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DESCRIPTION

[0001]. Field of the invention

[0002]. The present invention relates to a disc for a disc brake .

[0003] . In particular, the present invention relates to a disc comprising a braking band and a bell assembled to each other.

[0004]. Furthermore, the present invention relates to a method for assembling a disc for disc brake.

[0005] . Background art

[0006] . In a disc brake, the brake caliper is generally arranged straddling the external peripheral margin of the disc. The disc is suitable to rotate about a rotation axis (A-A) defining an axial direction (A-A) . In a disc brake, a radial direction (R-R) , arranged substantially orthogonal to said axial direction (A-A) , and a tangential or circumferential direction (C-C) , orthogonal to both said axial direction (A-A) and said radial direction (R-R) , are further defined.

[0007] . In a typical arrangement of a disc for disc brake on a vehicle, a braking surface of the brake disc faces the outside of the vehicle or towards the vehicle wheel, thus defining the vehicle facing side of the disc, and the opposite braking surface of the brake disc faces the vehicle itself, thus defining the vehicle facing side of the disc. [0008] . Nowadays, many embodiments of discs for disc brake provide for making at least two parts separately: a braking band, on which the gripper acts to generate the braking torque, and a bell fixed to the wheel hub and associated with the braking band. The connection system between braking band and bell is very important because it ensures the transfer of braking torque from band to bell.

[0009] . Usually, the constraint in circumferential (C-C) or tangential (C-C) direction between braking band and bell can be achieved by means of radial protuberances which extend from the braking band towards the rotation axis of the disc and couple in respective seats of the bell in order to achieve a tangential constraint system between band and bell having a particularly simple structure and therefore low production costs.

[0010] . Document WO-02-33280 in the name of the same Applicant shows a solution of the disc for a disc brake in which the connecting system between braking band and the disc bell is formed by the coupling between the radially directed teeth of the braking band and axially directed teeth of the bell. An elastic blade is fixed on the face directed towards the rotation axis of the disc of the radially internal end of each tooth of the braking band. Said plate comprises opposite arms which embrace the tooth of the braking band to which the blade is fixed interposed in circumferential direction (C-C) between the tooth of the braking band and two consecutive axial teeth of the bell to apply a preload direct in circumferential direction (C-C) suitable to prevent the occurrence of circumferential impacts between braking band and bell at the beginning and at the end of the braking action .

[0011]. A predetermined, albeit minimal, clearance is guaranteed in axial direction (A-A) by virtue of the joint provision of an axial retaining ring which is screwed onto the face directed towards the vehicle of the teeth of the bell and an opposite axial abutment for the braking band made on the body of the bell itself. In this manner, during the braking action, when the brake caliper clamps the braking band between the pads, said braking band slides axially on the bell so as to orient itself coplanar to said pads.

[0012] . Solutions of this type, although advantageous from some points of view, still generate axial impacts between braking band and the axial abutment achieved on the bell body.

[0013] . Particularly for applications on commercial vehicles and industrial vehicles, document WO-2008-026990 shows a solution of brake disc for dual wheels. In this disclosure, the connection system between the axial teeth of the bell and the radial teeth of the braking band comprises fixing elements which sandwich the band against the bell by virtue of an elastic blade which, with its front portions, also performs the function of axial restraint towards the side of the brake disc facing the vehicle.

[0014]. Although advantageous from some points of view, this solution does not fully solve the problem of the occurrence of undesired rattling due to the impacts of the braking band against the disc bell.

[0015] . The need is therefore strongly felt to minimize the occurrence of rattling noises due to impacts between braking band and the disc bell in circumferential direction and in axial direction .

[0016] . At the same time, the need is strongly felt to provide a brake disc solution which is compact in axial direction and concurrently capable of delimiting a large volume of space within the dimensions of the disc bell in which to accommodate bearings or other connecting devices to the wheel hub and the like.

[0017]. Solution

[0018]. It is an object of the present invention to solve the drawbacks of the prior art mentioned above and to provide a solution to the needs described hereto with reference to the prior art .

[0019] . It is an object of the present invention to provide a solution of disc for disc brake of quieter operation, as well as limited axial dimensions, albeit suitable to provide a large volume of space in the zone surrounding the rotation axis of the disc .

