JP2007225057A - Disk brake and its manufacturing method - Google Patents

Disk brake and its manufacturing method Download PDF

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JP2007225057A
JP2007225057A JP2006048842A JP2006048842A JP2007225057A JP 2007225057 A JP2007225057 A JP 2007225057A JP 2006048842 A JP2006048842 A JP 2006048842A JP 2006048842 A JP2006048842 A JP 2006048842A JP 2007225057 A JP2007225057 A JP 2007225057A
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opening
lid member
cylinder
bore
bottom wall
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JP4864486B2 (en
JP2007225057A5 (en
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Keisuke Nanri
圭介 南里
Tomoji Sato
知司 佐藤
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Hitachi Ltd
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Hitachi Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a disk brake enabling a reduction in size and weight by fixing a cover member to the opening of a cylinder body with a sufficient strength without increasing the thickness of the bottom part of a cylinder, and its manufacturing method. <P>SOLUTION: The opening 45 having a diameter smaller than the inner diameter of a bore 26 is formed at the bottom of the bore 26 of a caliper body 46. An annular bottom wall 50 is formed in the peripheral area of the opening 45. The thickness of the annular bottom wall 50 is made equal to that of the cover member 43. After a supporter 97 is made to abut on the annular bottom wall 50 from the inside of the bore 26, the cover member 43 is inserted into the opening 45 in the caliper body 46 to make it abut on the support base 97. Then, the cover member 43 is joined to the opening 45 by friction stirring welding. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

この発明は、車両の車軸回転の制動等に用いられるディスクブレーキとその製造方法に関するものである。   The present invention relates to a disc brake used for braking of axle rotation of a vehicle and a manufacturing method thereof.

車両の車輪制動に用いられるディスクブレーキは、ブレーキキャリパにシリンダが設けられ、シリンダのボア内に収容されたピストンが液圧を受けてブレーキパッドをディスクに押圧する構造となっている。
このようなディスクブレーキにおいて、例えばシリンダ内の加工を容易にする等の目的のために、シリンダを、底部の蓋部材と、この蓋部材で閉塞される開口部を有する筒状のシリンダ本体とに分割し、開口部を介してシリンダ本体内の加工等を行った後に、開口部を閉塞するように開口部に蓋部材を取り付けるものがある。この場合、蓋部材の取り付けは、シリンダ本体の開口部に蓋部材を螺合することによって行われている（例えば、特許文献１参照。）。
実開平６−６９４５６号公報 A disc brake used for vehicle wheel braking has a structure in which a cylinder is provided in a brake caliper, and a piston housed in a bore of the cylinder receives a hydraulic pressure to press a brake pad against the disc.
In such a disc brake, for example, for the purpose of facilitating machining in the cylinder, the cylinder is divided into a bottom lid member and a cylindrical cylinder body having an opening closed by the lid member. There is a type in which a lid member is attached to an opening so as to close the opening after being divided and processed in the cylinder body through the opening. In this case, the lid member is attached by screwing the lid member into the opening of the cylinder body (see, for example, Patent Document 1).
Japanese Utility Model Publication No. 6-69456

しかし、この従来のディスクブレーキの場合、シリンダ本体の開口部と蓋部材にネジ溝とネジ山を切らなければならないため、両者の結合を確実にするためには螺合部の軸長をある程度長く確保しなければならない。このため、シリンダの底部の肉厚が厚くなり、ブレーキキャリパが大型・重量化することが懸念されている。   However, in the case of this conventional disc brake, since the thread groove and the thread must be cut in the opening of the cylinder body and the lid member, the axial length of the threaded portion is increased to some extent in order to ensure the coupling between the two. Must be secured. For this reason, there is a concern that the thickness of the bottom of the cylinder becomes thick and the brake caliper becomes large and heavy.

この対策として、現在シリンダ本体の開口部と蓋部材を溶接等によって固着することが検討されている。この場合の具体的手段としては、シリンダ本体の開口部と蓋部材の嵌合部に段差部を設け、両者を段差部の突き合わせによって軸方向に位置決めし、その状態において両者を溶接等によって固着することが考えられている。
しかし、この場合、シリンダ本体の開口部と蓋部材の段差部の加工時に加工誤差が生じ易く、この加工誤差が大きくなると、開口部の周縁部と蓋部材の間に段差ができ、充分な接合強度を得ることが難しくなる。 As a countermeasure, it has been studied to fix the opening of the cylinder body and the lid member by welding or the like. As specific means in this case, a stepped portion is provided in the opening of the cylinder body and the fitting portion of the lid member, both are positioned in the axial direction by butting of the stepped portion, and in this state, both are fixed by welding or the like. It is considered.
However, in this case, a machining error is likely to occur when machining the opening of the cylinder body and the stepped portion of the lid member, and if this machining error becomes large, a step is formed between the peripheral edge of the opening and the lid member, and sufficient bonding is achieved. It becomes difficult to obtain strength.

