Brakes – Wheel – Axially movable brake element or housing therefor
Reexamination Certificate
2002-09-24
2004-04-06
Schwartz, Christopher P. (Department: 3683)
Brakes
Wheel
Axially movable brake element or housing therefor
Reexamination Certificate
active
06715588
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to automotive braking systems and in particular to spot-type automotive disc brakes incorporating a secondary or parking brake function.
2. Description of the Related Art
The state of development of spot-type automotive disc brakes is such that it is indisputable that the absence of a simple and successful and cost-effective parking brake function comes as a surprise and is indicative of serious technical difficulties in providing this fundamental requirement for automotive vehicles, bearing in mind the considerable investment of the automotive industry in design and development of disc brake systems over four or five or more decades.
Automotive vehicles incorporating disc brake systems are of course provided with parking and secondary brake systems which are in use, and these will be reviewed below together with the most pertinent ones of the paper proposals which are also known to the applicants. So far as parking brake systems in actual use are concerned, the position is that (with one exception, see below) there is not in actual commercial use, to the best of the Applicants' knowledge, a spot type automotive disc brake in which a parking or secondary brake function is provided using the same friction elements as are actuated by the primary braking system. Usually of course the primary braking system is a hydraulic system. The nearest approach to such a dual purpose disc brake is provided on certain models of Jaguar cars and utilises an additional pair of friction elements and an associated additional mechanical actuating mechanism for these, so that the primary hydraulic disc brake system is provided with a secondary mechanical disc brake offering the parking brake function. Such an arrangement is an undesirable response to the need for a simple and economical disc brake system which would be applicable to small inexpensive vehicles as well as to larger and more costly ones.
All the other parking brake systems currently used in relation to automotive vehicles having disc brakes involve some use of drum brakes, such as the provision of rear drums (in substitution for the rear disc), or the provision of rear drums as a supplement to the rear disc brakes, or the provision of a drum-type transmission brake. None of these proposals, likewise, meets the requirement for a simple and cost-effective and compact disc brake system providing both primary and secondary/parking brake functions.
So far as paper proposals are concerned, the applicants are aware of:
U.S. Pat. No. 4,499,977 (Wang)
U.S. Pat. No. 3,941,221 (Pringle)
U.S. Pat. No. 3,724,605 (Naismith)
and these prior proposals will be reviewed.
The Wang specification discloses an integral park brake mechanism for a disc brake of the fixed disc and moving caliper kind in which the usual hydraulic piston and cylinder assembly
1
,
15
in the caliper on one side of the disc acts through a rod
2
so as to actuate the friction element at that side of the disc (and through the moving caliper the other friction element is also actuated). The parking brake function is integrated with the hydraulic actuating function by means of an apertured locking collar
3
through which the rod
2
extends and which can be tilted to grip the rod and to apply to the rod an actuating thrust from a parking brake lever
4
.
This arrangement is stated to meet the requirement for locking during actuation and self-releasing after actuation. However, the Applicants know that such an arrangement is technically undesirable for actual commercial use due to the obvious fact that a simple locking mechanism involving a rod and a locking collar, with the rod sliding in a bore formed in the hydraulic piston, is completely undesirable in terms of mechanical reliability for a mechanism located in the hostile environment of automotive disc brakes where temperature extremes and significant amounts of water and dust and other foreign matter are routinely applied to the mechanism during routine daily use. As a result, the mechanism is obviously unreliable and the statements in the description at column 4 line 25 onwards that the operation of the park brake mechanism is quite independent of the operation of the hydraulic brake, and the reference to the failure of one of the brakes not affecting the function of the other, is clearly technically wrong. Obviously a locking mechanism of the kind disclosed is liable to stay locked after use in the conditions described. Likewise the free sliding of the rod
2
within the bore in the hydraulic piston is likely to become restricted and finally prevented so that the hydraulic and parking brake functions are locked together and rendered unreliable if not inoperative. Hence the reasons why this mechanism has never been introduced in actual commercial use.
The Pringle brake takes a different approach to the construction of the parking brake mechanism by adopting a mechanical actuator located within the piston and cylinder assembly of the primary brake actuator system. This is also the “one exception” mentioned earlier and a fixed disc disc brake having such a parking brake (but otherwise not constructed as disclosed in Pringle) is in commercial use. Such an arrangement is mechanically difficult and costly to construct. This is partly because the mechanism has to be constructed relatively so small due to the space constraints imposed by the correspondingly small piston and cylinder assemblies utilised in disc brakes for the rear wheels of small vehicles, taking account of the front/rear braking proportions which are conventionally utilised. As a result, the mechanical parking brake mechanism within the hydraulic cylinder is effectively a mechanism almost of watch-like construction complexity and proportions and which is required to operate in the hostile environment of a braking system in terms of the temperatures and hydraulic fluid. In short, such an arrangement is technically and commercially undesirable as a solution to the requirement for a simple and cost effective mechanism. These same comments apply equally to the Naismith disclosure which shows a similar mechanism.
Two additional prior art references which have come to the attention of the applicants are:
GB2177171A (Kelsey Hayes)
WO98/05879 (Brake Technologies Pty)
The Kelsey-Hayes specification discloses improvements in self-adjusting parking brakes, particularly for use on rear-axle disc brake assemblies. The parking brake actuator is preferably a “bolt-on” type assembly intended for external mounting to a disc brake caliper. Use of a “bolt-on” parking-brake actuating assembly eliminates the necessity of having front and rear axle disc brake assemblies of different design since the parking brake mechanism is not an integral part of the disc brake assembly (page 1, column 1, at lines 35 to 40). Therefore, as shown in
FIG. 3
, the parking brake arrangement is asymmetrically arranged with respect to the main structure of the brake, and such is unacceptable in terms of its effect on the operation of the primary braking mechanism due to the need for balanced and uniform operating and wear characteristics, as far as possible. The deliberate adoption of an asymmetric configuration causing corresponding non-uniformity of operating and wear characteristics is generally unacceptable.
In the Brake Technologies Pty specification, there is disclosed a disc brake assembly of the kind in which the brake disc
23
is oil-immersed, and provided with full-annulus (or substantially full-annulus) friction element engagement facilities. Brakes of this kind are conventionally used as transmission brakes in heavy duty vehicular applications, including tractor brakes, for example. A primary actuating mechanism of the hydraulic kind is provided, together with a fail-safe emergency/parking type braking mechanism based upon spring elements
62
,
63
to cause application of the emergency-parking brake in the event of failure of the hydraulic fluid system. The general arrangement of the brake can be seen in
FIGS.
Bunker Kenneth James
Orton Stephen Roy
Delphi Technologies Inc.
Howard & Howard
Schwartz Christopher P.
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