Abstract:
There is provided a brake disc in a disc brake for a vehicle, which can be manufactured lightweight, suppress the thermal deformation and is effective to prevent the brake noises. This brake disc ( 2 ) is supported by a wheel  4  through a plurality of support members ( 10 ) and is operable to exert a braking force when sandwiched by frictional pads ( 8, 8 ). The brake disc ( 2 ) has an outer peripheral face ( 2   b ) formed with a plurality of outer recesses ( 11 ) deploying in a circumferential direction. Accordingly, the radial width (f) of the braking surfaces ( 9 ), with which the frictional pads ( 8 ) is engageable, varies in a direction circumferentially thereof.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates to a brake disc in a disc brake used in a vehicle such as a motorcycle.  
         [0003]     2. Description of the Related Art  
         [0004]     As the conventional brake disc used in motorcycles, a brake disc  50  shown in  FIG. 5  has been well known (See the Japanese Design Registration No. 1151976.). The brake disc  50  has a circular outer periphery and also has an inner peripheral portion adapted to be coupled with an outer peripheral portion of a disc hub  52  by a plurality of rivet-like pins  51  arranged in a circumferential direction. When the disc hub  52  is bolted to a hub (not shown) of the wheel, the brake disc  50  is supported by the wheel through the disc hub  52 . A braking force is applied to the wheel when opposite braking surfaces of the brake disc  50  are sandwiched by a pair of frictional pads in a caliper fitted to a vehicle frame structure.  
         [0005]     In the meantime, the brake disk  50  is required to reduce its outer diameter and plate thickness in view of the demand for reduction in weight. However, if the outer diameter and the plate thickness are reduced, the heat capacity and the amount of heat dissipation decrease, so that during braking the temperature of the brake disc  50  may increase to result in thermal deformation of the brake disc  50 . Also, since the radial width of the braking surfaces of the disc  50  is fixed in the circumferential direction, brake squeal or noises tend to occur during braking as a result of resonance taking place between the brake disc  50  and the frictional pads.  
         [0006]     In view of the above, there is known a brake disc having an outer peripheral surface formed with a circumferentially extending groove in order to secure the amount of heat dissipation, but the effectiveness of the groove is still insufficient. According to a series of experiments conducted by the inventor of the present invention, it was found that the effectiveness of the groove was something within the range of a measurement error. Also, since the radial width of the braking surfaces of the brake disc is fixed in the circumferential direction, the brake noises cannot be prevented.  
         [0007]     In addition, as a brake disc for use in automotive vehicles that is designed to reduce the weight and increase the amount of heat dissipation, the brake disc disclosed in U.S. Pat. No. 6,386,340 is known in which the outer peripheral face and the inner peripheral face are formed in a sinusoidal waveform. However, the radial width of the braking surfaces of the brake disc remains fixed in the circumferential direction and, accordingly, the brake noises cannot be avoided.  
       SUMMARY OF THE INVENTION  
       [0008]     The present invention has been devised in view of the foregoing situations and is intended to provide a brake disc in a disc brake for a vehicle, which can be manufactured lightweight, suppress the thermal deformation and is effective to prevent brake noises.  
         [0009]     In order to accomplish the foregoing object, a brake disc for a vehicle according to a first construction of the present invention is a brake disc that is supported by a wheel at an inner peripheral portion thereof through a plurality of support members and is operable to exert a braking force when sandwiched by frictional pads and which includes a plurality of outer recesses defined in an outer peripheral face so as to deploy in a circumferential direction, and braking surfaces engageable with the frictional pads and having a radial width that varies in a direction circumferentially thereof.  
