STATOR PAD ASSEMBLY

Abstract

A stator pad assembly includes a backing plate including a plate slot extending to a plate slot end, the backing plate carrying a stator lining including a lining slot extending to a lining slot end, the lining slot being generally positioned with a portion of the plate slot such that the plate slot end and the lining slot end are of similar position, and the plate slot defining a tool-engaging surface adapted to receive a tool to thereby cause the stator pad assembly to travel.

Description

TECHNICAL FIELD

This invention relates to a stator pad assembly. More particularly, this invention relates to a stator pad assembly that includes a stator release slot and a tab.

BACKGROUND ART

To service a hydraulic caliper brake, it is generally necessary to push back the pistons of the brake. This is typically a cumbersome and relatively slow process. The common design for hydraulic caliper brakes provides no particular feature to aid the service technician in pushing the caliper pistons back. The typical method involves the use of C-clamps, which is slow and awkward.

A second problem that is common in hydraulic calipers is removal and reinstallation of stator assemblies. Most designs require removal of the caliper in order to accomplish removal and replacement of the stator assemblies. Handling of the stators is generally a problem, especially if the caliper is not removed. There is generally not an effective way to get a hold of the stator. Again, this is also a slow process.

There are existing designs that do not require removal of the caliper, but the stators are hard to handle without removal of the caliper. These designs lack an effective manner for holding and manipulating the components during removal and replacement.

Thus, there is a need for a stator assembly that offers one or more improvements over the prior art, such as ease of pushing a piston back.

SUMMARY OF THE INVENTION

In general, a stator pad assembly and corresponding methods are provided. In accordance with an aspect of the invention, the stator pad assembly may include a backing plate including a plate slot extending to a plate slot end, the backing plate carrying a stator lining including a lining slot extending to a lining slot end, the lining slot being generally positioned with a portion of the plate slot such that the plate slot end and the lining slot end are of similar position, and the plate slot defining a tool-engaging surface adapted to receive a tool to thereby cause the stator pad assembly to travel.

In accordance with another aspect of the invention, a method of servicing a stator pad assembly may include providing a brake including a housing having two pairs of torque pin holes, each pair of the torque pin holes receiving a respective torque pin, the torque pins carrying a pair of stator pad assemblies, each of the stator pad assemblies including a respective backing plate with a plate slot, each of the stator pad assemblies adapted to be acted on by a respective pair of piston assemblies in normal operation of the brake, inserting a tool in one of the plate slots to thereby force the respective backing plate against the respective pair of piston assemblies, removing one of the torque pins from the respective pair of torque pin holes, rotating at least one of the pair of stator pad assemblies about the other of the torque pins, and servicing the at least one of the pair of stator pad assemblies that was rotated in the step of rotating.

It is an object of one aspect of the present invention to provide a stator pad assembly allowing for ease of pushing a piston back without complicated tools or awkward motions.

It is an object of another aspect of the present invention to provide a stator pad assembly, as above, that will allow for easy handling for removal and reinstallation.

These and other objects of the present invention, as well as the advantages thereof over existing prior art forms, which will become apparent from the description to follow, are accomplished by the improvements hereinafter described and claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective front view of a stator pad assembly having a release slot according to the concepts of the present invention.

FIG. 2 is a perspective rear view of the stator pad assembly according to the concepts of the present invention.

FIG. 3 is a perspective view of the opposed stator pad assemblies in position with a caliper brake housing according to the concepts of the present invention.

FIG. 4 is a perspective view of the opposed stator pad assemblies in position with the caliper brake housing, showing a tool in position in the release slot for pushing back the piston according to the concepts of the present invention.

FIG. 5 is a perspective view of the opposed stator pad assemblies in position with the housing, showing each stator pad assembly rotated away from the caliper brake housing according to the concepts of the present invention.

FIG. 6 is a perspective view of the caliper brake housing, spaced from a wheel rotor according to the concepts of the present invention.

