Spring brake actuator for use in a commercial vehicle and commercial vehicle therewith

1. An actuator ( 2 ) for a commercial vehicle, the actuator ( 2 ) comprising a service brake portion ( 4 ) and a spring brake portion ( 6 ), the spring brake portion ( 6 ) having a housing ( 8 ) with

a first end ( 10 ) proximal to the service brake portion ( 4 ),

a wall section ( 12 ) extending from the first end ( 10 ),

a second end ( 14 ) being distal to the service brake portion ( 4 ), and

wherein a locking mechanism ( 16 ) is arranged between the wall section ( 12 ) and the second end ( 14 ) of the housing ( 8 ) and locks the wall section ( 12 ) to the second end ( 14 ) of the housing ( 8 ),

wherein the second end ( 14 , 114 ) comprises a base plate ( 24 , 124 ) that encloses the housing ( 8 , 108 ) at the second end ( 14 , 114 );

wherein the locking mechanism ( 16 ) comprises a circumferential projection ( 46 ) of the base plate ( 24 ) that crimps the base plate ( 24 ) around a radially projecting circumferential flange ( 40 ) of the wall section ( 12 );

wherein the circumferential projection ( 46 ) of the base plate ( 24 ) is crimped over and wraps around the radially projecting circumferential flange ( 40 ) of the wall section such that material of the base plate ( 24 ) is disposed on opposite axial sides of the radially projecting circumferential flange ( 40 ) of the wall section ( 12 ) and is also disposed radially outboard relative to the radially projecting circumferential flange ( 40 ) of the wall section ( 12 );

wherein the second end of the housing is an axially terminal end of the housing and the base plate ( 24 ) and locking mechanism ( 16 ) thereof are disposed at the axially terminal end of the housing.

2. The spring brake actuator ( 2 ) according to claim 1 , further comprising:

a spring brake portion piston ( 18 ) located in the housing ( 8 ) for applying a braking force, the spring brake portion piston ( 18 ) including a piston pipe ( 20 ) configured to transfer the braking force to the service brake ( 4 ), and

a compression spring ( 22 ) located between the second end ( 14 ) of the housing ( 8 ) and the spring brake portion piston ( 18 ), the compression spring ( 22 ) being operative to push the spring brake portion piston ( 18 ) away from the second end ( 14 ).

3. The spring brake actuator ( 2 ) according to claim 1 ,

wherein the spring brake actuator ( 2 ) comprises a brake release device ( 28 ) having a brake release bolt ( 30 ) for moving the spring brake portion piston ( 18 ) against a force of the compression spring ( 22 ) towards a release state, and

wherein the base plate ( 24 ) comprises a threaded boss ( 34 ) for receiving a threaded portion ( 36 ) of the brake release bolt ( 30 ) therein.

4. The spring brake actuator ( 2 ) according to claim 3 , wherein the threaded boss ( 34 ) is arranged at an outside surface ( 38 ) of the base plate ( 24 ).

5. The spring brake actuator ( 2 ) according to claim 1 , wherein at least one seal ( 50 ) is arranged between the base plate ( 24 ) and the wall section ( 12 ).

6. The spring brake actuator ( 2 ) according to claim 1 , wherein the first end ( 10 ) comprises a cover surface ( 52 ), the cover surface ( 52 ) being arranged opposite from the base plate ( 24 ), and wherein the cover surface ( 52 ) is substantially flat.

7. The spring brake actuator ( 2 ) according to claim 6 , wherein the cover surface ( 52 ) comprises a boss ( 54 ) for accommodating a piston pipe ( 20 ).

8. A commercial vehicle comprising the actuator ( 2 ) of claim 1 .

9. An actuator ( 2 ) for a commercial vehicle, the actuator ( 2 ) comprising a service brake portion ( 4 ) and a spring brake portion ( 6 ), the spring brake portion ( 6 ) having a housing ( 8 , 108 ) with

a first end ( 10 , 110 ) proximal to the service brake portion ( 4 ),

a wall section ( 12 , 112 ) extending from the first end ( 10 , 110 ),

a second end ( 14 , 114 ) being distal to the service brake portion ( 4 ), and

a locking mechanism ( 16 , 116 ),

wherein the locking mechanism ( 16 , 116 ) secures the wall section ( 12 , 112 ) to the second end ( 14 , 114 ) of the housing ( 8 , 108 );