         [0010]     With the brake disc of the structure described above, not only can the weight be reduced in a quantity corresponding to the outer recesses, but also an outer peripheral portion of the brake disc, which has a greater thermal deformation than the inner peripheral portion because of the diameter greater than that of the inner peripheral portion, can expand along the outer recesses in the circumferential direction and, therefore, the thermal expansion of the outer peripheral portion can be sufficiently allowed not only in the circumferential direction, but also in the radial direction. In other words, the thermal deformation of the outer peripheral portion can easily be accommodated and an undesirable deformation of the brake disc in a direction across the thickness thereof (i.e., the axial direction) can be suppressed. Also, since the radial width of the braking surfaces changes in the circumferential direction of the brake disc, the surface area of each of the braking surfaces in contact with the frictional pads varies as the brake disc rotates and, therefore, resonance which would occur between the brake disc and the frictional pads can advantageously be prevented to thereby minimize the phenomenon of brake noises resulting from the resonance during braking.  
         [0011]     The number of the outer recesses is preferably equal to or greater than that of the support members. According to this structural feature, because the number of the outer recesses in a number equal to or greater than that of locations at which the brake disc are fastened by the support members, the thermal deformation of the outer peripheral portion can easily be accommodated in the outer recesses.  
         [0012]     In one preferred embodiment of the present invention, each of the outer recesses has a bottom having an arcuate shape. Accordingly, since the bottom of each of the outer recesses forms a convex surface or a surface smoothly curved to bulge in a direction radially outwardly, dirt and grits would hardly be accumulated in the outer recesses.  
         [0013]     Preferably, each of the outer recesses has a depth that is set to a value within the range of 0.15 to 0.25 times a maximum width of the braking surface delimited between outermost and innermost peripheral edges of the braking surface. If the depth of each outer recess is smaller than the value 0.15 times the maximum width of the braking surface, the degree of change of the radial width of the braking surface in the circumferential direction becomes too small and, therefore, respective effects of the present invention to reduce the weight, suppress the thermal deformation and prevent the brake noises would be minimal. On the other hand, if the depth of each outer recess is more than the value 0.25 times the maximum width of the braking surface, the radial width of the braking surface becomes too small at an area where the outer recesses exist and, therefore, the braking force will decrease.  
         [0014]     The brake disc may have an inner peripheral face formed with a plurality of inner recesses. According to this structural feature, additional formation of the inner recesses makes it possible to further reduce the weight of the brake disc and also to further facilitate change of the radial width of the braking surface, preventing the phenomenon of the brake noises which would occur during braking.  
         [0015]     Each of the inner recesses may be formed in the inner peripheral face of the braking surface at a location between the neighboring support members.  
         [0016]     Also, the inner recesses may be formed at respective locations of the inner peripheral face that confront with some of the plural outer recesses in a direction radially inwardly thereof. According to this feature, change of the radial width of the braking surface can be increased at such locations of the brake disc where the inner recesses exist.  
         [0017]     Each of the inner recesses has a bottom which may be of, for example, an arcuate shape.  
         [0018]     Preferably, each of the inner recesses has a depth that is set to a value within the range of 0.15 to 0.25 times a maximum width of the braking surface delimited between outermost and innermost peripheral edges of the braking surface. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]      FIG. 1  is a side view showing a motorcycle front wheel provided with a brake disc for an automotive disc brake assembly according to a first preferred embodiment of the present invention;  
         [0020]      FIG. 2  is a transverse sectional view of the brake disc showing the manner in which the brake disc is fitted to the motorcycle front wheel;  
         [0021]      FIG. 3A  is a side view of the brake disc shown as coupled with a disc hub;  
         [0022]      FIG. 3B  is a fragmentary side view, on enlarged scale, showing the brake disc shown in  FIG. 3B ;  
         [0023]      FIG. 4A  is a side view of the brake disc shown as coupled with the disc hub according to a second preferred embodiment of the present invention;  
         [0024]      FIG. 4B  is a fragmentary side view, on enlarged scale, showing the brake disc shown in  FIG. 4A ; and  
         [0025]      FIG. 5  is a side view of the conventional brake disc. 
