Caliper body for a disc brake and method for manufacturing a caliper body

Patent metadata

Field	Value
Publication number	US-10502275-B2
Application number	US-201615750263-A
Country	US
Kind code	B2
Filing date	Jul 26, 2016
Priority date	Aug 5, 2015
Publication date	Dec 10, 2019
Grant date	Dec 10, 2019

Abstract

A caliper body for a disc brake is described. The caliper body is adapted to straddle an associable brake disc. The caliper body may have a first elongated portion, or a vehicle-side elongated portion, at least partially adapted to face the first braking surface. The caliper body may also have a second elongated portion, or wheel-side elongated portion, opposite to the first elongated portion and at least partially adapted to face the second braking surface. At least one part of the first elongated portion has at least a first module and at least one part of the second elongated portion has at least a second module. The first module and the second module are obtained by at least one non-additive manufacturing technique.

First claim

The invention claimed is:

1. A method for manufacturing a caliper body, comprising the following steps, listed according to a preferred order:
(A) obtaining a first module and a second module by at least one non-additive manufacturing technique;
(B) carrying out at least one machining operation by material removal from said first module and/or from said second module;
(C) obtaining a junction element via laser sintering of layers of metal powders so that it is a single piece with said first module and with said second module;
wherein said junction element is suspended by its sides between the first and second modules and
between the step (B) and the step (C), providing at least one removable equipment, suitable for maintaining said first positioning surface and said second positioning surface facing each other and substantially parallel.

2. A method for manufacturing a caliper body for a disc brake, wherein said caliper body is suitable for straddling an associable disc brake having a first braking surface, or a vehicle-side braking surface, and a second braking surface, or wheel-side braking surface, opposite said first braking surface, further comprising:
defining an axial direction coinciding or parallel with the rotation axis of the disc, a radial direction orthogonal with said axial direction and a tangential direction orthogonal both to said axial direction and to said radial direction;
providing said caliper body with a first elongated portion, or vehicle-side elongated portion, at least partially suitable for facing said first braking surface and a second elongated portion, or wheel-side elongated portion, opposite said first elongated portion and at least partially suitable for facing said second braking surface;
wherein at least one part of said first elongated portion is constituted by at least one first module and at least one part of said second elongated portion is constituted by at least one second module,
wherein said first module and said second module are obtained by at least one non-additive manufacturing technique,
wherein said first module comprises at least one first positioning surface and wherein said second module comprises at least one second positioning surface,
wherein said first positioning surface and said second positioning surface are suitable for being arranged, when facing, substantially parallel to each other,
wherein said caliper body comprises at least one junction element obtained by laser sintering of layers of metal powders,
and wherein said junction element connects said first module and said second module to each other to form a single piece, blocking the relative position of said first module and said second module with said first and second positioning surfaces substantially parallel to each other,
wherein said junction element is only supported on its sides between the first and second modules.

3. The method according to claim 2 , wherein said junction element is suitable for maintaining the geometric position of the modules so that the braking is optimal,
and wherein said first positioning surface and said second positioning surface together form an angle with respect to the tangential direction comprised between −10° and +10°.

4. The method according to claim 2 , wherein said first module comprises a first attachment portion, and wherein said second module comprises a second attachment portion,
and wherein said first attachment portion and said second attachment portion are tapered,
and wherein said first attachment portion comprises at least one first attachment surface arranged substantially as an undercut with respect to the axial direction for said second module,
and wherein said second attachment portion comprises at least one second attachment surface, arranged as an undercut with respect to the axial direction for said first module;
and wherein said first attachment surface and said second attachment surface are opposite each other,
and wherein said junction element is suitable for hooping, or embracing, said first and second attachment surfaces.

5. The method according to claim 2 , wherein at least one of said first module and said second module comprises at least one of the following:
at least one portion of a brake fluid distribution circuit;
at least one pad-housing portion, suitable for receiving at least one pad associable with the caliper body;
at least one portion of a thrust system seat, suitable for receiving at least one portion of a thrust system suitable for exerting a thrust action on said pad associable with the caliper body;
at least one machining operation carried out by material removal.

6. The method according to claim 2 , wherein said first module comprises at least one first junction surface and said second module comprises at least one second junction surface,
and wherein said first and second junction surfaces are suitable for being connected to each other by means of said junction element; and/or wherein
said first and second junction surfaces are opposite and facing each other; and/or wherein
said first and second junction surfaces are arranged in a plane substantially orthogonal to the radial direction; and/or wherein
said junction element connects said first and second junction surfaces to each other; and/or wherein
said first positioning surface and said second positioning surface form together an angle with respect to the tangential direction comprised between −1° and +1°.

7. The method according to claim 2 , wherein said junction element is suitable to form at least one bridge, and wherein said bridge is suitable for straddling the brake disc, when said caliper body is assembled to the brake disc; and/or wherein
said first module comprises at least one first bulge, suitable for jutting cantilevered from said first module so as to form at least one first bridge shoulder portion; and/or wherein
said first bulge comprises said first positioning surface; and/or wherein
said second module comprises at least one second bulge, suitable for jutting cantilevered from said second module so as to form at least one second bridge shoulder portion; and/or wherein
said second bulge comprises said second positioning surface; and/or wherein
said junction element comprises at least one portion of a distribution duct, suitable for conveying a fluid; and/or wherein
said distribution duct is suitable for putting in fluid communication a portion of said first module with a portion of said second module; and/or wherein
said distribution duct is a conduct for supplying air for cooling the pads, suitable for conveying cooling air for example for said at least one brake pad associable with the caliper body.

8. The method according to claim 2 , wherein said junction element comprises at least one from among:
a porous portion,
a reticular portion,
a trabecular portion;
and/or wherein said junction element comprises at least one reticular portion comprising at least one reticular unit; and/or wherein
said reticular unit comprises a structure, or a micro-structure, substantially cubic, in which the material is distributed mainly on the edges of a cube and on segments, tie bars or struts connecting the vertices of said cube.

9. The caliper body according to claim 2 , wherein said junction element is suitable for forming at least one floating portion of a brake caliper of the floating type; and/or wherein
each of said first and second module is suitable for forming a portion of a fixed caliper; and/or wherein
at least one of said first module and said second module is obtained by at least one of the following non-additive manufacturing techniques:
melting,
molding,
material removal.

Assignees

• Freni Brembo Spa

Inventors

• Piccoli Mauro
• Oldoni Paulo
• Previtali Alberto

Classifications

• B22F2005/002

  Tools other than cutting tools · CPC title

• F16D2055/0016

  Brake calipers · CPC title

• F16D65/0068 Primary

  Brake calipers · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• F16D65/0075 Primary

  assembled from a plurality of parts · CPC title