U.S. patent application number 09/903860 was filed with the patent office on 2003-01-16 for disc brake caliper assembly.
This patent application is currently assigned to Shimano Inc.. Invention is credited to Nakamura, Yasushi.
Application Number | 20030010580 09/903860 |
Document ID | / |
Family ID | 25418175 |
Filed Date | 2003-01-16 |
United States Patent
Application |
20030010580 |
Kind Code |
A1 |
Nakamura, Yasushi |
January 16, 2003 |
DISC BRAKE CALIPER ASSEMBLY
Abstract
A disc brake includes a caliper housing, a pair of friction
members, and a piston. The caliper housing includes a support
portion and a cylinder portion coupled to the support portion. The
cylinder portion has a piston chamber with a fluid inlet opening.
The cylinder portion is an independent component from the support
portion. Preferably, the caliper housing includes parts constructed
of deformed sheet material such as press formed sheet metal. The
parts are preferably fixedly coupled together by welding, brazing
and bolts. The friction members are coupled to the caliper housing
to form a rotor slot. The piston is mounted in the piston chamber
to move one friction member between a release position and a
braking position. In one embodiment, an integrated mounting member
and a flanged cylinder is provided. In another embodiment, a pair
of flanged cylinders with a pair of movable pistons is
provided.
Inventors: |
Nakamura, Yasushi;
(Nishinomiya, JP) |
Correspondence
Address: |
SHINJYU GLOBAL IP COUNSELORS, LLP
1233 20TH STREET, NW, SUITE 700
WASHINGTON
DC
20036-2680
US
|
Assignee: |
Shimano Inc.
|
Family ID: |
25418175 |
Appl. No.: |
09/903860 |
Filed: |
July 13, 2001 |
Current U.S.
Class: |
188/73.31 ;
188/71.1 |
Current CPC
Class: |
F16D 2055/002 20130101;
F16D 2200/0004 20130101; F16D 2055/0008 20130101; F16D 2250/0076
20130101; F16D 55/226 20130101; B62L 1/005 20130101; F16D 2250/0084
20130101; F16D 2250/0023 20130101; F16D 55/228 20130101 |
Class at
Publication: |
188/73.31 ;
188/71.1 |
International
Class: |
F16D 055/00 |
Claims
What is claimed is:
1. A disc brake caliper assembly comprising: a caliper housing
including a support portion and a first cylinder portion coupled to
said support portion, said first cylinder portion having a first
piston chamber with a first fluid inlet opening fluidly coupled to
said first piston chamber and a first piston receiving opening,
said first cylinder portion being an independent component from
said support portion; first and second friction members coupled to
said caliper housing to form a rotor receiving slot therebetween,
at least said first friction member being movably coupled to said
caliper housing; and a first piston movably coupled in said first
piston chamber of said caliper housing to move said first friction
member between a release position and a braking position.
2. The disc brake caliper assembly according to claim 1, wherein
said first cylinder portion is constructed of deformed sheet
material.
3. The disc brake caliper assembly according to claim 2, wherein
said first cylinder portion is constructed of press formed sheet
metal.
4. The disc brake caliper assembly according to claim 1, wherein
said support portion is at least partially formed of metal and said
first cylinder portion is fixedly coupled to said support portion
by welding or brazing.
5. The disc brake caliper assembly according to claim 1, wherein
said support portion includes a first housing part with said first
cylinder portion fixedly coupled thereto and a second housing part
coupled to said first housing part and supporting said second
friction member.
6. The disc brake caliper assembly according to claim 5, wherein
said first and second housing parts are formed of deformed sheet
material.
7. The disc brake caliper assembly according to claim 6, wherein
said first cylinder portion is constructed of deformed sheet
material.
8. The disc brake caliper assembly according to claim 7, wherein
said support portion includes a mounting portion fixedly coupled
with said first housing part and said first cylinder portion.
9. The disc brake caliper assembly according to claim 8, wherein
said mounting portion is a strap member with a pair of mounting
sections.
10. The disc brake caliper assembly according to claim 9, wherein
said strap member is constructed of deformed sheet material.
11. The disc brake caliper assembly according to claim 10, wherein
said first cylinder portion, said first housing part and said strap
member are constructed of press formed sheet metal and are fixedly
coupled together by welding or brazing.
12. The disc brake caliper assembly according to claim 6, wherein
said first and second housing parts are fixedly coupled together
with a spacer coupled between said first and second housing
parts.
13. The disc brake caliper assembly according to claim 5, wherein
said support portion includes a mounting portion fixedly coupled
with said first housing part and said first cylinder portion.
14. The disc brake caliper assembly according to claim 13, wherein
said mounting portion is a strap member with a pair of mounting
sections.
15. The disc brake caliper assembly according to claim 5, wherein
said first housing part includes a pair of mounting sections
integrally formed therewith.
16. The disc brake caliper assembly according to claim 5, wherein
said first and second housing parts are fixedly coupled together
with a spacer coupled between said first and second housing
parts.
17. The disc brake caliper assembly according to claim 5, wherein
said second friction member is fixedly coupled to said second
housing part.
18. The disc brake caliper assembly according to claim 5, wherein
said first and second housing parts are constructed of press formed
sheet metal.
19. The disc brake caliper assembly according to claim 5, wherein
said second friction part is movably coupled to said second housing
part to move said second friction member between a release position
and a braking position.
20. The disc brake caliper assembly according to claim 19, wherein
said caliper housing includes a second cylinder portion fixedly
coupled to said second housing part, said second cylinder portion
having a second piston chamber a second fluid inlet opening fluidly
coupled to said second piston chamber and a second piston receiving
opening with a second piston movably coupled therein to move said
second friction member between said release position and said
braking position.