     
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS  
       [0026]     Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings. Referring first to  FIG. 1  illustrating, in a side view, a motorcycle front wheel provided with a brake disc for a vehicle according to a first preferred embodiment of the present invention, the brake disc identified by  2  forms a part of and is operatively associated with a disc brake assembly  1  that is mounted on a motorcycle. This brake disc  2  is fixedly mounted on a wheel  4  for rotation together therewith and has braking surfaces  9  and  9  opposite to each other. The disc brake assembly  1  also includes a caliper  6  mounted on a motorcycle body structure, for example, a front fork  5 . As shown in  FIG. 2 , the brake disc  2  is fixedly mounted on the wheel  4  through a disc hub  3  rigidly secured to a wheel hub  4   a  of the wheel  4  by a plurality of bolts  7 . The caliper  6  includes left and right frictional pads  8  and  8  that can be driven through caliper pistons (not shown) by a hydraulic pressure, generated in a master cylinder (not shown), so as to move close towards and away from each other. As will be described later, the caliper  6  includes two pairs of frictional pads  8  and  8 . The left and right frictional pads  8  and  8  sandwich the braking surfaces  9  and  9  of the brake disc  2  to apply a braking force to the wheel  4 .  
         [0027]      FIG. 3A  illustrates a side view of the brake disc  2  coupled with the disc hub  3 . The brake disc  2  has inner and outer peripheral faces  2   a  and  2   b  opposite to each other and also has a plurality of, for example, seven, support limbs  22  protruding radially inwardly from the inner peripheral face  2   a  and spaced an equal distance from each other in a circumferential direction. This brake disc  2  is connected with the disc hub  3  in coaxial relation through the support limbs  22  by the use of a corresponding number of support members  10  that are positioned spaced an equal distance from each other in the circumferential direction of the disc hub  3 . The disc hub  3  has an inner peripheral portion formed with a circular row of bolt insertion holes  16  spaced equally in the circumferential direction and is mounted on the wheel  4  by threading bolts  7 , which have been inserted in the bolt insertion holes  16 , into screw holes  17  that are formed in the wheel hub  4   a  as shown in  FIG. 2 . The support members  10  shown in  FIG. 3A  may be a rivet-like pin and connection of the disc hub  3  with the brake disc  2  can be accomplished by upsetting those support members  10 . Thus, it will readily be seen that the brake disc  2  is supported by the wheel  4  ( FIG. 2 ) through the disc hub  3  by way of the support members  10 .  
         [0028]     More specifically, as shown in  FIG. 3B , each of the support members  10  is loosely accommodated within semi-circular mounting grooves  20  and  30  defined respectively in the brake disc  2  and the disc hub  3 , with a slight gap formed between the support member  10  and the corresponding mounting grooves  20 ,  30 , so that vibrations of the brake disc  2  during braking can be prevented from being directly transmitted to the wheel  4  ( FIG. 2 ). It is to be noted that each support member  10  may be a bolt.  
         [0029]     Referring again to  FIG. 3A , the outer peripheral face  2   b  of the brake disc  2  is formed with a plurality of circumferentially equidistantly spaced outer recesses  11 , leaving protrusions  21  between the neighboring outer recesses  11 . Thus, the outer peripheral face  2   b  of the brake disc  2  has the outer recesses  11  and the protrusions  21  that alternate with each other in a direction circumferentially thereof. The fourteen outer recesses  11  are employed herein. On the other hand, the inner peripheral face  2   a  of the brake disc  2  is formed with a plurality of circumferentially equidistantly spaced inner recesses  12  defined therein so as to extend radially inwardly of the brake disc  2  and positioned generally in alignment with the outer recesses  11 . In the illustrated embodiment, each support limb  22  or each support member  10  is employed and arranged every other outer recess  11  in the outer periphery of the brake disc  2  while each inner recess  12  in the inner periphery of the brake disc  2  is employed and arranged every other outer recess  11  and generally in alignment with one of the outer recesses  11  which is out of alignment with the corresponding support limb  22  or the corresponding support member  10 , i.e., between the neighboring support limbs  22  or the support members  10 . Accordingly, it will readily be seen that the opposite braking surfaces  9  and  9  engageable with the frictional pads  8  and  8  has a width as measured in a direction radially thereof, which varies discretely in a direction circumferentially of the brake disc  2 . It is also to be noted that although the two pairs of circumferentially spaced frictional pads  8  and  8  have been described as employed in the illustrated embodiment, only one pair of the frictional pads  8  and  8  may be employed.  
