plate welded to the outer side face of the respective limb.

10. The fixed type disc brake caliper of claim 9, in which the plate is electron beam welded to the outer side face of the limb.

11. The fixed type disc brake caliper of claim 9, in which the outer side face of each limb is recessed to accommodate a respective cover plate.

12. The fixed type disc brake caliper of claim 11, in which the channel in each limb extends from a base of the recess, transversely of the caliper into the limb.

13. The fixed type disc brake caliper of claim 1, in which the body is formed from two parts, each part being machined from a single piece of material.

14. The fixed type disc brake caliper of claim 1, in which the body is formed as a single unitary part.

15. A method of manufacturing a fixed type disc brake caliper having a machined from solid body, the body comprising a pair of limbs interconnected by spaced bridging members, wherein each limb houses at least one hydraulic cylinder, the method comprising forming a cooling fluid passage for circulating cooling water through both limbs, in which, in each limb, the passage is formed so as to extend at least partially through both an upper peripheral wall region of the limb between the at least one cylinder and an upper face of the limb and a lower peripheral wall region of the limb between the at least one cylinder and a lower face of the limb, such that the passage at least partially surrounds opposing side wall regions of each cylinder in the limb.

16. The method of claim 15, in which the cooling fluid passage is formed so as to substantially encircle an area of each limb which contains the at least one cylinder.

17. The method of claim 15, in which the step of forming the cooling fluid passage comprises forming a channel in an outer side face of each of the limbs and mounting a cover to the outer side face of each limb to close off an open side of the channel.

18. The method of claim 17, in which the method comprises welding a cover plate to the outer side face of each limb.

19. The method of claim 18, in which the method comprises electron beam welding each cover plate to the outer side face of its respective limb.

20. The method of claim 18, in which the method further comprises forming a recess in the outer side face of each limb to receive a respective cover plate.

21. The method of 20, in which the step of forming the channels comprises forming each channel in a base of the recess in the respective limb so that the channel extends transversely of the caliper into the limb.

22. The method of claim 17, in which the depth of the channel in each limb is varied along its length to form regions of greater depth separated by regions of lesser depth.

23. The method of claim 22, in which at least some of the regions of greater depth are extended into a peripheral wall region of the respective limb so as to overlap a side wall region of at least one cylinder.

24. The method of claim 23, in which there are at least two cylinders in each limb and at least one region of greater depth of the channel in each limb is formed so as to overlap a side wall region of two adjacent cylinders.

25. The method of claim 17, in which the step of forming the channels is carried out using an end mill.

26. The method of claim 17, in which the channel in each limb is formed so as to have a first end and a second end and the method further comprises forming a bore in one of the bridging members to fluidly interconnect the first end of the channel in one of the limbs with the first end of the channel in the other of the limbs.

27. The method of claim 26, in which the method further comprises forming a first port and a second port and forming a first further bore to connect the second end of the channel in one of the limbs with the first port and forming a second further bore to connect the second end of the channel in the other of the limbs to the second port.

28. The method of claim 15, in which the method comprises machining the body in two-parts from two solid pieces of material.

29. The method of claim 16, in which the method comprises machining the body as a single integral part from a single solid piece of material.