21. The disc brake caliper assembly according to claim 20, wherein
said first fluid inlet opening of said first cylinder portion is
fixedly coupled to a fluid supply hose.
22. The disc brake caliper assembly according to claim 21, wherein
said first cylinder portion includes a first fluid outlet opening
in fluid communication with said first piston chamber and said
second fluid inlet opening of said second cylinder portion.
23. The disc brake caliper assembly according to claim 22, wherein
said first fluid outlet opening of said first cylinder portion and
said second fluid inlet opening of said second cylinder portion are
fixedly coupled to opposite ends of a fluid connection hose.
24. The disc brake caliper assembly according to claim 23, wherein
said second cylinder portion includes an access opening formed at a
free end thereof with a sealing cap mounted in said access
opening.
25. The disc brake caliper assembly according to claim 24, wherein
said second cylinder portion is identical to said first cylinder
portion.
26. The disc brake caliper assembly according to claim 20, wherein
said first and second pistons are normally biased toward said
release positions by first and second biasing members,
respectively.
27. The disc brake caliper assembly according to claim 26, wherein
said first and second biasing members are cone springs.
28. The disc brake caliper assembly according to claim 1, wherein
said first fluid inlet opening of said first cylinder portion is
fixedly coupled to a fluid supply hose.
29. The disc brake caliper assembly according to claim 28, wherein
said first cylinder portion and said fluid supply hose are
constructed metal and are fixedly coupled together by welding or
brazing.
30. The disc brake caliper assembly according to claim 1, wherein
said first piston is normally biased toward said release position
by a first biasing member.
31. The disc brake caliper assembly according to claim 30, wherein
said first biasing member is a cone spring.
32. The disc brake caliper assembly according to claim 30, wherein
said first cylinder portion includes an abutment ring coupled
therein to engage one end of said biasing member and the first
piston includes a contact surface arranged to engage the other end
of said biasing member.
33. The disc brake caliper assembly according to claim 32, wherein
said first piston is a step shaped member with a first enlarged end
arranged adjacent said first fluid inlet opening to form said
contact surface and a second reduced end arranged adjacent said
first friction member.
34. The disc brake caliper assembly according to claim 33, wherein
said enlarged end includes an annular external groove with an
O-ring received therein to form a fluid tight seal with an interior
wall of said first cylinder portion.
35. The disc brake caliper assembly according to claim 33, wherein
said enlarged end includes a plurality of protrusions extending
axially therefrom to form a free end of said first piston.
36. The disc brake caliper assembly according to claim 35, wherein
each of said protrusions is arc-shaped.
37. The disc brake caliper assembly according to claim 33, wherein
said first friction member is coupled to said reduced end and
arranged to contact said abutment ring when said first piston is in
said release position.
38. The disc brake caliper assembly according to claim 37, wherein
said reduced end has an opening formed in a free end thereof and
said first friction member includes a projection coupled within
said opening.
39. The disc brake caliper assembly according to claim 1, wherein
said support portion includes a first housing part with an
attachment plate and a first side plate extending from said
attachment plate to support said first cylinder portion.
40. The disc brake caliper assembly according to claim 39, wherein
said first housing part includes a second side plate extending from
said attachment plate to form a substantially U-shaped member.
41. The disc brake caliper assembly according to claim 40, wherein
each of said first and second side plates includes a cylinder
support flange arranged to contact an end plate of said first
cylinder portion.
42. The disc brake caliper assembly according to claim 40, wherein
each of said first and second side plates is a substantially
L-shaped member.
43. The disc brake caliper assembly according to claim 39, wherein
said support portion includes a second housing part coupled to said
attachment plate.
44. A disc brake caliper assembly comprising: a caliper housing
including a support portion and a first cylinder portion coupled to
said support portion, said first cylinder portion being formed of
deformed sheet material, said first cylinder portion having a first
piston chamber with a first fluid inlet opening fluidly coupled to
said first piston chamber and a first piston receiving opening;
first and second friction members coupled to said caliper housing
to form a rotor receiving slot therebetween, at least said first
friction member being movably coupled to said caliper housing; and
a first piston movably coupled in said first piston chamber of said
caliper housing to move said first friction member between a
release position and a braking position.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention generally relates to a disc brake assembly
for a bicycle. More specifically, the present invention relates a
disc brake assembly having a caliper housing that is primary
constructed of deformed sheet material.
[0003] 2. Background Information
[0004] Bicycling is becoming an increasingly popular form of
recreation as well as a means of transportation. Moreover,
bicycling has become a very popular competitive sport. Whether the
bicycle is used for recreation, transportation or competition, the
bicycle industry is constantly improving their components. One
particular component of the bicycle, which has been extensively
redesigned over the past years, is the braking systems of
bicycles.
[0005] There are several types of bicycle brake devices, which are
currently available on the market. Examples of some types of common
bicycle brake devices include rim brakes, caliper brakes and disc
brakes. If a rider wants a very high performance brake system, then
the rider typically wants a disc brake system. Disc brake systems
provide a substantial braking power in relationship to the amount
of braking force applied to the brake lever. Moreover, disc brake
systems typically provide a high level of consistency in all types
of weather and riding conditions. However, one problem with disc
brakes is that they can be complicated and expensive to manufacture
and assemble.
[0006] Specifically, these prior art disc brakes are typically
constructed of several parts with each part constructed of die cast
metallic material. Alternatively, these parts can be machined, or
both die cast and subsequently machined. These processes can be
time consuming and expensive. The parts are usually connected via
numerous bolts and utilize sealing members to prevent leakage of
the hydraulic or actuating fluid. Thus, these prior disc brakes are
somewhat complicated. Some prior disc brakes utilize dual pistons
and/or opposing single pistons to move the friction member(s) to
engage the brake rotor and apply a stopping force. Thus, these
prior art disc brakes can require internal fluid passageways and
can be somewhat intricate internally. Moreover, these prior disc
brakes can be quite heavy.