         [0030]     To reduce the weight of the brake disc  2  to a value as small as possible, the brake disc  2  has a multiplicity of perforations  13  and  14  defined therein so as to extend completely across the thickness of the brake disc  2 . As shown by the double-dotted phantom line in  FIG. 3A , the frictional pads  8  and  8  have a width as measured in a direction radially with respect to the brake disc  2  and are engageable with the corresponding braking surface  9  of the brake disc  2  over the entire width thereof. Accordingly, as shown in  FIG. 3B , each of the braking surfaces  9  of the brake disc  2  is represented by a surface region bound within an annular area S of a radial width W delimited between an innermost peripheral edge  9   b  and an outermost peripheral edges  9   a  of the respective braking surface  9  shown by the double-dotted lines extending in areas where no outer recesses  11  is formed.  
         [0031]     Also, each outer recess  11  has a depth e defined between the bottom  11   a  thereof and the imaginary line extending in touch with respective radially outermost edges of the neighboring radially outward protrusions  21  as shown in  FIG. 3B , which depth e is preferably chosen to be within the range of 0.15 to 0.25 times and, more preferably, within the range of 0.17 to 0.23 times the maximum radial width f of each braking surface  9 , that is, the radial distance fm between the outermost peripheral edge  9   a  and the innermost peripheral edge  9   b . It is to be noted that in the illustrated embodiment the radial distance fm referred to above is shown to be equal to the maximum radial width W and, in such case, the depth e of each outer recess  11  is chosen to be 0.20 times the radial distance fm.  
         [0032]     Each outer recess  11  also has an effective circumferential length L as measured between the neighboring radially outward protrusions  21  on respective sides of such outer recess  11  and along the imaginary circle depicted so as to pass through points each intermediate between the hill, represented by the radially outermost edge of the respective radially outward protrusion  21 , and the dale represented by the bottom  11   a  of the respective outer recess  11 . This effective circumferential length L of each of the outer recesses  11  is of a value preferably within the range of 0.30 to 1.40 times and, more preferably, within the range of 0.60 to 1.30 times the maximum radial width fm between the outermost peripheral edge  9   a  and the innermost peripheral edge  9   b . In the illustrated embodiment, however, the effective circumferential length L is chosen to be 1.0 times the maximum radial width fin, i.e., of a value equal to the maximum radial width fm. Thus, the bottom  11   a  of each outer recess  11  is of an arcuate shape occupying a portion of the circle concentric with the axis of rotation of the brake disc  2  and is positioned radially inwardly from the outermost peripheral edge  9   a.    
         [0033]     Similarly, each inner recess  12  has a depth h defined between the bottom  12   a  thereof and the innermost peripheral edge  9   b , which depth h is chosen to be preferably within the range of 0.15 to 0.25 times and, more preferably, within the range of 0.17 to 0.23 times the maximum radial width fm of each braking surface  9  as is the case with the depth e of each outer recesses  11 . In the illustrated embodiment, however, the depth h of each of the inner recesses  12  is chosen to be 0.20 times the maximum radial width fin. It is accordingly clear that the bottom  12   a  of each of the inner recesses  12  is positioned radially outwardly from the innermost peripheral edge  9   b.    