[0020]. These and other objects are achieved by a disc according to claim 1 and by a method according to claim 9.

[0021] . Some advantageous embodiments are the subject of the dependent claims .

[0022]. Thanks to the suggested solutions, it is possible to eliminate or at least minimize the clearances between braking band and bell in axial direction and in circumferential direction, substantially eliminating the occurrence of impacts between the braking band and the bell in operating conditions.

[0023] . At the same time, by virtue of the suggested solutions, it is possible to reduce the dimensions of the disc in the axial direction without reducing the mechanical strength properties of the disc itself and in all cases ensuring a large volume of space enclosed at least partially by the body of the disc bell.

[0024]. Figures

[0025] . Further features and advantages of the disc and of the method will be apparent from the following description of its preferred embodiments, by way of non-limiting examples, with reference to the accompanying figures, in which:

[0026] . - figure 1 is an axonometric view of a disc, according to an embodiment,

[0027]. - figures 2 and 3 are axonometric views with separated parts of a disc, according to an embodiment;

[0028] . - figure 4 is an axonometric view of a braking band and a plurality of elastic elements, according to an embodiment, as well as a possible step of an assembling method according to an operating method;

[0029] . - figure 4B shows an enlarged detail of the braking band and of the elastic elements shown in figure 4;

[0030] . - figure 5 shows an axonometric view of a braking band and of a plurality of elastic elements, according to an embodiment, as well as a possible step of an assembling method according to an operating method;

[0031]. - figure 6 is an axonometric view with separated parts of a disc, according to an embodiment, as well as a possible step of an assembling method according to an operating method;

[0032]. - figure 7 is an axonometric view of a disc, according to an embodiment, in which the fixing devices of the elastic elements are shown as separate devices;

[0033] . - figure 8 is an axonometric view of a disc, according to a further embodiment;

[0034]. - figure 9 is a vertical elevation view of a disc, according to an embodiment;

[0035] . - figure 10 is a circumferential and axial section view taken along the plotting plane indicated by the arrows X-X in figure 9;

[0036] . - figure 11 is a circumferential and axial section view taken along the plotting plane indicated by the arrows XI-XI in figure 9;

[0037]. - figures 12 and 13 are axial and radial section views of a portion of a disc taken along the plotting planes indicated by the arrows XII-XII and XIII-XIII in figure 9, respectively.

[0038] . Description of some preferred embodiments

[0039] . According to a general embodiment, a disc 1 for disc brake is provided, suitable to rotate about a rotation axis A-A which defines an axial direction A-A either coincident with or parallel to the rotation axis of the disc. Said disc 1 further defines a radial direction R-R, which is orthogonal to the axial direction A-A, and a circumferential direction C-C, which is orthogonal to both said axial direction A-A and said radial direction R-R. Preferably, said radial direction R-R further defines a radially internal sense RI facing the rotation axis A-A of the disc 1 and an opposite radially external sense RE, opposite to said radially internal sense RI .

[0040] . Said disc 1 comprises a braking band 2, a disc bell 6 or bell 6, suitable to form a connection with the wheel hub of a vehicle which can be associated with the disc 1, and a plurality of elastic elements 11, suitable to elastically bias the braking band 2 with respect to said bell 6.

[0041] . Said braking band 2 comprise a first braking surface 3 and a second braking surface 4, opposite to said first braking surface 3.

[0042] . Said first braking surface defines an axially internal side 13 or vehicle facing side 13 of the disc 1.

[0043] . Said second braking surface 4 defines an axially external side 14 or wheel facing side 14 of the disc 1, opposite to said vehicle facing side 13.

[0044] . Said braking band 2 comprises at least one radially internal edge portion 5, suitable to face the rotation axis A-A of the disc 1.

[0045] . Said bell 6 has a body which delimits a central bell seat 15 of substantially cylindrical shape. Preferably, said bell

6 has a substantially axisymmetric body which develops about said rotation axis A-A of the disc 1. Preferably, said bell central seat 15 forms a substantially axisymmetric cavity which develops about said rotation axis A-A of the disc 1.