[0007] In view of the above, there exists a need for a disc brake
for a bicycle which overcomes the above mentioned problems in the
prior art. This invention addresses this need in the prior art as
well as other needs, which will become apparent to those skilled in
the art from this disclosure.
SUMMARY OF THE INVENTION
[0008] One object of the present invention is to provide a disc
brake, which is relatively simple and inexpensive to manufacture
and assemble.
[0009] Another object of the present invention is to provide disc
brake, which is relatively lightweight.
[0010] Another object of the present invention is to provide disc
brake, which provides efficient and reliable stopping power.
[0011] The foregoing objects can basically be achieved by providing
a disc brake caliper assembly comprising a caliper housing, first
and second friction members, and a first piston. The caliper
housing includes a support portion and a first cylinder portion
coupled to the support portion. The first cylinder portion has a
first piston chamber with a first fluid inlet opening fluidly
coupled to the first piston chamber and a first piston receiving
opening. The first cylinder portion is an independent component
from the support portion. The first and second friction members are
coupled to the caliper housing to form a rotor receiving slot
therebetween. At least the first friction member is movably coupled
to the caliper housing. The first piston is movably coupled in the
first piston chamber of the caliper housing to move the first
friction member between a release position and a braking
position.
[0012] The foregoing objects can also basically be achieved by
providing a a disc brake caliper assembly comprising a caliper
housing, first and second friction members, and a first piston. The
caliper housing includes a support portion and a first cylinder
portion coupled to the support portion. The first cylinder portion
is formed of deformed sheet material. The first cylinder portion
has a first piston chamber with a first fluid inlet opening fluidly
coupled to the first piston chamber and a first piston receiving
opening. The first and second friction members are coupled to the
caliper housing to form a rotor receiving slot therebetween. At
least the first friction member is movably coupled to the caliper
housing. The first piston is movably coupled in the first piston
chamber of the caliper housing to move the first friction member
between a release position and a braking position.
[0013] These and other objects, features, aspects and advantages of
the present invention will become apparent to those skilled in the
art from the following detailed description, which, taken in
conjunction with the annexed drawings, discloses preferred
embodiments of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Referring now to the attached drawings which form a part of
this original disclosure:
[0015] FIG. 1 is a diagrammatic elevational view of a bicycle disc
brake with a disc brake caliper assembly in accordance with a first
embodiment of the present invention;
[0016] FIG. 2 is an enlarged outside elevational view of the disc
brake caliper assembly illustrated in FIG. 1, with portions of the
disc brake rotor cut away;
[0017] FIG. 3 is a partially exploded view of the disc brake
caliper assembly illustrated in FIG. 2, with the front fork removed
from the front wheel for the purpose of illustration;
[0018] FIG. 4 is an end elevational view of the front hub of the
front bicycle wheel illustrated in FIGS. 1 and 2, with portions
broken away to show the attachment between the disc brake rotor and
the hub body;
[0019] FIG. 5 is an end elevational view of the disc brake caliper
assembly illustrated in FIGS. 1-3, with the disc brake caliper
assembly removed from the front fork;
[0020] FIG. 6 is a partial, cross-sectional view of the disc brake
caliper assembly illustrated in FIGS. 1-3 and 5, as viewed along
section line 6-6 of FIG. 2;
[0021] FIG. 7 is an end elevational view of a first housing part of
the disc brake caliper assembly illustrated in FIGS. 1-3, 5 and
6;
[0022] FIG. 8 is an inside elevational view of the first housing
part illustrated in FIG. 7;
[0023] FIG. 9 is a bottom view of the first housing part
illustrated in FIGS. 7 and 8;
[0024] FIG. 10 is an outside elevational view of the first housing
part illustrated in FIGS. 7-9;
[0025] FIG. 11 is a cross-sectional view of the first housing part
illustrated in FIGS. 7-10, as viewed along section line 11-11 in
FIG. 10;
[0026] FIG. 12 is an end elevational view of a second housing part
of the disc brake caliper assembly illustrated in FIGS. 1-3, 5 and
6;
[0027] FIG. 13 is an inside elevational view of the second housing
part illustrated in FIG. 12;
[0028] FIG. 14 is an outside elevational view of the second housing
part illustrated in FIGS. 12 and 13;
[0029] FIG. 15 is a cross-sectional view of the second housing part
illustrated in FIGS. 12-14, as viewed along section line 15-15 of
FIG. 14;
[0030] FIG. 16 is an end elevational view of a cylinder portion of
the disc brake caliper assembly illustrated in FIGS. 1-3, 5 and
6;
[0031] FIG. 17 is an inside elevational view of the cylinder
portion illustrated in FIG. 16;
[0032] FIG. 18 is an outside elevational view of the cylinder
portion illustrated in FIGS. 16 and 17;
[0033] FIG. 19 is a cross-sectional view of the cylinder portion
illustrated in FIGS. 16-18, as viewed along section line 19-19 of
FIG. 18;
[0034] FIG. 20 is an end elevational view of a mounting member of
the disc brake caliper assembly illustrated in FIGS. 1-3, 5 and
6;
[0035] FIG. 21 is an inside elevational view of the mounting member
illustrated in FIG. 20;
[0036] FIG. 22 is a transverse end elevational view of the mounting
member illustrated in FIGS. 21 and 22;
[0037] FIG. 23 is an end elevational view of a piston of the disc
brake caliper assembly illustrated in FIGS. 1-3, 5 and 6;
[0038] FIG. 24 is an inside elevational view of the piston
illustrated in FIG. 23;
[0039] FIG. 25 is an outside elevational view of the piston
illustrated in FIGS. 23 and 24;
[0040] FIG. 26 is a cross-sectional view of the piston illustrated
in FIGS. 23-25, as viewed along section line 26-26 of FIG. 25;
[0041] FIG. 27 is an end elevational view of a first friction
member of the disc brake caliper assembly illustrated in FIGS. 1-3,
5 and 6;
[0042] FIG. 28 is an inside elevational view of the first friction
member illustrated in FIG. 27;
[0043] FIG. 29 is an outside elevational view of the first friction
member illustrated in FIGS. 27 and 28;
[0044] FIG. 30 is a cross-sectional view of the first friction
member illustrated in FIGS. 27-29, as viewed along section line
30-30 of FIG. 29;
[0045] FIG. 31 is an enlarged outside elevational view of a disc
brake caliper assembly in accordance with a second embodiment of
the present invention;
[0046] FIG. 32 is a partial cross-sectional view of the disc brake
caliper assembly illustrated in FIG. 31, as viewed along section
line 32-32 of FIG. 31;
[0047] FIG. 33 is an outside elevational view of a first housing
part of the disc brake caliper assembly illustrated in FIGS. 31 and
32;
[0048] FIG. 34 is an end elevational view of the first housing part
illustrated in FIG. 33;
[0049] FIG. 35 is an end elevational view of the first housing part
illustrated in FIGS. 33 and 34, as viewed along arrow A in FIG.