FIG. 7 is a perspective view of the opposed stator pad assemblies and caliper brake housing in position with the wheel rotor according to the concepts of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the Figures, a stator pad assembly according to the concepts of the present invention is generally indicated by the numeral 10. Stator pad assembly 10, which may also be described as stator assembly 10, includes a backing plate, generally indicated by the numeral 12, which carries a stator lining, generally indicated by the numeral 14, which may also be described as a stator pad 14. Stator pad 14 may be secured to backing plate 12 by way of an adhesive or other generally known means, Installation and removal of stator pad 14 may include utilizing integral molding holes 17 within backing plate 12. Integral molding holes 17 generally serve as anchor points for stator pad 14 material.

Backing plate 12 includes a slot 16 formed therein. Slot 16 may have a first end within a tab 38 of backing plate 12, which will be further described herein below with respect to the function of tab 38. Slot 16, which may also be referred to as release slot 16, may be formed in the center or the central portion of the width of backing plate 12. This may be described as slot 16 being aligned with the centerline of a pair of piston assemblies 18, which may also be described as pistons 18. A respective pair of piston assemblies 18 is provided for each stator assembly 10 and piston assemblies 18 are adapted to move stator assembly 10 to a braking position by way of hydraulic fluid.

Slot 16 extends only into a portion of backing plate 12. That is to say, slot 16 does not extend entirely through the length of backing plate 12, such that slot 16 extends to an end 20 within backing plate 12. End 20 may be a curved end, which may be in the particular shape of a semi-circle as shown in the Figures. In other embodiments, end 20 may be rectangular or rectangular with corner radii or another suitable shape. As best seen in FIGS. 3 and 4, and as will be discussed further herein below, a pair of opposed stator pad assemblies 10 may be utilized, such that slot 16 from one stator assembly 10 faces inward toward slot 16 of the other stator assembly 10.

In a corresponding position as end 20 and a lower portion of slot 16, stator lining 14 includes a slot 22 formed therein. Slot 22 may be formed in the center or the central portion of the width of stator lining 14. This may be described as slot 16 being formed in the centerline of the pair of piston assemblies 18. Slot 22 extends only into a portion of stator lining 14. That is to say, slot 22 does not extend entirely through the length of stator lining 14, such that slot 22 extends to an end 24 within stator lining 14. End 24 may be a curved end, which may be in the particular shape of a semi-circle. In other embodiments, end 24 may be rectangular or rectangular with corner radii or another suitable shape. As best seen in FIGS. 3 and 4, in the pair of stator assemblies 10, slot 22 from one stator assembly 10 faces inward toward slot 22 of the other stator assembly 10.

In one or more embodiments, end 24 may be of the same or similar shape as end 20. That is to say, end 24 may aligned or substantially aligned with end 20. This may be useful for providing a constant surface for contacting a distal end of a tool 26 with the constant surface, as will be further discussed herein below.

End 24 of slot 22 may include a central wear slot 42 extending therefrom, which slot 42 is useful for knowing the condition of stator lining 14, as further discussed below. Central wear slot 42 with slot 22 together extend entirely through the length of stator lining 14. Though, as mentioned above, slot 22 itself does not extend entirely through the length of stator lining 14. It should be readily appreciated that slot 22 is of a different shape than the central wear slot 42.

A pair of opposed stator pad assemblies 10 may be particularly suitable for use with a caliper brake, generally indicated by the numeral 30, including piston assemblies 18. Caliper brake 30 is adapted to provide braking function to a wheel rotor 36, which is part of a wheel end assembly, which is generally indicated by the numeral 44. Caliper brake 30 may be mounted to wheel end assembly 44 by way of bolts 46.

In the configuration of caliper brake 30, when stator assemblies 10 require servicing, it is generally necessary to push back the respective pair of piston assemblies 18 with which stator assembly 10 is coupled. That is, stator assembly 10 needs to be moved toward the respective pair of piston assemblies 18.