[ 0046 ] . Said bell 6 comprises an internal bell surface 16 of substantially cylindrical shape and facing said central bell seat 15.

[ 0047 ] . Said braking band 2 comprises a plurality of radial teeth 7 which project from said radially internal edge portion 5 of the braking band 2 towards the rotation axis A-A of the disc 1, thus delimiting a plurality of band seats 8. Preferably, said plurality of radial teeth 7 of the braking band 2 extend substantially in radial direction R-R from the radially internal edge portion 5 towards the rotation axis of the disc A-A. According to a preferred embodiment, said plurality of band seats 8 defined by said plurality of radial teeth 7 are accessible or at least open in axial direction A-A, preferably can be accessed or open in axial direction A-A at least from said wheel facing side 14 of the disc 1.

[ 0048 ] . According to an embodiment, said plurality of band seats 8 defined by said plurality of radial teeth 7 are accessible or open in axial direction A-A and in radial direction R-R.

[ 0049 ] . Each radial tooth 7 of said plurality of radial teeth 7 of the braking band 2 comprises a radially internal edge surface 17 facing the rotation axis A-A of the disc 1.

[ 0050 ] . Each radial tooth 7 of said plurality of radial teeth 7 of the braking band 2 comprises a first axial tooth side 18 facing said vehicle facing side 13 of the disc 1 and a second opposite axial tooth side 19, opposite with respect to said first axial tooth side 18 and facing said wheel facing side 14 of the disc 1.

[0051]. Each radial tooth 7 of said plurality of radial teeth 7 of the braking band 2 comprises at least one circumferential side 20 facing in circumferential direction C-C. Preferably, said at least one circumferential side 20 facing in the circumferential direction C-C at least partly defines a band seat 8 in circumferential direction C-C.

[0052]. According to an embodiment, each radial tooth 7 of the braking band 2 has dimensions delimited axially by said first axial tooth side 18 and said second axial tooth side 19 and defined circumferentially by a pair of opposite circumferential sides 20, opposite with respect to said radial tooth 7 in circumferential direction C-C.

[0053] . According to a preferred embodiment, each circumferential side 20 of the radial tooth 7 is connected to said first axial tooth side 18 and to said second axial tooth side 19 forming a beveled or cut corner 27.

[0054] . Said bell 6 comprises a plurality of axial teeth 9 which project from the body of said bell 6 towards said vehicle facing side 14 of the disc 1 at least partially delimiting a plurality of bell seats 10. According to a preferred embodiment, said plurality of bell seats 10 either can be accessed or are open at least in axial direction A-A on said vehicle facing side 13 of the disc 1. According to an embodiment, said plurality of bell seats 10 either can be accessed or is open at least in axial direction A-A on said vehicle facing side 13 of the disc 1 and in radial direction R-R, preferably at least according to said radially internal sense RI .

[0055] . Said bell 6 comprises a plurality of axial abutting surfaces 12 which delimit in axial direction A-A said plurality of bell seats 10. Preferably, said plurality of axial abutting surfaces 12 are positioned directed towards said vehicle facing side 13 of the disc 1, thus forming the bottom seat walls which axially close respective bell seats 10 thus making them inaccessible from said wheel facing side 14 of the disc 1.

[0056] . Said plurality of radial teeth 7 of the braking band 2 are housed in said plurality of bell seats 10, so that said internal bell surface 16 is locally aligned with said radially internal edge surface 17 of each radial tooth 7 of the braking band 2. In this manner, said internal bell surface 16 is locally substantially coplanar with said radially internal edge surface 17 of each radial tooth 7. Preferably, said internal bell surface 16 is substantially flush with the radially internal edge surfaces 17 of said plurality of radial teeth 7 of the braking band 2.

[0057]. By virtue of such a relative arrangement of the bell internal surface 16 and the radially internal edge surface 17 of each radial tooth 7, it is possible to reduce the overall dimension of the disc 1 at least in axial direction A-A, the structural strength of the disc itself being equal.

[0058] . Preferably, said second axial tooth side 19 comprises an abutment surface which abuts, either directly or indirectly by means of the interposition of at least one portion of the at least one elastic element 11 of said plurality of elastic elements 11, against said abutting surface 12 of the bell 6.