また、別の手段としては、シリンダ本体の開口部の内径をボアの内径と同じ、若しくは、それよりもよりも大きく形成し、ボアの内側から支持台を挿入した後に開口部に蓋部材を挿入して、蓋部材を支持台上に支持させた状態で蓋部材と開口部を固着することも考えられている。
しかし、この場合も、支持台を開口部に対して高さ方向に正確に位置決めすることが難しく、この位置決めが正確に行われないとやはり開口部の周縁部と蓋部材の間に段差ができてしまい、充分な接合強度の確保が難しくなる。 As another means, the inner diameter of the opening of the cylinder main body is formed to be the same as or larger than the inner diameter of the bore, and the cover member is inserted into the opening after inserting the support base from the inside of the bore. Then, it is also considered that the lid member and the opening are fixed in a state where the lid member is supported on the support base.
However, in this case as well, it is difficult to accurately position the support base in the height direction with respect to the opening, and if this positioning is not performed accurately, there will still be a step between the peripheral edge of the opening and the lid member. As a result, it becomes difficult to ensure sufficient bonding strength.

そこでこの発明は、シリンダの底部の肉厚増加を招くことなく、シリンダ本体の開口部に蓋部材を充分な強度をもって固着できるようにして、装置の小型・軽量化を図ることが可能なディスクブレーキとその製造方法を提供しようとするものである。   Accordingly, the present invention provides a disc brake capable of reducing the size and weight of the device by allowing the lid member to be fixed with sufficient strength to the opening of the cylinder body without increasing the thickness of the bottom of the cylinder. And a method of manufacturing the same.

上記目的を達成するために、請求項１に記載の発明は、ピストンをシリンダのボア内で摺動させて該ピストンによりブレーキパッドをディスクに押圧するディスクブレーキであって、前記シリンダが、底部の蓋部材と、該蓋部材で閉塞される開口部を有するシリンダ本体とによって構成されるディスクブレーキにおいて、前記シリンダ本体の開口部の内径を前記ボアの内径よりも小さくして、前記ボアの底部に前記開口部に沿う環状底壁を設けるとともに、該環状底壁と前記蓋部材の肉厚を同じにするようにした。   In order to achieve the above object, the invention according to claim 1 is a disc brake in which a piston is slid in a bore of a cylinder and a brake pad is pressed against the disc by the piston, and the cylinder has a bottom portion. In a disc brake including a lid member and a cylinder body having an opening closed by the lid member, an inner diameter of the opening of the cylinder body is made smaller than an inner diameter of the bore, and the bottom of the bore is formed. An annular bottom wall is provided along the opening, and the wall thickness of the annular bottom wall and the lid member is the same.

請求項２に記載の発明は、請求項１に記載の発明において、前記蓋部材を、前記シリンダ本体の開口部に摩擦攪拌接合によって接合するようにした。   According to a second aspect of the present invention, in the first aspect of the present invention, the lid member is joined to the opening of the cylinder body by friction stir welding.

請求項３に記載の発明は、ピストンをシリンダのボア内で摺動させて該ピストンによりブレーキパッドをディスクに押圧するディスクブレーキであって、前記シリンダが、底部の蓋部材と、該蓋部材で閉塞される開口部を有するシリンダ本体とによって構成されるディスクブレーキの製造方法において、前記シリンダ本体の開口部の内径を前記ボアの内径よりも小さくして、前記ボアの底部に前記開口部に沿う環状底壁を設けるとともに、該環状底壁と前記蓋部材の肉厚を同じにし、前記ボアの内側から前記環状底壁に支持台を突き当てた後に、前記蓋部材を前記シリンダ本体の開口部に挿入して前記支持台に当接させ、その状態から前記蓋部材と前記開口部とを摩擦攪拌接合によって接合するようにした。   According to a third aspect of the present invention, there is provided a disc brake in which a piston is slid in a bore of a cylinder and the brake pad is pressed against the disc by the piston. The cylinder includes a bottom lid member and the lid member. In a manufacturing method of a disc brake constituted by a cylinder body having an opening to be closed, the inner diameter of the opening of the cylinder body is made smaller than the inner diameter of the bore, and the bottom of the bore follows the opening. An annular bottom wall is provided, the wall thickness of the annular bottom wall is equal to that of the lid member, and after a support is abutted against the annular bottom wall from the inside of the bore, the lid member is opened to the opening of the cylinder body. Then, the lid member and the opening are joined by friction stir welding.

請求項１に記載の発明によれば、ボアの内側からその底部の環状底壁に支持台を突き当て、その状態において蓋部材をシリンダ本体の開口部に挿入して支持台に当接させ、同一高さになった蓋部材と開口部とを固着することができるため、シリンダの底部を薄肉にしたまま蓋部材の取り付け強度を高めることが可能となる。したがって、この発明により、蓋部材の取り付け強度の向上と、装置の小型・軽量化の両立を図ることができる。   According to the first aspect of the present invention, the support base is abutted against the annular bottom wall of the bottom portion from the inside of the bore, and in that state, the lid member is inserted into the opening of the cylinder body and brought into contact with the support base, Since the lid member and the opening having the same height can be fixed, it is possible to increase the attachment strength of the lid member while keeping the bottom of the cylinder thin. Therefore, according to the present invention, it is possible to improve both the attachment strength of the lid member and reduce the size and weight of the apparatus.

請求項２に記載の発明によれば、蓋部材をシリンダ本体の開口部に摩擦攪拌接合するため、上記の基本的な効果を得ることができることに加え、蓋部材をシリンダ本体に確実に密封状態で一体化させることができる。   According to the invention described in claim 2, since the lid member is friction stir joined to the opening of the cylinder body, the above basic effect can be obtained, and the lid member is securely sealed to the cylinder body. Can be integrated.