33;
[0050] FIG. 36 is an end elevational view of the first housing part
illustrated in FIGS. 33-35 as viewed along arrow B in FIG. 33;
[0051] FIG. 37 is a cross-sectional view of the first housing part
illustrated in FIGS. 33-36, as viewed along section line 37-37 in
FIG. 33;
[0052] FIG. 38 is an end elevational view of a second housing part
of the disc brake caliper assembly illustrated in FIGS. 31 and
32;
[0053] FIG. 39 is an inside elevational view of the second housing
part illustrated in FIG. 38;
[0054] FIG. 40 is an outside elevational view of the second housing
part illustrated in FIGS. 38 and 39;
[0055] FIG. 41 is a cross-sectional view of the second housing part
illustrated in FIGS. 38-40, as viewed along section line 41-41 of
FIG. 40;
[0056] FIG. 42 is a side elevational view of a spacer of the disc
brake caliper assembly illustrated in FIGS. 31 and 32;
[0057] FIG. 43 is an end elevational view of the spacer illustrated
in FIG. 42;
[0058] FIG. 44 is an end elevational view of a cylinder portion of
the disc brake caliper assembly illustrated in FIGS. 31 and 32;
[0059] FIG. 45 is an inside elevational view of the first cylinder
portion illustrated in FIG. 44;
[0060] FIG. 46 is an outside elevational view of the first cylinder
portion illustrated in FIGS. 44 and 45;
[0061] FIG. 47 is a cross-sectional view of the first cylinder
portion illustrated in FIGS. 44-46, as viewed along section lines
47-47 of FIG. 44; and
[0062] FIG. 48 is a partial, cross-sectional view of a disc brake
caliper assembly in accordance with a third embodiment of the
present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0063] Referring initially to FIG. 1, a front portion of a bicycle
is illustrated with a disc brake assembly 12 coupled thereto in
accordance with one embodiment of the present invention. Bicycles
are well known in the art, and thus, the bicycle and its various
components will not be discussed or illustrated in detail herein.
Rather, it will be apparent to those skilled in the art that the
bicycle can be any type of bicycle, e.g., mountain bike, a hybrid
bike, downhill bike or a road bike. The bicycle basically includes
a conventional bicycle frame with a handle bar 14, front and rear
forks 16 (only a portion of the front fork shown), front and rear
wheels 18 (only a portion of the front wheel shown) and a drive
train (not shown).
[0064] Only the front portion of the bicycle (front fork 16) is
illustrated as having the disc brake assembly 12. However, it will
be apparent to those skilled in the art from this disclosure that a
second disc brake assembly 12 can be utilized for stopping the rear
wheel of the bicycle. Moreover, it will also be apparent to those
skilled in the art from this disclosure that various changes and
modifications can be made from the embodiments disclosed herein
without departing from the scope of the invention as defined in the
appended claims.
[0065] Referring to FIGS. 2-6, the disc brake assembly 12 basically
includes a disc brake caliper assembly 20, a disc brake rotor 22
and a brake operating mechanism 24. The disc brake caliper assembly
20 is mounted on front fork 16 of the bicycle adjacent the disc
brake rotor 22. The disc brake rotor 22 is fixedly coupled to front
wheel 18 for rotation therewith in a conventional manner. The brake
operating mechanism 24 is preferably fixedly mounted on handle bar
14 adjacent the hand portion of handle bar 14. The brake operating
mechanism 24 is operated such that at least one friction member of
the disc brake caliper assembly 20 moves from a release position to
a braking position. In the release position, the bicycle wheel 18
and the disc brake rotor 22 are free to rotate, while in the
braking position a braking force is applied against the disc brake
rotor 22 to stop rotation of the bicycle wheel 18 and the disc
brake rotor 22.
[0066] As best seen in FIGS. 5 and 6, the disc brake caliper
assembly 20 basically includes a caliper housing 26 with a pair
(first and second) of friction members 28a and 28b coupled to the
caliper housing 26. In the illustrated embodiment, the (second)
friction member 28b is fixedly coupled to the caliper housing 26,
while the other (first) friction member 28a is movable coupled to
the caliper housing 26. A rotor receiving slot is formed between
friction members 28a and 28b to receive the disc brake rotor 22.
The movable friction member 28a (first friction member) is moved by
a piston mechanism 30 in response to movement of the brake
operating mechanism 24 to apply a braking force on the disc brake
rotor 22, as discussed in more detail below.