[0059] . Preferably, said at least one circumferential side 20 of the radial tooth 7 comprises a feeding surface suitable to directly or indirectly exchange a thrust action with at least one portion of at least one axial tooth 9 of said plurality of axial teeth 9 of the bell 6, in operating conditions by means of the interposition of at least one portion of the at least one elastic element 11 of said plurality of elastic elements 11.

[0060] . Each elastic element 11 of said plurality of elastic elements 11 is removably connected to at least one axial tooth 9 of said bell. According to a preferred embodiment, each axial tooth 9 of the bell 6 comprises a bell tooth front surface 21 axially facing said vehicle facing side 13 of the disc 1, and each elastic element 11 is connected in removable manner to said bell tooth front surface 21. Preferably, each elastic element 11 is connected in removable manner on said bell tooth front surface 21 by means of a fixing device 22.

[0061]. Advantageously, each elastic element 11 of said plurality of elastic elements 11 embraces at least one portion of said first axial tooth side 18, of said second axial tooth side 19 and of said at least one circumferential tooth side 20 of at least one radial tooth 7 of the braking band 2, elastically preloading said at least one radial tooth 7 with respect to said bell 6.

[0062]. By virtue of the provision of such elastic elements 11 it is possible to elastically preload said plurality of radial teeth 7 of the braking band 2 with respect to said plurality of axial teeth 9 of the bell 6 at least in axial direction A-A from both of said vehicle side facing 13 and said wheel facing side 14 of the disc 1.

[0063] . By virtue of the provision of such elastic elements 11 it is also possible to apply an elastic preload directed in circumferential direction C-C between each radial tooth 7 of the braking band 2 and each axial tooth 9 of the bell 6.

[0064]. Such a disc 1 allows to minimize the occurrence of annoying rattling noises due to impacts between the braking band and the bell.

[0065] . By virtue of such a disc 1 it is possible to eliminate or at least minimize the clearances between braking band 2 and bell 6 in axial direction A-A and in circumferential direction C-

C.

[0066] . According to a preferred embodiment, each elastic element 11 is made in one piece.

[0067]. According to an embodiment, each elastic element 11 comprises a front elastic element portion 23, suitable to be removably connected to said front bell tooth surface 21 by means of a fixing device 22.

[0068] . According to an embodiment, each elastic element 11 comprises at least one axial arm 24, suitable to embrace at least one portion of said at least one circumferential side 20 of said radial tooth 7 of the braking band 2.

[0069] . According to an embodiment, said at least one axial arm 24 of the elastic element 11 comprises a free end portion 26 which embraces at least one portion of said second axial tooth side 19 of each radial tooth 7 of the braking band 2.

[0070] . According to an embodiment, said at least one axial arm

24 of the elastic element 11 comprises a front connecting portion

25 which embraces at least one portion of said first axial tooth side 18 of each radial tooth 7 of the braking band 2, connecting to said front elastic element portion 23.

[0071]. According to an embodiment, said at least one axial arm 24 comprises a leaf spring which elastically biases away from one another said at least one circumferential tooth side 20 of each radial tooth 7 of the braking band 2 and a facing adjacent axial tooth 9 of the bell 6.

[0072]. According to an embodiment, said front connecting portion 25 of the elastic element elastically biases, preferably in axial direction A-A, said radial tooth 7 of the braking band 2 towards said axial abutting surface 12 of said bell 6.

[0073] . According to an embodiment, said free end portion 26 of the at least one axial arm 24 of the elastic element 11 comprises a leaf spring substantially interposed between said second axial side 19 of the radial tooth 7 of the braking band 2 and said axial abutting surface 12 of the bell 6 which biases away from one another said second axial side 19 of the radial tooth 7 of the braking band 2 and said axial abutting surface 12 of the bell 6.

[0074]. According to an embodiment, each elastic element 11 comprises a couple of opposing axial arms 24, so as to interpose itself between each of the opposite sides of each axial tooth 9 of the bell 6 and two opposite adjacent radial teeth 7 of the braking band 2.