請求項３に記載の発明によれば、ボアの底部の環状底壁に内側から支持部材を突き当て、その状態で蓋部材をシリンダ本体の開口部から支持台に当接させ、蓋部材と開口部とを摩擦攪拌接合することで、蓋部材を強固に、かつ密封状態で開口部に固着することができるため、シリンダの底部を薄肉化してブレーキキャリパの小型・軽量化を図りつつも、製造の容易化も図ることが可能となる。   According to the third aspect of the present invention, the support member is abutted against the annular bottom wall of the bottom portion of the bore from the inside, and in this state, the lid member is brought into contact with the support base from the opening of the cylinder body. Because the lid member can be firmly and firmly fixed to the opening in a sealed state by friction stir welding with the parts, the bottom part of the cylinder can be made thinner, making the brake caliper smaller and lighter. It is also possible to facilitate this.

以下、この発明の第１の実施形態を図１〜図６に基づいて説明する。
図１は、この発明に係るディスクブレーキであって自動二輪車に適用される例を示す。このディスクブレーキ１は、制動対象となる車輪（回転体）と一体回転するディスク１２と、このディスク１２に摩擦抵抗を付与するキャリパ１１を備えている。キャリパ１１は、ディスク１２を跨いだ状態で車両の非回転部９５にブラケット９６を介して取り付けられるキャリパボディ１６と、ディスク１２を挟んで互いに対向するようにキャリパボディ１６に摺動可能に設けられる複数対、具体的には二対（図３の断面図において一対のみ示す。）のピストン１７とを有する対向ピストン型のものである。なお、以下においては、車両への取付状態をもって説明し、この取付状態におけるディスク１２の半径方向をディスク半径方向と称し、ディスク１２の軸線方向をディスク軸線方向と称し、ディスク１２の円周方向をディスク円周方向と称す。なお、図１において矢印Ｆは車両前進時におけるディスク１２の回転方向を示している。 A first embodiment of the present invention will be described below with reference to FIGS.
FIG. 1 shows an example of a disc brake according to the present invention, which is applied to a motorcycle. The disc brake 1 includes a disc 12 that rotates integrally with a wheel (rotating body) to be braked, and a caliper 11 that imparts friction resistance to the disc 12. The caliper 11 is slidably provided on the caliper body 16 that is attached to the non-rotating portion 95 of the vehicle via the bracket 96 while straddling the disc 12 so as to face each other across the disc 12. This is an opposed piston type having a plurality of pairs, specifically two pairs (only one pair is shown in the sectional view of FIG. 3). In the following, description will be given with the state of attachment to the vehicle, the radial direction of the disk 12 in this attachment state will be referred to as the disk radial direction, the axial direction of the disk 12 will be referred to as the disk axial direction, and the circumferential direction of the disk 12 It is called the disk circumferential direction. In FIG. 1, an arrow F indicates the direction of rotation of the disk 12 when the vehicle moves forward.

キャリパボディ１６は、図１〜図３に示すように、ディスク１２を挟んでアウタ側（車輪に対し反対側）に配置されるアウタ側シリンダ部２０と、インナ側（車輪側）に配置されるインナ側シリンダ部（シリンダ）２１と、アウタ側シリンダ部２０とインナ側シリンダ部２１をディスク１２の半径方向外側で結ぶディスクパス部２２とを有している。   1-3, the caliper body 16 is disposed on the outer side cylinder portion 20 disposed on the outer side (opposite side to the wheel) with the disc 12 interposed therebetween, and on the inner side (wheel side). It has an inner side cylinder part (cylinder) 21, and a disk path part 22 that connects the outer side cylinder part 20 and the inner side cylinder part 21 on the outer side in the radial direction of the disk 12.

キャリパボディ１６には、ディスク軸線方向に沿ってアウタ側シリンダ部２０及びインナ側シリンダ部２１間に橋架されるパッドピン２４がディスク円周方向に離間して複数本具体的には二本設けられている。   The caliper body 16 is provided with a plurality of, specifically two, pad pins 24 spaced apart in the circumferential direction of the disk, which are bridged between the outer cylinder part 20 and the inner cylinder part 21 along the disk axial direction. Yes.

アウタ側シリンダ部２０及びインナ側シリンダ部２１には、互いにディスク軸線方向において対向して対をなすボア２６が、ディスク円周方向に離間して複数対具体的には二対設けられており、これらボア２６それぞれに上記したピストン１７が嵌挿されている。これにより、ディスク軸線方向に対向する一対のボア２６がディスク円周方向に複数対、具体的には二対並列に形成され、ディスク軸線方向に対向する一対のピストン１７がディスク円周方向に複数対、具体的には二対並列に配置されている。   The outer cylinder portion 20 and the inner cylinder portion 21 are provided with a pair of bores 26 that are opposed to each other in the disc axial direction and are spaced apart in the disc circumferential direction, specifically two pairs. The pistons 17 are inserted into the bores 26, respectively. As a result, a plurality of pairs of bores 26 facing in the disk axial direction are formed in a plurality of pairs in the disk circumferential direction, specifically, two pairs in parallel, and a plurality of pistons 17 facing in the disk axial direction are formed in the plurality of disk circumferential directions. It is arranged in parallel, specifically two pairs in parallel.