         [0034]     In the brake disc  2  so constructed as hereinabove described, since the outer peripheral face  2   b  of the brake disc  2  of  FIG. 3A  is formed with the plural outer recesses  11  deployed in a direction circumferentially thereof, the weight of the brake disc  2  can advantageously be reduced. Also, the formation of the plural outer recesses  11  in the brake disc  2  permits the outer peripheral portion, which has a greater thermal deformation than the inner peripheral portion because of the diameter greater than that of the inner peripheral portion, to expand along the outer recesses  11  in the circumferential direction and, therefore, thermal expansion of the outer peripheral portion can be sufficiently allowed not only in the circumferential direction, but also in the radial direction. In other words, thermal deformation of the outer peripheral portion can easily be accommodated. As a result thereof, an undesirable deformation of the brake disc  2  in a direction across the thickness thereof can advantageously be suppressed. Also, since the presence of the outer recesses  11  allows the radial width f of the braking surfaces  9 , with which the frictional pads  8  are engageable, to vary in the circumferential direction of the brake disc  2 , the surface area of each of the braking surfaces  9 , with which the frictional pads  8  are engageable, varies as the brake disc  2  rotates and, therefore, resonance which would occur between the brake disc  2  and the frictional pads  8  if such surface area does not vary can advantageously be prevented to thereby minimize the phenomenon of brake noises resulting from the resonance during braking.  
         [0035]     In addition, since respective portions of the inner peripheral face  2   a  of the brake disc  2  which confront the outer recesses  11  in the radial direction thereof are formed with the inner recesses  12 , the weight of the brake disc  2  can advantageously be further reduced. Also, the formation of the plural inner recesses  12  in the brake disc  2  permits the radial width f of the braking surfaces  9 , with which the frictional pads  8  are engageable respectively, to vary considerably in the circumferential direction of the brake disc  2 , resulting in increase of the effect of preventing the resonance between the brake disc  2  and the frictional pads  8  during braking and, therefore, the phenomenon of brake noises resulting from the resonance during braking can advantageously be minimized.  
         [0036]     Considering that the number of the outer recesses  11  is chosen to be equal to or greater than that of the support members  10  (although in the illustrated embodiment the outer recesses  11  are employed in a number twice that of the support member  10 ), the number of the outer recesses  11  which serve to accommodate thermal deformation comes to be equal to or greater than that of the support limbs  22  that are fastened by the respective support members  10  and, therefore, the thermal deformation can easily be accommodated.  
         [0037]      FIG. 4A  illustrates a side view of the brake disc according to a second preferred embodiment of the present invention, which disc is shown as coupled with the disc hub. The brake disc now identified by  2 A is similar to the brake disc  2  shown in and described with particular reference to  FIGS. 3A and 3B , except that the outer peripheral face  2   b  ( FIG. 4B ) of the brake disc  2 A is so corrugated as to leave circumferentially alternating recesses and protrusions  15   a  and  15   b  that are arranged spaced an equidistant from each other in the circumferential direction thereof. On the other hand, the inner peripheral face  2   a  of the brake disc  2 A is formed with the inner recesses  12  each positioned between the neighboring support members  10  and  10  in a manner similar to those described in connection with the previously described embodiment and, thus, it is clear that the radial width f of the braking surfaces  9 , with which the frictional pads  8  are engageable, varies discretely in the circumferential direction of the brake disc  2 A.  
         [0038]     Even in the embodiment now under discussion, as shown in  FIG. 4B  showing a portion of the brake disc  2 A on an enlarged scale, each of the outer recesses  15   a  has the depth e which is chosen to be of a value preferably within the range of 0.15 to 0.25 times the maximum radial width fm of the braking surfaces  9 , although in the illustrated embodiment the depth e is chosen to be of a value 0.20 times the maximum radial width fin. Similarly, each of the outer recesses  15   a  has the effective circumferential length L that is chosen to be of a value 0.33 times the maximum radial width fin of the braking surface  9 . Unlike the outer recesses  11  of which bottoms  11   a  represent the arcuate shape occupying a portion of the circle concentric with the axis of rotation of the brake disc  2  in the previously described embodiment, the outer recesses  15   a  shown in  FIGS. 4A and 4B  have their bottoms representing not the arcuate shape, but a generally sinusoidal waveform. Also, in the embodiment of  FIGS. 4A and 4B , the inner recesses  12  has the depth h which is chosen to be of a value preferably within the range of 0.15 to 0.25 times the maximum radial width fm of the braking surfaces  9 , although so far shown therein the depth h is chosen to be 0.20 times the maximum radial width fin.  