[0075] . According to an embodiment, each elastic element 11 comprises two opposing axial arms 24 each forming a front connecting portion 25 and a free end portion 26, wherein the front connecting portions 25 axially bias two radial teeth 7 of the braking band 2 adjacent to each axial tooth 9 of the bell 6 and opposite in a circumferential direction C-C with respect to the axial tooth 9, and wherein said free end portions 26 axially bias said two radial teeth 7 of the braking band 2 adjacent to each axial tooth 9 of the bell 6 and opposite in circumferential direction C-C with respect to said axial tooth 9.

[0076] . According to an embodiment, each circumferential side 20 of the radial tooth 7 is joined to said first axial tooth side 18 and to said second axial tooth side 19 forming beveled edges 27, and wherein each axial arm 24 of each elastic element 11 comprises curved portions 28 which avoid staying in contact with said beveled corners 27. In this manner, repeatability and reliability of the action of the elastic bias applied by the plurality of elastic elements 11 on the braking band 2 and on the bell 6 is improved, thus preventing the elastic elements 11 from working on corner portions 27 which would prematurely deteriorate by fatigue and which at the same time would reduce the working life of the elastic element.

[0077]. Preferably, "beveled corners" also refers to the provision of radial teeth 7 having cuts or recesses between each circumferential side 20 and each of said first and second axial edges 18,10 of the radial tooth 7 which substantially face a flat surface .

[0078] . The provision of such elastic elements 11 by avoiding to constrain the braking band to the bell in radial direction in any case allows the relative sliding of braking band and bell in radial direction R-R due to thermal deformation caused by thermal stresses which occur during the braking action.

[0079] . According to an embodiment, said braking band 2 comprises two plates 29, 30 facing each other in axial direction A-A and spaced apart from each other by a predetermined axial distance thus forming a gap 31, wherein said braking band comprises a plurality of connecting-spacing elements 32 which extend to connect said two facing plates 29, 30 to each other, thus delimiting ventilation channels suitable to convey a flow of cooling fluid. [0080] . According to an embodiment, said radially internal edge portion 5 of the braking band delimits mouths 33, open in an axial direction A-A, for accessing the ventilation channels inside said gap 31, so as to allow cooling fluid to access the ventilation channels. Preferably, at least some of said mouths 33 for accessing the ventilation channels are open towards said vehicle facing side 13 of the disc 1. Preferably, at least some of said mouths 33 for accessing the ventilation channels are open towards said wheel facing side 14 of the disc 1.

[0081]. A method of assembling a disc for disc brake 1 is described below.

[0082]. According to a general embodiment, a method of assembling a disc 1 for a disc brake comprises the following steps :

[0083] . - providing a braking band having a plurality of radial teeth 7 which project from a radially internal edge portion 5 of the braking band 2 towards the rotation axis A-A of the disc 1, delimiting a plurality of band seats 8;

[0084]. - providing a plurality of elastic elements 11;

[0085] . - inserting, preferably in radial direction R-R and even more preferably in radially external sense RE, each elastic element 11 of said plurality of elastic elements 11 into a band seat 8 of the braking band 2;

[0086] . - associating with said braking band a bell 6 comprising a plurality of axial teeth 9 which project from the body of said bell 6 towards said vehicle facing side 14 of the disc 1 at least partially delimiting a plurality of bell seats 10, so that the internal surface of the bell is locally aligned with the radially internal edge surface 17 of each radial tooth 7 of the braking band 2;

[0087] . - connecting each elastic element 11 to an axial tooth 9 of the bell 6, preferably by using a fixing device 22;

[0088] . - elastically preloading said plurality of radial teeth 7 of the braking band 2 with respect to said bell 6 in axial direction A-A and in circumferential direction C-C.

[0089] . According to a possible mode of operation, said step of providing a braking band 2 is performed by providing a braking band according to any one of the embodiments described above.

[0090] . According to a possible mode of operation, said step of providing a braking band 11 is performed by providing a plurality of elastic elements according to any one of the embodiments described above.

[0091]. According to a possible mode of operation, said step of inserting is performed by snapping each elastic element 11 onto at least one portion of at least one radial tooth 7 of the braking band 2.