ここで、各ボア２６は、図３に示すように、ピストン１７を摺動可能に嵌合させる嵌合内径部２７と、嵌合内径部２７よりも奥側にあってこの嵌合内径部２７よりも大径の大径内径部２８とを有しており、嵌合内径部２７の軸線方向における略中間位置には、ピストンシール９０を保持するための複数具体的に二カ所のシール周溝２９，３０が形成されている。   Here, as shown in FIG. 3, each bore 26 has a fitting inner diameter portion 27 in which the piston 17 is slidably fitted, and a rear side of the fitting inner diameter portion 27, and the fitting inner diameter portion 27. A plurality of specifically, two seal circumferential grooves for holding the piston seal 90 at a substantially intermediate position in the axial direction of the fitting inner diameter portion 27. 29 and 30 are formed.

キャリパボディ１６の各パッドピン２４には、それぞれ一対合計二対のブレーキパッド３３がディスク軸線方向に移動可能に支持されている（図３の断面図において一対のみ示す）。これらパッド３３は、ディスク１２の軸線方向における両側にそれぞれ配置されることになり、これらパッド３３に対してディスク１２の反対側に位置するようにキャリパボディ１６に設けられたピストン１７でそれぞれディスク１２に押し付けられ、これにより、車両に制動力を発生させるようになっている。なお、キャリパボディ１６には、各ピストン１７を作動させるためのブレーキ液をボア２６に導入する通路が形成されているが、そのうち、対向するボア２６同士を連通させる連通路３５，３６（図１，図２に点線で図示）が、互いにキャリパボディ１６内で交差するように外側から穿設されており、一方の連通路３５の外側に開口する口部３７にエア抜き用のブリーダプラグ３９が取り付けられ、他方の連通路３６の外側に開口する口部３８は閉塞プラグ４０で閉塞されている。   A total of two pairs of brake pads 33 are supported on each pad pin 24 of the caliper body 16 so as to be movable in the disc axial direction (only one pair is shown in the sectional view of FIG. 3). These pads 33 are respectively arranged on both sides in the axial direction of the disk 12, and the disks 12 are respectively provided by pistons 17 provided on the caliper body 16 so as to be located on the opposite side of the disk 12 with respect to the pads 33. Thus, a braking force is generated in the vehicle. The caliper body 16 is formed with passages for introducing brake fluid for operating the pistons 17 into the bores 26. Of these, communication passages 35 and 36 for communicating the opposing bores 26 (FIG. 1). , Shown by a dotted line in FIG. 2) are bored from the outside so as to intersect each other in the caliper body 16, and a bleeder plug 39 for releasing air is formed in a mouth portion 37 opened to the outside of one communication path 35. A mouth portion 38 that is attached and opens to the outside of the other communication passage 36 is closed by a closing plug 40.

そして、第１実施形態において、キャリパボディ１６は、上記したアウタ側シリンダ部２０とインナ側シリンダ部２１とディスクパス部２２とが、アウタ側シリンダ部２０及びインナ側シリンダ部２１のうちの一方側具体的にはインナ側シリンダ部２１の底部の一部を除いて、例えばアルミニウム鋳造品からなる一体成形の素材から加工されて形成されており、インナ側シリンダ部２１の底部の一部が別体の蓋部材４３とされている。   In the first embodiment, the caliper body 16 includes the outer side cylinder part 20, the inner side cylinder part 21, and the disk path part 22, one side of the outer side cylinder part 20 and the inner side cylinder part 21. Specifically, except for a part of the bottom part of the inner cylinder part 21, it is formed by processing from an integrally formed material made of, for example, an aluminum casting, and a part of the bottom part of the inner cylinder part 21 is a separate body. The lid member 43 is used.

つまり、キャリパボディ１６は、アウタ側シリンダ部２０とインナ側シリンダ部２１とディスクパス部２２とから成り、インナ側シリンダ部２１は、図４（ａ）に示すようにボア２６の底部位置に開口部４５を有する一体形状のキャリパボディ本体（シリンダ本体）４６と、このキャリパボディ本体４６の開口部４５を塞ぐ図４（ｂ），（ｃ）に示す蓋部材４３と、を備えている。
蓋部材４３は、例えばアルミニウム製で円板状に形成され、キャリパボディ本体４６の開口部４５より僅かに小さい外形に形成されている。開口部４５は、内周面に段差部等のないストレートな形状とされ、蓋部材４３も同様に外周面がストレート形状とされている。 That is, the caliper body 16 includes an outer cylinder portion 20, an inner cylinder portion 21, and a disc path portion 22. The inner cylinder portion 21 is opened at the bottom position of the bore 26 as shown in FIG. 4, an integrally formed caliper body main body (cylinder main body) 46 having a portion 45, and a lid member 43 shown in FIGS. 4B and 4C that closes the opening 45 of the caliper body main body 46.
The lid member 43 is made of, for example, aluminum and has a disk shape, and has an outer shape slightly smaller than the opening 45 of the caliper body main body 46. The opening 45 has a straight shape with no stepped portion on the inner peripheral surface, and the lid member 43 has a straight outer peripheral surface as well.