[0067] The caliper housing 26 basically includes a support portion
32 and a first cylinder portion 34 coupled to the support portion
32. The caliper housing 26 also preferably includes a mounting
portion 36 for coupling with the support portion 32 and the
cylinder portion 34 to the front fork 16. Preferably, the support
portion 32, the cylinder portion 34 and the mounting portion 36 are
each formed of one or more pieces of deformed sheet material such
as press formed sheet metal. The various pieces are preferably
fixedly coupled together by welding and/or brazing and/or bolted
together as discussed below in more detail. In other words, each of
the support portion 32, the cylinder portion 34 and the mounting
portion 36 are preferably formed by one or more independent members
that are subsequently fixedly coupled together to form the caliper
housing 26. In any event, preferably the cylinder portion 34 is at
least an independent member from the support portion 32 such that
the cylinder portion 34 can be primarily formed of deformed sheet
material.
[0068] The support portion 32 basically includes a first housing
part 38a and a second housing part 38b fixedly coupled together.
Preferably, the first and second housing parts38a and 38b are
fixedly coupled together by a pair of bolts 39a with a pair of nuts
39b threadedly coupled to the bolts 39a. The first housing part 38a
is preferably constructed of a single piece of deformed sheet
material such as press formed sheet metal. Likewise, the second
housing part 38b is also preferably formed of a single piece of
deformed sheet material such as press formed sheet metal. The
cylinder portion 34 is preferably fixedly coupled to the first
housing part 38a by welding or brazing to form a rigid unitary body
with the first housing part 38a. Likewise, the mounting portion 36
is also preferably fixedly coupled with the first housing part 38a
and the cylinder portion 34 by welding or brazing to form the rigid
unitary body with the cylinder portion 34 and the first housing
part 38a. Accordingly, each part of the caliper housing 26 is of
deformed sheet material, except for the fastening elements (the
welds, the bolts and the nuts).
[0069] Referring to FIGS. 7-11, the first housing part 38a
basically includes an (first) attachment plate 40 and a pair (first
and second) of side plates 42. The first housing part 38a is
preferably constructed of a single piece of deformed sheet material
such press formed sheet metal. The attachment plate 40 has a pair
of attachment holes 41 formed therein to receive the bolts 39a.
Each of the side plates 42 is preferably a substantially L-shaped
plate member. More specifically, each of the side plates 43 is
preferably a curved L-shaped member (or J-shaped member), and
includes a cylinder support flange 43 formed at a free end thereof.
The cylinder support flanges 43 extend at substantially right
angles relative to the side plates 42, and extend toward each
other. The support flanges 43 are configured to support an end of
the cylinder portion 34 of the caliper housing 26. The side plates
42 are also configured to support the mounting portion 36, as
discussed below in more detail. The attachment plate 40 is
preferably a substantially flat rectangular-shaped member that is
designed to contact a portion of the second housing part 38b.
[0070] Referring to FIGS. 12-15, the second housing part 38b
basically includes an (second) attachment plate 44 and a
reinforcing flange 46. The second housing part 38b is preferably
constructed of a single piece of deformed sheet material such press
formed sheet metal. The attachment plate 44 has a pair of
attachment holes 45 formed therein to receive the bolts 39a. When
the second housing part 38b is coupled to the first housing part
38a via the bolts 39a and the nuts 39b, a portion of the (second)
attachment plate 44 contacts the (first) attachment plate 40 of the
first housing part 38. In other words, the attachment holes 45 are
aligned with the attachment holes 41 such that bolts 39a can be
mounted therein. The reinforcing flange 46 is a substantially
U-shaped flange extending from one side of the attachment plate 44.
The second friction member 28b is attached to the opposite side of
the attachment plate 44 from the reinforcing flange 46 at a free
end of the attachment plate 44.
[0071] Preferably, the second friction member 28b is fixedly
coupled to the attachment plate 44 via adhesive or glue. Of course,
it will be apparent to those skilled in the art that the second
friction member 28b could be fixedly coupled to the second housing
part 38b utilizing any suitable technique as needed and/or desired.
The reinforcing flange 46 preferably extends at substantially a
right angle relative to the attachment plate 44, and includes a
transverse section 48 and a pair of longitudinal sections 49. The
longitudinal sections 49 are tapered toward the attachment plate 44
as the longitudinal sections 49 extend away from the transverse
section 48. Preferably, the longitudinal sections 49 extend
completely to the free end of the attachment plate 44 such that a
lightweight, rigid member is formed.
[0072] Referring to FIGS. 16-19, the (first) cylinder portion 34
basically includes an enlarged section 50 integrally formed with a
reduced diameter section 52. The cylinder portion 34 is preferably
a tubular member that isconstructed of a single piece of deformed
sheet material such as press formed sheet metal. In other words,
the cylinder portion 34 is an independent member from the support
portion 32 (the first and second housing parts 38a and 38b).
[0073] The enlarged section 50 and the reduced section 52 are
preferably cylindrical sections that have a circular-shaped cross
section. An end plate 54 connects the enlarged section 50 with the
reduced section 52 to form a one-piece unitary member. The internal
surface of the end plate 54 forms an abutment surface for the
piston mechanism 30, while the external surface of the end plate 54
forms an attachment surface configured to be supported by the
cylinder support flanges 43 of the first housing part 38a.
Preferably, the cylinder support flanges 43 are fixedly coupled to
the end plate 54 of the cylinder portion 34 by welding or brazing
such that the cylinder portion 34 is fixedly coupled to the first
housing part 38a.