To achieve this movement of stator assembly 10, a user may utilize tool 26, which may be a screwdriver or crow bar or other suitable implement. A first end of tool 26 may be inserted into slot 16 and slot 22. Tool 26 may be inserted until a distal end thereof contacts end 20 and/or end 24. Slot 16 may be said to define a tool-engaging surface 28 in backing plate 12. The user of tool 26 may contact tool 26 with tool-engaging surface 28 when tool 26 is inserted into slot 16 and slot 22. Upon tool 26 contacting tool-engaging surface 28, the user causes tool 26 to apply sufficient force on tool-engaging surface 28 to thereby cause stator assembly 10 to move against the pair of piston assemblies 18. This thereby pushes back the pair of piston assemblies 18.

As suggested above, slot 16 and slot 22 are centrally located in the respective components. Thus, the force of tool 26 also acts centrally on the pair of piston assemblies 18. Advantageously, this causes consistent movement of piston assemblies 18 and avoids cocking piston assemblies 18 and otherwise damaging piston assemblies 18 and respective components thereof.

For servicing stator assemblies 10 of caliper brake 30, the hydraulic pressure normally supplied to caliper brake 30 is deactivated. Thus, the force of tool 26 against stator assemblies 10 is able to push back the respective piston assembly 18. This may also release any hydraulic pressure that may remain when caliper brake 30 is in the deactivated state. Once stator assemblies 10 move the respective piston assembly 18 by tool 26 as discussed above, piston assemblies 18 will remain in that position because no further hydraulic pressure is being supplied in this mode of caliper brake 30.

Caliper brake 30 includes a pair of torque pins 32 for securing stator assemblies 10 within a caliper brake housing 33, which may also be referred to as housing 33. For servicing stator assemblies 10 once piston assemblies 18 are moved, one of the torque pins 32 may be removed from the respective torque pin holes 34 of stator assemblies 10 and the respective torque pin holes 35 within housing 33. This may also include removing a respective spring 37 positioned around torque pin 32 and between the pair of stator assemblies 10.

Stator assemblies 10 may then be rotated about the other torque pin 32 (and spring 37) that remains within caliper housing 33. Stator assemblies 10 may be rotated away from caliper housing 33 of caliper brake 30 such that they can be accessed by a user for performing maintenance thereon. This maintenance may include replacing stator linings 14. In other embodiments, both of the torque pins 32 and both of the springs 37 may be removed to completely remove stator assemblies 10 from caliper brake 30.

Once maintenance of stator assemblies 10 is completed, stator assemblies 10 may be reassembled with caliper brake 30 in a reverse manner as described above, which includes reactivating the hydraulic pressure to piston assemblies 18. In this normal, non-maintenance operation of caliper brake 30, a portion of wheel rotor 36 is positioned between the pair of stator assemblies 10.

As suggested above, for assisting with ease of servicing stator assemblies 10, backing plate 12 may include tab 38 as an extension of backing plate 12. Tab 38 may particularly extend from a central position with respect to the width of backing plate 12. As discussed above, tab 38 includes a portion of slot 16, including a distal end of slot 16.

Tab 38 protrudes from backing plate 12 and extends far enough from backing plate 12 as to be outside of an outer perimeter of caliper housing 33 of brake 30, as perhaps best seen in FIG. 7. This extension of tab 38 outside of caliper housing 33 enables tab 38 to be easily grabbed by a user for rotation and/or removal of stator assemblies 10. For additional ease, caliper housing 33 may include a slot 40, which may also be described as a depression 40, generally corresponding to the position of tab 38, such that tab 38 serves as an even longer extension from caliper housing 33.

For assisting a user with knowing when stator assemblies 10 need servicing, stator lining 14 may include one or more wear slots 42 formed therein. Any suitable number of wear slots 42 may be utilized. Stator assemblies 10 of brake 30 include three wear slots 42—a central wear slot, and one wear slot on each side of stator lining 14.

As shown in FIG. 1, slots 42 may extend all the way through the height or length of stator lining 14. In other embodiments, slots 42 do not extend all the way through the height or length of stator lining 14. As shown in FIG. 1, slots 42 may not extend all the way through the depth or thickness of stator lining 14. In other embodiments, slots 42 do extend all the way through the depth or thickness of stator lining 14. Slots 42 are shown as linear shaped, but other suitable configurations may be utilized. Though, slot 22 is adapted to receive tool 26, slots 42 are generally too narrow to fit tool 26.