ここで、キャリパボディ本体４６の開口部４５は、ボア２６の底部側にボア２６と同軸中心の円形に形成され、その内径はボア２６の内径（嵌合内径部２７及び大径内径部２８の内径）よりも小さく設定されている。したがって、これによりボア２６の底部には、ボア２６の軸心方向に張り出して開口部４５の周縁を成す環状底壁５０が形成されている。この環状底壁５０の肉厚は蓋部材４３の肉厚と同厚みに設定されている。   Here, the opening 45 of the caliper body main body 46 is formed in a circular shape coaxial with the bore 26 on the bottom side of the bore 26, and the inner diameter thereof is the inner diameter of the bore 26 (the fitting inner diameter portion 27 and the large diameter inner diameter portion 28). Smaller than the inner diameter). Accordingly, an annular bottom wall 50 is formed at the bottom of the bore 26 so as to project in the axial direction of the bore 26 and form the periphery of the opening 45. The wall thickness of the annular bottom wall 50 is set to be the same as the wall thickness of the lid member 43.

また、キャリパボディ本体４６の開口部４５は、キャリパボディ本体４６の鋳造後に内部の加工を行うための加工孔として利用される。例えば、この開口部４５は、開口部４５自体の加工を終えた時点、または、鋳造直後の開口部４５の下孔の段階で、インナ側及びアウタ側のシリンダ部２１，２０の嵌合内径部２７やシール周溝２９，３０を切削する際に切削工具の挿入孔として用いられる。   The opening 45 of the caliper body main body 46 is used as a processing hole for performing internal processing after the caliper body main body 46 is cast. For example, the opening 45 is formed by fitting inner diameter portions of the inner and outer cylinder portions 21 and 20 at the time when the processing of the opening 45 itself is finished or at the stage of the pilot hole of the opening 45 immediately after casting. 27 and seal circumferential grooves 29 and 30 are used as cutting tool insertion holes when cutting.

キャリパボディ本体４６は、鋳造後に内部の切削加工等を終了すると、底部側の開口部４５に蓋部材４３が以下のようにして摩擦攪拌接合（ＦＳＷ）によって取り付けられる。
この摩擦攪拌接合で使用される接合工具７１は、図５示すように、円柱状の大径軸部７２とこの大径軸部７２よりも小径でこの大径軸部７２と同軸の円柱状の先端軸部７３とを有している。大径軸部７２の先端側は円弧状の凹部７４が形成され、凹部７４の中心から先端軸部７３が立設している。また、先端軸部７３の先端７５は球面状となっている。なお、上記接合工具７１を用いた摩擦攪拌接合の具体的な方法に関しては、例えば、米国特許第5,460,317号のFig12A〜Cに示されている。 When the caliper body main body 46 finishes internal cutting processing after casting, the lid member 43 is attached to the opening 45 on the bottom side by friction stir welding (FSW) as follows.
As shown in FIG. 5, a welding tool 71 used in the friction stir welding has a cylindrical large-diameter shaft portion 72 and a cylindrical shape that is smaller in diameter than the large-diameter shaft portion 72 and coaxial with the large-diameter shaft portion 72. A distal end shaft portion 73. An arc-shaped concave portion 74 is formed on the distal end side of the large-diameter shaft portion 72, and the distal shaft portion 73 is erected from the center of the concave portion 74. Further, the tip 75 of the tip shaft portion 73 is spherical. A specific method of friction stir welding using the welding tool 71 is shown in FIGS. 12A to 12C of US Pat. No. 5,460,317, for example.

蓋部材４３の取り付けにあたっては、図６に示すように、まず、キャリパボディ本体４６のインナ側のシリンダ部２１のボア２６内に内側（開口部４５と逆側）から、ボア２６の嵌合内径部２７とほぼ同径の円柱状の鉄製の支持台９７を挿入し、その支持台９７の頂部をボア２６の底部の環状底壁５０に突き当てて支持台９７の基部をさらにベース台９８を介して図示しない支持装置に支持させる。次に、キャリパボディ本体４６の外面側（ボア２６の底部外面側）から開口部４５に蓋部材４３を嵌入し、蓋部材４３の裏面を支持台９７の頂面に当接させる。このとき、環状底壁５０と蓋部材４３が支持台９７の頂面に当接し、その頂面を基準面として両者５０，４３が裏面側で位置決めされることとなるため、肉厚の同じ両者５０，４３の外面は段差無く面一に揃えられる。   When attaching the lid member 43, as shown in FIG. 6, first, the inner diameter of the bore 26 of the inner cylinder portion 21 of the caliper body main body 46 is fitted from the inside (opposite side of the opening 45) to the inner diameter of the bore 26. A cylindrical iron support 97 having the same diameter as the portion 27 is inserted, the top of the support 97 is abutted against the annular bottom wall 50 at the bottom of the bore 26, and the base of the support 97 is further attached to the base 98. Via a support device (not shown). Next, the lid member 43 is fitted into the opening 45 from the outer surface side of the caliper body main body 46 (the bottom outer surface side of the bore 26), and the back surface of the lid member 43 is brought into contact with the top surface of the support base 97. At this time, the annular bottom wall 50 and the lid member 43 are in contact with the top surface of the support base 97, and the both surfaces 50 and 43 are positioned on the back side with the top surface as a reference surface. The outer surfaces 50 and 43 are flush with each other without any step.