[0074] The cylinder portion 34 includes a (first) piston chamber 56
with a (first) fluid inlet opening 57 fluidly coupled to the piston
chamber 56 and a (first) piston receiving opening 59. The piston
mechanism 30 is at least partially received in the piston chamber
56. The enlarged section 50 of the cylinder portion 34 includes an
annular groove 51 designed to engage a portion of the piston
mechanism 30, as discussed below in more detail. Preferably, the
open end of the reduced diameter section 52 forms the fluid inlet
opening 57 of the cylinder portion 34. The fluid inlet opening 57
is designed to be directly fixedly coupled to a fluid supply hose
60, as also discussed in more detail below.
[0075] Referring to FIGS. 19-22, the mounting portion 36 is
preferably a plate-shaped strap member constructed of a single
piece of deformed sheet material such as press formed sheet metal.
The mounting portion 36 basically includes a curved cylinder
support section 62 with a pair of mounting sections 64 extending
from opposite ends of the curved cylinder support section 62. Each
of the mounting sections 64 includes a mounting hole 65. The
mounting sections 64 are utilized to fixedly couple the disc brake
caliper assembly 20 to the front fork 16 of the bicycle in a
relatively conventional manner.
[0076] The mounting portion 36 is preferably fixedly coupled to
both the cylinder portion 34 and the first housing part 38a by
welding or brazing. More specifically, the curved cylinder support
section 62 is preferably coupled to the external surface of the
enlarged section 50 of the cylinder portion 34. Also, the curved
cylinder support section 62 is preferably coupled to the inner
edges of the side plates 42 of the first housing part 38a. In other
words, the mounting portion 36 is preferably fixedly coupled to and
arranged between the cylinder portion 34 and the first housing part
38a. Preferably, these members are coupled together by welding or
brazing.
[0077] As discussed above, preferably the mounting portion 36 is
formed as a one-piece unitary member that is separate from the
cylinder portion 34 and the support portion 32 (first housing part
38a and second housing part 38b). However, it will be apparent to
those skilled in the art that mounting portion 36 could be
integrally formed with the first housing part 38a, as discussed
below in reference to another preferred embodiment of the present
invention.
[0078] Referring to FIGS. 6 and 23-30, the piston mechanism 30
basically includes a (first) piston 70 movably coupled in the
piston chamber 56 and a friction member support portion 72 coupled
to the piston 70. The piston 70 is that can be constructed of any
suitable material. For example, the piston 70 can be constructed of
machined metallic material such as machined aluminum or a resin
with heat resistant characteristics. The piston 70 preferably has a
step-shaped configuration. The friction member support portion 72
is also preferably constructed of a machined metallic material such
as machined steel. The friction member support portion 72 is
releasably coupled to the piston 72 to move with the piston 70
during actuation. The piston 70 is normally biased toward a release
position from a braking position. The piston 70 is moved from the
release position to the braking position via fluid pressure
supplied by the brake operating mechanism 24 in a conventional
manner.
[0079] The piston 70 basically includes a seal portion 74 (first
enlarged end) with a central protrusion 76 (second reduced end)
extending axially therefrom. The seal portion 74 has a plurality of
arc-shaped projections 75 extending axially from the opposite side
from the central protrusion 76. The projections 75 contact the
internal contact surface of the end plate 54 of the cylinder
portion 34 when the piston 70 is in the release position. The
projections 75 aid in the transmission of hydraulic pressure. While
the projections 75 are illustrated as arc-shaped, it will be
apparent to those skilled in the art that other shapes could be
utilized if needed and/or desired. An annular groove 78 is formed
in the external surface of the seal portion 74. An O-ring 79 is
mounted in the groove 78 to form a fluid tight seal. A biasing
member (e.g., a cone spring or a coil spring or Belleville washers)
80 is mounted on the central protrusion 76 of the piston 70. One
end of the biasing member 80 is arranged to contact the seal
portion 74 of the piston 70, while the other end of the biasing
member 80 is arranged to contact an annular abutment ring 82.
[0080] The annular ring 82 is preferably a snap ring that is
mounted in the annular groove 51 formed in the enlarged section 50
of the cylinder portion 34 to retain the piston 70 within the
piston chamber 56. The friction member support portion 72 is also
preferably a step shaped member. More specifically, the friction
member support portion 72 includes a central stump 84 extending
from a base portion 86. The central stump 84 includes an annular
groove 85 with an O-ring received therein. The central protrusion
76 of the piston 70 includes a stepped bore 88 that is sized and
configured to retain the central stump 84 with the O-ring therein.
Thus, the friction member support portion 72 is releasable coupled
to the piston 70. When the piston 70 is in the release position,
the base portion 86 contacts an opposite end of the annular ring
82.
[0081] In the illustrated embodiment, the friction member support
portion 72 has the first friction member 28a fixedly coupled
thereto via adhesive or glue. Of course, it will be apparent to
those skilled in the art that the first friction member 28a could
be coupled to the friction member support portion in any
conventional manner if needed and/or desired. Moreover, it will be
apparent to those skilled in the art that the first friction member
28a could be integrally formed with friction member support portion
72 if needed and/or desired. Furthermore, it will be apparent to
those skilled in the art from this disclosure that the piston 70
and/or the friction member support portion 72 could be constructed
of other materials as needed and/or desired. For example, the
piston 70 and/or the friction member support portion 72 could be
constructed of a heat resistant material such as resin, molded
plastic or the like, if needed and/or desired.
[0082] Referring again to FIG. 3, the fluid supply hose 60 is
fixedly coupled to the reduced diameter section 52 of the cylinder
portion 34 by brazing or welding. Specifically, the fluid supply
hose 60 is preferably constructed of rigid metallic material with
one end of the fluid supply hose received in the fluid inlet
opening 57 of the cylinder portion 34, and welded or brazed
thereto. The opposite end of the fluid supply hose 60 is preferably
fixedly coupled to a metal connection member 61 by welding or
brazing. The connection member 61 is fluidly coupled to the brake
operating mechanism 24 in a conventional manner such that actuating
fluid is supplied to the disc brake caliper assembly 20.