[0092]. According to a possible mode of operation, said step of inserting is performed by snapping each elastic element 11 onto at least one portion of at least two contiguous radial teeth 7 of the braking band 2. [0093] . According to a possible mode of operation, said step of associating is performed by providing a bell 6 according to any one of the embodiments described above.

[0094]. According to a possible mode of operation, said step of associating is performed mutually approaching the bell 6 to the braking band 2 in axial direction A-A, and preferably in axial direction A-A from said wheel facing side 14 of the disc 1.

[0095] . According to a possible mode of operation, said step of associating is performed by inserting said plurality of radial teeth 7 of the braking band 2 into said plurality of bell seats 10 of the bell 6 and at the same time by inserting said plurality of axial teeth 9 of the bell 6 into said plurality of band seats 8 of the braking band 2.

[0096] . According to a possible mode of operation, said associating step is performed by interposing at least one portion of said plurality of elastic elements 11 between said second axial side 19 of said plurality of radial teeth 7 of the braking band 2 and said axial abutting surface 12 of the bell 6.

[0097]. According to a possible mode of operation, said step of associating is performed by interposing at least one portion of said plurality of elastic elements 11 between at least one circumferential side 20 of said plurality of radial teeth 7 of the braking band 2 and an adjacent axial tooth 9 of the bell 6.

[0098] . According to a possible mode of operation, said step of preloading is performed by elastically preloading each radial tooth 7 of the braking band 2 with respect to said bell 6 from both said vehicle facing side 13 and said wheel facing side 14 of the disc 1.

[0099] . By virtue of the features described above, provided either separately or in combination, where applicable, it is possible to satisfy the sometimes-contrasting needs mentioned above, and to obtain the aforesaid advantages, in particular:

[00100] . - a disc 1 which is compact in axial direction is provided;

[00101] . - a large central seat of the bell 15 about the rotation axis of the disc A-A is provided delimited at least partially by the bell 6, so as to be able to house connecting devices to the wheel hub, such as rolling members and the like;

[00102] . - a disc 1 for disc brake is provided in which impacts between the braking band and the bell in operating conditions are eliminated or at least minimized, thus preventing the onset of annoying rattling;

[00103] . - said plurality of elastic elements are made to work about a chosen axial and/or circumferential elastic preload value;

[00104] . - a disc is provided able to dissipate rapidly the heat accumulated during the braking action as well as during repeated braking;

[00105] . - the relative sliding is allowed in radial direction between the braking band and the bell to dissipate the thermal stresses which occur during the braking action; [00106] . - a silent braking can be obtained in operating conditions .

[00107] . Those skilled in the art may make many changes and adaptations to the embodiments described above or may replace elements with others which are functionally equivalent in order to meet contingent needs without however departing from the scope of the appended claims .

LIST OF REFERENCE NUMERALS

1- Disc for brake disc

2- Disc braking band

3- First braking surface

4- Second braking surface

5- Radially internal edge portion of the braking band

6- Disc bell

7- Radial tooth of the braking band

8- Band seat

9- Axial tooth of the bell

10- Bell seat

11- Elastic element

12- Bell axial abutting surface

13- Vehicle facing side of the disc

14- Wheel facing side of the disc

15- Central bell seat

16- Bell internal surface

17- Radially internal edge surface of the radial tooth of the braking band

18- First axial side of the radial tooth of the braking band

19- Second axial side of the radial tooth of the braking band

20- Circumferential side of the radial tooth of the braking band

21- Axial surface of the axial tooth of the bell

22- Fixing device of the elastic element

23- Front portion of the elastic element

24- Axial arm of the elastic element

25- Front connecting portion of the axial arm of the elastic element

26- Free end portion of the axial arm of the elastic element

27- Radial tooth corner of the braking band

28- Curved portion of the axial arm of the elastic element

29- Braking band plate

30- Braking band plate

31- Braking band gap

32- Connecting-spacing elements of the braking band 33- Access mouth to the ventilation channels of the braking band

A-A- Disc rotation axis and axial direction

R-R- Radial direction

RE- Radially external sense

RI- Radially internal sense

C-C- Circumferential direction