次に、この状態から開口部４５と蓋部材４３の接合境界８２に対して摩擦攪拌接合（ＦＳＷ）を行う。この摩擦攪拌接合の際には、接合工具７１の先端軸部７３を開口部４５と蓋部材４３の接合境界８２に沿わせて連続的に移動させ、蓋部材４３の全周に亘ってループ状に摩擦攪拌接合を行う。接合工具７１は、蓋部材４３の外周の溶接開始点位置に戻ったところで、蓋部材４３の接合境界８２の円周の接線方向に沿わせてキャリパボディ本体４６上を所定量移動させ、その移動を完了した時点でキャリパボディ本体４６から引き抜く。   Next, friction stir welding (FSW) is performed on the joint boundary 82 between the opening 45 and the lid member 43 from this state. At the time of this friction stir welding, the distal end shaft portion 73 of the welding tool 71 is continuously moved along the bonding boundary 82 between the opening 45 and the lid member 43 so as to form a loop over the entire circumference of the lid member 43. Friction stir welding is performed. When the joining tool 71 returns to the welding start point position on the outer periphery of the lid member 43, the joining tool 71 moves a predetermined amount on the caliper body main body 46 along the circumferential tangential direction of the joint boundary 82 of the lid member 43, and the movement When the process is completed, the caliper body 46 is pulled out.

これにより、開口部４５と蓋部材４３の全周が溶接されるとともに、接合境界８２の接線方向に沿った蓋部材４３の外側位置に残留形状部７８が形成される。この残留形状部７８は、接合工具７１の引き抜き点にのみ形成されるものであり、接合工具７１の先端軸部７３と大径軸部７２に対応した中央穴７９と周囲凹部８０とから成る。残留形状部７８は中央穴７９を最深部として凹設されるが、この残留形状部７８は接合境界８２からキャリパボディ本体４６側に外れた位置に形成されることになるため、接合部７７の強度低下や液漏れの発生原因になるようなことはない。   As a result, the entire circumference of the opening 45 and the lid member 43 is welded, and a residual shape portion 78 is formed at an outer position of the lid member 43 along the tangential direction of the joint boundary 82. This residual shape portion 78 is formed only at the pulling point of the joining tool 71, and includes a distal end shaft portion 73 of the joining tool 71, a central hole 79 corresponding to the large diameter shaft portion 72, and a peripheral recess 80. The residual shape portion 78 is recessed with the central hole 79 as the deepest portion. However, since the residual shape portion 78 is formed at a position deviating from the joint boundary 82 toward the caliper body main body 46, It will not cause a drop in strength or leakage.

以上に述べた第１実施形態によれば、蓋部材４３がキャリパボディ本体４６の開口部４５に摩擦攪拌接合によって固定されるため、ネジ止めの場合ようにキャリパボディ本体４６の底部の肉厚を厚くする必要がなく、しかも、蓋部材４３をキャリパボディ本体４６に密封状態で一体化させることができる。   According to the first embodiment described above, since the lid member 43 is fixed to the opening 45 of the caliper body main body 46 by friction stir welding, the thickness of the bottom portion of the caliper body main body 46 is reduced as in the case of screwing. It is not necessary to increase the thickness, and the lid member 43 can be integrated with the caliper body main body 46 in a sealed state.

特に、この実施形態においては、キャリパボディ本体４６のボア２６の底部に蓋部材４３と同厚みの環状底壁５０を形成しておき、蓋部材４３の摩擦攪拌接合時に、環状底壁５０の裏面に突き当てた支持台９７の頂面に、開口部４５を通して蓋部材４３を当接させるようにしているため、開口部４５の周縁と蓋部材４３を段差のない状態に保ったまま安定して摩擦攪拌溶接を行うことができる。そして、このとき環状底壁５０と蓋部材４３の裏面に鉄製の支持台９７を頂面を接触させて摩擦攪拌溶接を行うため、環状底壁５０と蓋部材４３の裏面側からの所謂裏波の発生によって溶接を促進させることができる。   In particular, in this embodiment, an annular bottom wall 50 having the same thickness as the lid member 43 is formed at the bottom of the bore 26 of the caliper body main body 46, and the back surface of the annular bottom wall 50 at the time of friction stir welding of the lid member 43. Since the lid member 43 is brought into contact with the top surface of the support base 97 abutted against the opening through the opening 45, the peripheral edge of the opening 45 and the lid member 43 can be stably maintained with no step. Friction stir welding can be performed. At this time, since the top surface is brought into contact with the bottom surface of the annular bottom wall 50 and the lid member 43 and friction stir welding is performed, a so-called back wave from the back surface side of the annular bottom wall 50 and the lid member 43 is performed. The welding can be promoted by the occurrence of.

したがって、これらのことから、キャリパボディ本体４６の底部の薄肉化によるキャリパ１１の小型・軽量化を図りつつも、蓋部材４３をキャリパボディ本体４６に強固に固定することができる。そして、上記のような工程で蓋部材４３の溶接を行う場合には、蓋部材４３やキャリパボディ本体４６に加工の難しい位置決め用の段差等を形成する必要がないため、キャリパ１２の製造が容易になり、製造コストの低減が可能になる。   Therefore, the lid member 43 can be firmly fixed to the caliper body main body 46 while reducing the size and weight of the caliper 11 by reducing the thickness of the bottom of the caliper body main body 46. When the lid member 43 is welded in the process as described above, it is not necessary to form a positioning step or the like that is difficult to process on the lid member 43 or the caliper body main body 46, and thus the caliper 12 can be easily manufactured. Thus, the manufacturing cost can be reduced.