[0083] Referring again to FIG. 1, the brake operating mechanism 24
will now be described in more detail. Basically, the brake
operating mechanism 24 is designed to actuate the disc brake
caliper assembly 20 to apply a forcible gripping action on the
brake disc 22 to stop rotation of the front wheel 18. The brake
operating mechanism 24 basically includes a brake lever 90, a
hydraulic or master cylinder 91, a hydraulic or master piston 92,
and an actuation fluid reservoir 93.
[0084] Preferably, the brake operating mechanism 24 is a single
unit, which is mounted on the handlebar 14. In particular, the
brake lever 90 includes a mounting portion 94 and a lever portion
95. The mounting portion 94 is designed to be clamped onto the
handle bar 14 in a conventional manner. The mounting portion 94 is
integrally formed with the master cylinder 91 such that the master
cylinder 91, the master piston 92 and the actuation fluid reservoir
93 are all supported on the mounting portion 94 of the brake lever
90. The lever portion 95 is pivotally coupled to the mounting
portion 94 for movement between a release position and a braking
position. Normally, the lever portion 94 is maintained in the
release position in a conventional manner.
[0085] The master piston 92 is movably mounted within the master
cylinder 91 in a conventional manner. More specifically, the
actuation fluid reservoir 93 is mounted on the master cylinder 92
and in fluid communication with the interior bore of the master
cylinder 91 for supplying the actuation fluid thereto. The master
piston 92 is connected at one end to the lever portion 95 for
axially moving the master piston 92 within the master cylinder 91.
Accordingly, actuation of the lever portion 95 causes the master
piston 92 to move axially within the master cylinder 91. This
movement of the master piston 92 within the master cylinder 91
directs fluid pressure through a hydraulic line 96, which is
coupled to the disc brake caliper assembly 20. Thus, the
pressurized actuation fluid causes the piston 70 and the friction
member 28a to move so as to engage the disc brake rotor 22 between
the friction members 28a and 28b to stop rotation of wheel 18.
Second Embodiment
[0086] Referring to FIGS. 31-47, a disc brake caliper assembly 120
is illustrated in accordance with a second embodiment of the
present invention. Disc brake caliper assembly 120 of this second
embodiment is substantially identical to the disc brake caliper
assembly 20 of the first embodiment, except that a modified caliper
housing 126 is utilized. Thus, this second embodiment will not be
discussed or illustrated in detail herein. Rather, the following
description will focus mainly on the differences. However, it will
be apparent to those skilled in the art that most of the
descriptions of the disc brake caliper assembly 20 of the first
embodiment also apply to the disc brake caliper assembly 120 of
this second embodiment.
[0087] The disc brake caliper assembly 120 is designed to be used
with the brake operating mechanism 24 of the first embodiment, and
basically includes the caliper housing 126, a pair (first and
second) of friction members 128a and 128b, and a piston mechanism
130. The friction members 128a and 128b are identical to the
friction members 28a and 28b of the first embodiment. Additionally,
the piston mechanism 130 is identical to the piston mechanism 30 of
the first embodiment. On the other hand, the caliper housing 126 is
a modified version of the caliper housing 26 of the first
embodiment.
[0088] Specifically, the caliper housing 126 includes a support
portion 132, a cylinder portion 134 and a mounting portion 136. The
support portion 132 includes a first housing part 138a, a spacer
138b and a second housing part 138c. The first and second housing
parts 138a and 138c are fixedly coupled together by a pair of bolts
139 with the spacer 138b located therebetween. The mounting portion
136 basically includes first and second mounting sections 162,
which are integrally formed with the first housing part 138a. The
first housing part 138a includes an attachment plate 140 with a
pair of attachment holes 141 and a pair of side plates 142a and
142b. The mounting sections 162 extend from the side plates 142a
and 142b. A cylinder support opening 143 is formed in the
attachment plate 140. In other words, the first housing part 138a
is integrally formed with the mounting sections 162 to form the
mounting portion 136 of the caliper housing 126.
[0089] The second housing part 138c includes an attachment plate
144 with a pair of threaded bores 145 formed therein. The second
friction member 128b is fixedly coupled to the attachment plate
144. Two reinforcing flanges 146 extend in a generally longitudinal
direction relative to attachment plate 144 and are substantially
perpendicular to the attachment plate 144. The threaded holes 145
of the attachment plate 144 eliminate the need for the nuts 39b (of
the first embodiment). The spacer 138b includes a pair of mounting
holes formed therein for receiving the bolts 139.
[0090] The cylinder portion 134 is a modified version of the
cylinder portion 34 of the first embodiment. Specifically, the
cylinder portion 134 includes and enlarged section 150, a reduced
diameter section 152 and an end plate 154. A piston chamber 156 is
formed within the cylinder portion 134 and includes a fluid inlet
opening 157 fluidly coupled to the piston chamber 156 and a piston
receiving opening 159 arranged at an opposite end of the piston
chamber 156 from the fluid inlet opening 157. A pair of flanges 151
are formed adjacent the piston receiving opening 159 and extend
substantially perpendicularly from the enlarged section 150. Two
cutouts or notches 161 are formed on opposite sides of the flanges
151. The flanges contact the attachment plate 144.
[0091] Preferably, the caliper housing assembly 120 of this second
embodiment is constructed and assembled in a manner identical to
the first embodiment, except that the specific structure of some of
the parts have been modified. In other words, the cylinder portion
134 is preferably constructed of a single piece of deformed sheet
material such as press formed sheet metal. Also, the first housing
part 138a is preferably constructed of a single piece of deformed
sheet material such as press formed sheet metal. The first cylinder
portion 134 is preferably fixedly coupled to the first housing part
138a by welding or brazing. The second housing part 138b is also
preferably constructed of a single piece of deformed sheet material
such as press formed sheet metal.