In operation of caliper brake 30, stator linings 14 will wear and become less thick. Thus, slots 42 will become less deep. During operation of caliper brake 30, slot 42 will be worn from its original depth to a subsequent depth. Slots 42 may be designed for a particular depth, such that a user will be able to identify, based on the subsequent depth, that stator linings 14 should be replaced. Stator linings 14 can be replaced by a user upon this identification. Slots 42 may also be helpful for controlling vibration and noise of caliper brake 30.

It is thus evident that a stator pad assembly constructed as described herein accomplishes the objects of the present invention and otherwise substantially improves the art.

Claims

1. A stator pad assembly comprising: a backing plate including a plate slot extending to a plate slot end,the backing plate carrying a stator lining including a lining slot extending to a lining slot end,the lining slot being generally positioned with a portion of the plate slot such that the plate slot end and the lining slot end are of similar position, andthe plate slot defining a tool-engaging surface adapted to receive a tool to thereby cause the stator pad assembly to travel.

2. The stator pad assembly of claim 1, the backing plate having a width with a plate central portion, the plate slot formed in the plate central portion, andthe stator lining having a width with a lining central portion, the lining slot formed in the plate central portion.

3. The stator pad assembly of claim 2, the plate slot end being of a shape selected from the group consisting of semi-circle, rectangular, and rectangular with corner radii, andthe lining slot end being of a shape selected from the group consisting of semi-circle, rectangular, and rectangular with corner radii.

4. The stator pad assembly of claim 1, the stator lining including a wear slot.

5. The stator pad assembly of claim 4, the wear slot extending centrally from the lining slot end.

6. The stator pad assembly of claim 5, the stator lining having a length, the stator pad assembly further comprising an additional wear slot extending through the entirety of the length of the stator lining.

7. The stator pad assembly of claim 1, the backing plate including a tab extending therefrom, andthe tab including a portion of the plate slot but not including the plate slot end.

8. The stator pad assembly of claim 7, the stator pad assembly positioned within a brake housing having an outer perimeter, andthe tab extending beyond the outer perimeter of the brake housing.

9. The stator pad assembly of claim 8, the housing including a housing slot generally corresponding to the position of the tab.

10. A method of servicing a stator pad assembly, the method comprising: providing a brake including a housing having two pairs of torque pin holes, each pair of the torque pin holes receiving a respective torque pin, the torque pins carrying a pair of stator pad assemblies, each of the stator pad assemblies including a respective backing plate with a plate slot, each of the stator pad assemblies adapted to be acted on by a respective pair of piston assemblies in normal operation of the brake,inserting a tool in one of the plate slots to thereby force the respective backing plate against the respective pair of piston assemblies,removing one of the torque pins from the respective pair of torque pin holes,rotating at least one of the pair of stator pad assemblies about the other of the torque pins, andservicing the at least one of the pair of stator pad assemblies that was rotated in the step of rotating.

11. The method of claim 10, further comprising removing the other of the torque pins such that the pair of stator pad assemblies can be entirely removed from the housing.

12. The method of claim 10, wherein each backing plate includes a stator lining having a wear slot having an original depth,further comprising a step of identifying that the wear slot of at least one of the stator linings has worn from the original depth to a subsequent depth, such that the stator lining having the wear slot at the subsequent depth is thereby in a condition needing maintenance.

13. The method of claim 12, wherein the step of servicing includes replacing the stator lining having the wear slot at the subsequent depth.

14. The method of claim 10, wherein the step of servicing includes replacing the stator lining of the at least one of the pair of stator pad assemblies that was rotated in the step of rotating.

15. The method of claim 10, wherein each of the backing plates includes a respective tab, andwherein the step of rotating includes grasping the tab of the at least one of the pair of stator pad assemblies to thereby cause the rotating.