つづいて、この発明の第２の実施形態を７図〜図１０に基づいて説明する。なお、第１の実施形態と同一部分には同一符号を付して重複する説明を一部省略するものとする。
この実施形態の場合、キャリパボディ１６のアウタ側が、第１の実施形態のアウタ側シリンダ部に換えてピストンを持たないアウタ側爪部８５とされている。よって、インナ側シリンダ部２１にのみ、図７に示すように、ディスク軸線方向に平行をなすボア２６が、ディスク円周方向に離間して複数具体的には二カ所に設けられている。この実施形態のキャリパボディ１６は、パッドを支持しつつ車体側の非回転部に取り付けられるキャリア８６に摺動可能に支持されるフローティング式のもので、ピストン１７とアウタ側爪部８５とでパッドをディスク１２に押し付けて車両に制動力を発生させるようになっている。 Next, a second embodiment of the present invention will be described with reference to FIGS. Note that the same parts as those in the first embodiment are denoted by the same reference numerals, and redundant description is partially omitted.
In this embodiment, the outer side of the caliper body 16 is an outer claw portion 85 that does not have a piston in place of the outer side cylinder portion of the first embodiment. Therefore, as shown in FIG. 7, only the inner cylinder portion 21 is provided with a plurality of bores 26 that are parallel to the disk axial direction and spaced apart in the disk circumferential direction. The caliper body 16 of this embodiment is a floating type that is slidably supported by a carrier 86 attached to a non-rotating part on the vehicle body side while supporting the pad. Is pressed against the disk 12 to generate a braking force on the vehicle.

キャリパボディ本体４６は、アウタ側爪部８５とインナ側シリンダ部２１がディスクパス部２２で連結され、これらの各部がインナ側シリンダ部２１の底部を除いて一体部品として製造されている。インナ側シリンダ部２１の底部には、第１の実施形態と同様に、内径がボア２６の内径よりも小さい開口部４５が形成されるとともに、その開口部４５を取り囲むように環状底壁５０が形成され、開口部４５に別体の蓋部材４３が摩擦攪拌溶接によって固着されている。   In the caliper body main body 46, the outer side claw portion 85 and the inner side cylinder portion 21 are connected by the disc path portion 22, and these portions are manufactured as an integral part except for the bottom portion of the inner side cylinder portion 21. As in the first embodiment, an opening 45 having an inner diameter smaller than the inner diameter of the bore 26 is formed at the bottom of the inner cylinder portion 21, and an annular bottom wall 50 is formed so as to surround the opening 45. A separate lid member 43 is fixed to the opening 45 by friction stir welding.

蓋部材４３を開口部４５に摩擦攪拌接合する場合には、図１０に示すようにキャリパボディ本体４６のボア２６内に支持台９７を挿入して環状底壁５０の裏面に支持台９７の頂面を突き当て、その状態から開口部４５に嵌入した蓋部材４３の裏面を支持台９７の頂面に当接させることにより、蓋部材４３をキャリパボディ本体４６に対して位置決めする。摩擦攪拌溶接はこの状態から蓋部材４３と開口部４５の接合境界８２に対して行う。   When the lid member 43 is friction stir welded to the opening 45, as shown in FIG. 10, the support base 97 is inserted into the bore 26 of the caliper body main body 46 and the top of the support base 97 is placed on the back surface of the annular bottom wall 50. The lid member 43 is positioned with respect to the caliper body main body 46 by abutting the surface and bringing the back surface of the lid member 43 fitted into the opening 45 from that state into contact with the top surface of the support base 97. From this state, friction stir welding is performed on the joint boundary 82 between the lid member 43 and the opening 45.

この実施形態の場合、キャリパボディ１６のアウタ側がアウタ側爪部８５で形成されているものの、インナ側シリンダ部２１は第１の実施形態と同様であるため、前述した第１の実施形態と同様の効果を得ることができる。   In the case of this embodiment, although the outer side of the caliper body 16 is formed by the outer claw portion 85, the inner side cylinder portion 21 is the same as that of the first embodiment, and thus is the same as that of the first embodiment described above. The effect of can be obtained.

なお、この発明は上記の実施形態に限定されるものではなく、その要旨を逸脱しない範囲で種々の設計変更が可能である。   In addition, this invention is not limited to said embodiment, A various design change is possible in the range which does not deviate from the summary.

この発明の第１の実施形態を示すディスクブレーキの正面図。The front view of the disc brake which shows 1st Embodiment of this invention. 同実施形態を示すキャリパの背面図。The rear view of the caliper which shows the same embodiment. 同実施形態を示す図２のＡ−Ａ断面に対応する断面図。Sectional drawing corresponding to the AA cross section of FIG. 2 which shows the same embodiment. 同実施形態を示すものであり、蓋部材を取り付る前のキャリパボディの断面図（ａ）と、蓋部材の背面図（ｂ）と、蓋部材の側面図（ｃ）を併せて記載した図。The same embodiment is shown, and a sectional view (a) of a caliper body before attaching a lid member, a rear view (b) of the lid member, and a side view (c) of the lid member are described together. Figure. 同実施形態を説明するための図であり、蓋部材の摩擦攪拌接合に用いられる接合工具の側面図。It is a figure for demonstrating the embodiment, and the side view of the joining tool used for the friction stir welding of a cover member. 同実施形態を示すものであり、蓋部材を取り付ける際のキャリパボディの断面図。Sectional drawing of the caliper body at the time of attaching the cover member which shows the embodiment. この発明の第２の実施形態を示すキャリパの正面図。The front view of the caliper which shows 2nd Embodiment of this invention. 同実施形態を示すキャリパの背面図。The rear view of the caliper which shows the same embodiment. 同実施形態を示す図７のＢ−Ｂ線に沿う断面図。Sectional drawing which follows the BB line of FIG. 7 which shows the same embodiment. 同実施形態を示すものであり、蓋部材を取り付ける際のキャリパボディの断面図。Sectional drawing of the caliper body at the time of attaching the cover member which shows the embodiment.