Third Embodiment
[0092] Referring now to FIG. 48, a disc brake caliper assembly 220
is illustrated in accordance with a third embodiment of the present
invention. The disc brake caliper assembly 220 of this third
embodiment is substantially identical to the disc brake caliper
assembly 120 of the second embodiment, except that the disc brake
caliper assembly 220 is designed to utilize a pair of modified
piston mechanisms 230. Since the disc brake caliper assembly 220 is
substantially identical to the disc brake caliper assembly 120, the
disc brake caliper assembly 220 will not be discussed and/or
illustrated in detail herein. Rather, the following description
will focus mainly on the differences of the disc brake caliper
assembly 220 from the prior embodiments. However, it will be
apparent to those skilled in the art from this disclosure that most
of the descriptions of the disc brake caliper assemblies 20 and 120
also apply to the disc brake caliper assembly 220.
[0093] The disc brake caliper assembly 220 is designed to be used
with the brake operating mechanism 24 of the first embodiment, and
basically includes a caliper housing 226, a pair (first and second)
of friction members 128a and 128b, and a pair of piston mechanisms
230. The friction members 228a and 228b are identical to the
friction members of the first embodiment. Additionally, each of the
piston mechanisms 230 is substantially identical to the piston
mechanism 130 of the second embodiment.
[0094] Specifically, the caliper housing 226 includes a support
portion 232, a pair (first and second) of cylinder portions 234 and
a mounting portion 236. The support portion 232 includes a first
housing part 238a, a spacer 238b and a second housing part 238c.
The first and second housing parts 238a and 238c are fixedly
coupled together by a pair of bolts 239 with the spacer 238b
located therebetween. The mounting portion 236 is basically
identically to the mounting portion 136, and thus, is integrally
formed with the first housing part 238a. The first housing part
238a is basically identically to the first housing part 138, and
thus, has a cylinder support opening 243 for supporting one of the
cylinder portions 234.
[0095] The second housing part 238c is basically identical to the
second housing part 138c of the second embodiment, except that the
attachment plate 244 has a cylinder support opening 245 for
supporting one of the cylinder portions 234 and the two reinforcing
flanges 246 (only one shown) are longer.
[0096] Each of the piston mechanisms 230 basically includes a
piston 270 movably coupled in the piston chamber 256 of the
corresponding cylinder portion 234 and a friction member support
portion 272 coupled to the piston 270. The pistons 270 are moved
from the release positions to the braking positions via fluid
pressure supplied by the brake operating mechanism 24 in a
conventional manner.
[0097] Each of the pistons 270 basically includes a seal portion
274 (first enlarged end) with a central protrusion 276 (second
reduced end) extending axially therefrom. The seal portion 274 has
a plurality of arc-shaped projections 275 extending axially from
the opposite side from the central protrusion 276. The projections
275 contact the internal contact surface of the cylinder portion
234 when the piston 270 is in the release position. The projections
275 aid in the transmission of hydraulic pressure. The projections
275 are preferably arc-shaped as in the prior embodiments, but
longer in the axial direction. An annular groove 278 is formed in
the external surface of the seal portion 274. An O-ring 279 is
mounted in the groove 278 to form a fluid tight seal. A biasing
member (e.g., Belleville washers) 280 is mounted on the central
protrusion 276 of each of the pistons 270. The first and second
pistons 270 are normally biased toward their release positions by
the first and second biasing members 280, respectively. Each
biasing member 280 in this embodiment is shorter in the axial
direction than in the prior embodiments, since there are two piston
mechanisms 230 with one biasing member 280 for each piston 270. One
end of the biasing member 280 is arranged to contact the seal
portion 274 of the piston 270, while the other end of the biasing
member 280 is arranged to contact an annular abutment ring 282. In
the illustrated embodiment, the friction member support portions
272 have the friction members 228a and 228b fixedly coupled thereto
via adhesive or glue.
[0098] The cylinder portions 234 are identical and fluidly
connected by a conduit or fluid connection hose 284. The cylinder
portions 234 are fixedly coupled to one of the housing parts 238a
and 238c. Each of the cylinder portions 234 forms a piston chamber
with a pair of inlet/outlet ports or fluid inlet/outlet openings
257 and 258. Thus, the cylinder portions 234 are identical to the
cylinder portion 134, except that inlet/outlet ports 258 are
provided to receive fittings of the fluid connection hose 284.
[0099] The piston chambers of the cylinder portions 234 are
interconnected by the fluid connection hose 284 so that both
pistons 270 move simultaneously. More specifically, one of the
cylinder portions 234 has the port 257 (first fluid inlet opening)
fixedly coupled to the fluid supply hose 260 and the port 258
(first fluid outlet opening) in fluid communication with the port
258 (second fluid inlet opening) of the other cylinder portion 234
via the fluid connection hose 284. The other cylinder portion 234
has a sealing cap 267 mounted in the port 257 (access opening).
[0100] The terms of degree such as "substantially", "about" and
"approximately" as used herein mean a reasonable amount of
deviation of the modified term such that the end result is not
significantly changed. These terms should be construed as including
a deviation of at least .+-.5% of the modified term if this
deviation would not negate the meaning of the word it modifies.
[0101] While only selected embodiments have been chosen to
illustrate the present invention, it will be apparent to those
skilled in the art from this disclosure that various changes and
modifications can be made herein without departing from the scope
of the invention as defined in the appended claims. Furthermore,
the foregoing description of the embodiments according to the
present invention are provided for illustration only, and not for
the purpose of limiting the invention as defined by the appended
claims and their equivalents.
* * * * *