wherein the second end comprises a base plate ( 24 , 124 ) that encloses the housing ( 8 , 108 ) at the second end ( 14 , 114 );

wherein the first end ( 10 , 110 ) comprises a cover surface ( 52 , 152 ), the cover surface ( 52 , 152 ) being arranged opposite from the base plate ( 24 , 124 ), and wherein the cover surface ( 52 , 152 ) is substantially flat and defines an central opening;

wherein the service brake portion ( 4 ) of the actuator ( 2 ) comprises a flange ( 56 , 156 ), the flange ( 56 , 156 ) being separate from the cover surface ( 52 , 152 ) and attached to the cover surface ( 52 , 152 ) at the first end ( 10 , 110 ), the flange ( 56 , 156 ) at least partially forming a service brake housing ( 58 ) of the service brake portion ( 4 );

wherein the cover surface ( 52 , 152 ) is a separate piece relative to the flange ( 56 , 156 ), such that the cover surface ( 52 , 152 ) is part of the housing ( 8 , 108 ) of the spring brake portion ( 6 ) and the flange ( 56 , 156 ) is part of the service brake housing ( 58 ) of the service brake portion ( 4 );

wherein the cover surface ( 52 , 152 ) fills the central opening combines with the flange ( 56 , 156 ) to enclose the housing ( 8 , 108 ) at the first end ( 10 , 110 );

wherein the second end of the housing ( 8 ) is an axially terminal end of the housing ( 8 ), and the locking mechanism ( 16 , 116 ) is disposed at the axially terminal end;

wherein the wall section ( 12 , 112 ) defines an outer cylindrical shape and includes a radially projecting flange ( 40 , 140 ) that projects radially outward from the outer cylindrical shape;

wherein the base plate ( 24 , 124 ) has a radially outer width that is greater than the outer cylindrical shape and wherein the base plate ( 24 , 124 ) is fixed to the radially projecting flange ( 40 , 140 ) radially outward relative to the outer cylindrical shape of the wall section ( 112 ) at the axially terminal end.

10. The spring brake actuator ( 2 ) according to claim 9 , wherein at least one of the flange ( 56 , 156 ) and a boss ( 54 , 154 ) is welded to the cover surface ( 52 , 152 ) of the housing ( 8 , 108 ).

11. The spring brake actuator ( 2 ) according to claim 9 , wherein at least one of the housing ( 8 , 108 ), the flange ( 56 , 156 ), and the base plate ( 24 , 124 ) comprises sheet metal.

12. An actuator ( 2 ) for a commercial vehicle, the actuator ( 2 ) comprising a service brake portion ( 4 ) and a spring brake portion ( 6 ), the spring brake portion ( 6 ) having a housing ( 8 , 108 ) with

a first end ( 10 , 110 ) of the housing ( 8 , 108 ) proximal to the service brake portion ( 4 ),

a wall section ( 12 , 112 ) extending axially from the first end ( 10 , 110 ),

a second end ( 14 , 114 ) of the housing ( 8 , 108 ) being distal to the service brake portion ( 4 ) and defining an axially terminal end of the housing ( 8 , 108 ), and

a locking mechanism ( 16 , 116 ) that locks a base plate ( 24 , 124 ) to the wall section ( 12 , 112 ),

wherein the locking mechanism ( 16 , 116 ) is arranged between the wall section ( 12 , 112 ) and the second end ( 14 , 114 ) of the housing ( 8 , 108 ) and secures the wall section ( 12 , 112 ) to the second end ( 14 , 114 ) of the housing ( 8 , 108 ) at an interface that is radially outward relative to the wall section ( 12 , 112 );

wherein the locking mechanism ( 16 , 116 ) is disposed at the axially terminal end of the housing;

wherein the base plate ( 24 , 124 ) is substantially planar and has a radially outer width that is greater than the wall section;

wherein a seal ( 50 , 150 ) is disposed at the axially terminal end between the base plate ( 24 , 124 ) and the wall section n( 12 , 112 ) that sealingly encloses the spring brake portion ( 6 ) at the second end ( 14 , 114 ) of the housing ( 8 , 108 );

wherein the base plate ( 24 , 124 ) includes a threaded boss ( 34 , 134 ) attached thereto at a radial central location of the base plate ( 24 , 124 ), wherein the threaded boss ( 34 , 134 ) receives a threaded portion ( 36 ) of a brake release bolt ( 30 ).