符号の説明Explanation of symbols

１…ディスクブレーキ
１７…ピストン
２１…インナ側シリンダ部（シリンダ）
２６…ボア
４３…蓋部材
４５…開口部
４６…キャリパボディ本体（シリンダ本体）
５０…環状底壁
９７…支持台

DESCRIPTION OF SYMBOLS 1 ... Disc brake 17 ... Piston 21 ... Inner side cylinder part (cylinder)
26 ... Bore 43 ... Lid member 45 ... Opening 46 ... Caliper body main body (cylinder main body)
50 ... annular bottom wall 97 ... support stand

Claims (3)

ピストンをシリンダのボア内で摺動させて該ピストンによりブレーキパッドをディスクに押圧するディスクブレーキであって、前記シリンダが、底部の蓋部材と、該蓋部材で閉塞される開口部を有するシリンダ本体とによって構成されるディスクブレーキにおいて、
前記シリンダ本体の開口部の内径を前記ボアの内径よりも小さくして、前記ボアの底部に前記開口部に沿う環状底壁を設けるとともに、該環状底壁と前記蓋部材の肉厚を同じにしたことを特徴とするディスクブレーキ。 A disc brake that slides a piston in a bore of a cylinder and presses a brake pad against the disc by the piston, wherein the cylinder has a bottom lid member and an opening closed by the lid member In the disc brake composed of
The inner diameter of the opening of the cylinder body is made smaller than the inner diameter of the bore, and an annular bottom wall is provided along the opening at the bottom of the bore, and the wall thickness of the annular bottom wall and the lid member is the same. Disc brakes characterized by 前記蓋部材を、前記シリンダ本体の開口部に摩擦攪拌接合によって接合することを特徴とする請求項１に記載のディスクブレーキ。   The disc brake according to claim 1, wherein the lid member is joined to the opening of the cylinder body by friction stir welding. ピストンをシリンダのボア内で摺動させて該ピストンによりブレーキパッドをディスクに押圧するディスクブレーキであって、前記シリンダが、底部の蓋部材と、該蓋部材で閉塞される開口部を有するシリンダ本体とによって構成されるディスクブレーキの製造方法において、
前記シリンダ本体の開口部の内径を前記ボアの内径よりも小さくして、前記ボアの底部に前記開口部に沿う環状底壁を設けるとともに、該環状底壁と前記蓋部材の肉厚を同じにし、
前記ボアの内側から前記環状底壁に支持台を突き当てた後に、
前記蓋部材を前記シリンダ本体の開口部に挿入して前記支持台に当接させ、
その状態から前記蓋部材と前記開口部とを摩擦攪拌接合によって接合する
ことを特徴とするディスクブレーキの製造方法。

A disc brake that slides a piston in a bore of a cylinder and presses a brake pad against the disc by the piston, wherein the cylinder has a bottom lid member and an opening closed by the lid member In the manufacturing method of the disc brake constituted by:
The inner diameter of the opening of the cylinder body is made smaller than the inner diameter of the bore, an annular bottom wall is provided along the opening at the bottom of the bore, and the wall thickness of the annular bottom wall and the lid member is the same. ,
After striking a support base against the annular bottom wall from the inside of the bore,
Inserting the lid member into the opening of the cylinder body and contacting the support base;
From the state, the lid member and the opening are joined by friction stir welding.

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JP2009103187A (en) * 2007-10-22 2009-05-14 Hitachi Ltd Disk brake and method for manufacturing disk brake
JP2010127440A (en) * 2008-11-28 2010-06-10 Hitachi Automotive Systems Ltd Manufacturing method for disc brake
JP2010281429A (en) * 2009-06-08 2010-12-16 Hitachi Automotive Systems Ltd Disc brake and method for producing the same
DE102011083306A1 (en) 2010-10-29 2012-05-03 Hitachi Automotive Systems, Ltd. disc brake

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2009103187A (en) * 2007-10-22 2009-05-14 Hitachi Ltd Disk brake and method for manufacturing disk brake
JP2010127440A (en) * 2008-11-28 2010-06-10 Hitachi Automotive Systems Ltd Manufacturing method for disc brake
JP2010281429A (en) * 2009-06-08 2010-12-16 Hitachi Automotive Systems Ltd Disc brake and method for producing the same
DE102011083306A1 (en) 2010-10-29 2012-05-03 Hitachi Automotive Systems, Ltd. disc brake
US8991564B2 (en) 2010-10-29 2015-03-31 Hitachi Automotive Systems, Ltd. Disk brake
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