         [0039]     As described above, in the brake disc  2 A so constructed, since the outer peripheral face  2   b  of the brake disc  2  is formed with the circumferentially alternating outer recesses and protrusions  15   a  and  15   b  deployed in a direction circumferentially thereof, the weight of the brake disc  2 A can advantageously be reduced. Also, the formation of the circumferentially alternating outer recesses and protrusions  15   a  and  15   b  in the brake disc  2  permits the outer peripheral portion, which has a greater thermal deformation than the inner peripheral portion because of the diameter greater than that of the inner peripheral portion, to expand along the outer recesses in the circumferential direction and, therefore, thermal expansion of the outer peripheral portion can be sufficiently tolerated not only in the circumferential direction, but also in the radial direction. As a result thereof, an undesirable deformation of the brake disc  2 A in a direction across the thickness thereof (i.e., the axial direction) can advantageously be suppressed. Also, since the presence of the outer recesses and protrusions  15   a  and  15   b  allows the radial width f of the braking surfaces  9 , with which the frictional pads  8  are engageable, to vary in the circumferential direction of the brake disc  2 A, the surface area of each of the braking surfaces  9 , with which the frictional pads  8  are engageable, varies as the brake disc  2 A rotates and, therefore, resonance which would occur between the brake disc  2 A and the frictional pads  8  can advantageously be prevented to thereby minimize the phenomenon of brake noises resulting from the resonance during braking. It is to be noted that in the second embodiment of the present invention shown in and described with reference to  FIGS. 4A and 4B , the width of each of the protrusions  15   b  as measured in a direction circumferentially of the brake disc  2 A is smaller than that of each protrusion  21  shown in  FIGS. 3A and 3B  and, therefore, the amount of thermal deformation of each protrusion  15   b  is correspondingly smaller than that occurring in the protrusion  21 . Accordingly, even though the circumferential width of each of the recesses  15   a  is small, thermal deformation of the protrusions  15   b  both in the radial direction and in the circumferential direction can be tolerated.  
         [0040]     In addition, since respective portions of the inner peripheral face  2   a  of the brake disc  2 A which are each encompassed between the neighboring support members  10  and  10  are formed with the inner recesses  12 , not only can the weight of the brake disc  2 A be further reduced advantageously, but also the phenomenon of brake noises resulting from the resonance between the brake disc  2 A and the frictional pads  8  during braking can also be further minimized.  
         [0041]     Yet, since the number of the outer recesses  15   a  is chosen to be equal to or greater than that of the support members  10 , it is effective to facilitate accommodation of the thermal deformation of the outer recesses  15   a  in a manner similar to that described in connection with the previously described embodiment.  
         [0042]     A series of experiments were conducted to determine the amount of thermal deformation occurring in the brake disc  2  and  2 A and the conventional brake disc  50  shown in  FIG. 5 . Results of those experiments are shown in Table 1 below. The amount of thermal deformation of the brake discs  2 ,  2 A and  50  in thickness (i.e., the axial thickness) was determined in terms of millimeter by heating to 500° C. one of the opposite braking surfaces of each of the brake discs  2 ,  2 A and  50  while the other of the opposite braking surfaces was left at room temperature.  
                           TABLE 1                           First   Second           Type of Disc   Embodiment   Embodiment   Conventional                   Amt. of Thermal   1.06   1.18   1.21       Deformation (mm)                  
 
         [0043]     From the results of measurement shown in Table 1, it is clear that the amount of thermal deformation (1.18 mm) in the brake disc  2 A according to the second embodiment of the present invention shown in and described with reference to  FIGS. 4A and 4B  is smaller than the amount of thermal deformation (1.21 mm) in the conventional brake disc  50  shown in  FIG. 5  and that the amount of thermal deformation (1.06 mm) in the brake disc  2  according to the first embodiment of the present invention shown in and described with reference to  FIGS. 3A and 3B  is much smaller than that in the conventional brake disc  50  shown in  FIG. 5 .