Stacked and cored locator brake caliper

Patent metadata

Field	Value
Publication number	US-10888918-B2
Application number	US-201815963951-A
Country	US
Kind code	B2
Filing date	Apr 26, 2018
Priority date	Apr 26, 2018
Publication date	Jan 12, 2021
Grant date	Jan 12, 2021

Abstract

Brake calipers, molds and method of producing brake calipers are disclosed including a brake caliper mold for molding a brake caliper, the brake caliper mold comprising: a first mold section; a second section half; a core member configured to form a piston bore, the core member comprising: a tower configured to form a tower window in a bridge of the brake caliper and a piston bore extension to form a piston bore of the brake caliper; and four locator forming surfaces located on the tower, each of the four locator forming surfaces configured to form a separate lateral data reference surface on the brake caliper, the lateral data reference surfaces capable of being used for subsequent machining of the brake caliper to predetermined tolerances.

First claim

We claim:

1. A brake caliper mold for molding a brake caliper, the brake caliper mold comprising:
a first mold section;
a second section half;
a core member configured to form a piston bore, the core member comprising:
a tower configured to form a tower window in a bridge of the brake caliper and
a piston bore extension to form a piston bore of the brake caliper; and
four lateral locator forming surfaces located on the tower, each of the four lateral locator forming surfaces configured to form a separate lateral data reference surface on the brake caliper, the lateral data reference surfaces capable of being used for subsequent machining of the brake caliper to predetermined tolerances,
wherein, the brake caliper mold is configured to form a rotor space in the brake caliper wherein a brake rotor is received when the brake caliper is installed on a vehicle.

2. The brake caliper mold of claim 1 , the core member further comprising a longitudinal locator forming surface configured to form a separate longitudinal data reference surface on the brake caliper, the longitudinal data reference surface capable of being used for subsequent machining of the brake caliper to predetermined tolerances.

3. The brake caliper mold of claim 2 , wherein a vertical plane passing through the core and dividing the tower into a first side and a second side, and passing through the piston bore extension and dividing the piston bore extension into a first side and a second side forms a plane of symmetry for the four lateral locator forming surfaces, with two of the lateral locator forming surfaces lying in the first side of the tower and two of the lateral locator forming surfaces lying on the second side of the tower, and the vertical plane passes through the longitudinal locator forming surfaces.

4. The brake caliper mold of claim 3 , wherein the vertical plane bisects the longitudinal locator forming surface.

5. The brake caliper mold of claim 1 , wherein a vertical plane passing through the core and dividing the tower into a first side and a second side, and passing through the piston bore extension and dividing the piston bore extension into a first side and a second side and forms a plane of symmetry for the four lateral locator forming surfaces, with two of the lateral locator forming surfaces lying in the first side of the tower and two of the lateral locator forming surfaces lying on the second side of the tower.

6. The brake caliper mold of claim 5 , wherein normal vectors extending from each of the four lateral locator forming surfaces have components lying in a common set of axes, wherein the common set of axes has a first axis that is perpendicular to the vertical plane, a second axis is perpendicular to the brake rotor that is present in the rotor space when the brake caliper is installed in a vehicle and a third axis that is perpendicular to the first and second axes, and the normal vector of two of the lateral locator forming surfaces have components only in the first and third axes.

7. The brake caliper mold of claim 6 , wherein a normal vector extending from one of the four lateral locator forming surfaces has a component that is in the second axis.

8. The brake caliper mold of claim 1 , wherein the core member further comprises a longitudinal locator forming surface configured to form a separate longitudinal data reference surface on the brake caliper, the longitudinal data reference surface capable of being used for subsequent machining of the brake caliper to predetermined tolerances located on an extension of the core member and the longitudinal locator forming surface faces the tower.

9. The brake caliper mold of claim 1 , further configured for molding a second brake caliper simultaneous to the molding of the first brake caliper, wherein the core member is configured to define a piston bore for the second brake caliper, and is configured to define four lateral locator forming surfaces located on the tower for the first brake caliper and to define four lateral locator forming surfaces located on the tower of the second brake caliper.

10. The brake caliper mold of claim 1 , wherein the brake caliper comprises:
inboard and outboard legs connected by the bridge and having a rotor space between the inboard and outboard legs configured to receive the brake rotor when the caliper is installed on the vehicle,
wherein the inboard leg comprises the piston bore and the outboard leg comprises fingers configured to hold a brake pad;
the bridge comprising the tower window, the tower window being defined by interior surfaces, the tower window having the four lateral data reference surfaces present on the interior surfaces capable of being used for machining of the brake caliper to predetermined tolerances.

11. The brake caliper mold of claim 10 , wherein the brake caliper further comprises a longitudinal data reference surface capable of being used for machining of the brake caliper to predetermined tolerances.

12. The brake caliper mold of claim 11 , wherein a vertical plane passing through the brake caliper and dividing the tower window into a first side and a second side, and passing through the piston bore and dividing the piston bore into a first side and a second side forms a plane of symmetry for the four lateral data reference surfaces, with two of the lateral data reference surfaces lying in the first side of the tower window and two of the lateral data reference surfaces lying on the second side of the tower window, and the vertical plane passes through the longitudinal data reference surface.

13. The brake caliper mold of claim 12 , wherein the vertical plane bisects the longitudinal data reference surface.

14. The brake caliper mold of claim 10 , wherein a vertical plane passing through the brake caliper and dividing the tower window into a first side and a second side, and passing through the piston bore and dividing the piston bore into a first side and a second side and forms a plane of symmetry for the four lateral data reference surfaces, with two of the lateral data reference surfaces lying in the first side of the tower window and two of the lateral data reference surfaces lying on the second side of the tower window.

15. The brake caliper mold of claim 14 , wherein normal vectors extending from each of the four lateral data reference surfaces have components lying in a common set of axes, wherein the common set of axes has a first axis that is perpendicular to the vertical plane, a second axis is perpendicular to the brake rotor that is present in the rotor space with the brake caliper is installed on a vehicle and a third axis that is perpendicular to the first and second axes, and the normal vector of two of the lateral data reference surfaces have components only in the first and third axes.

16. The brake caliper mold of claim 15 , wherein a normal vector extending from one of the four lateral data reference surfaces has a component that is in the second axis.

17. The brake caliper mold of claim 14 , wherein the core member further comprises a longitudinal data reference surface, the longitudinal data reference surface capable of being used for subsequent machining of the brake caliper to predetermined tolerances, the longitudinal data reference surface located on the bridge and a normal vector to the longitudinal data reference surface faces away from the tower and is parallel to the plane of symmetry.

18. A method of producing a brake caliper, the method comprising:
supplying a suitable casting material to a mold so as to form a cast brake caliper within

Assignees

• Mando Corp

Inventors

• Koduri Suresh Babu
• Smith Daniel Alan
• Demorais Antonio Eduardo

Classifications

• F16D2250/0015

  around inserts · CPC title

• F16D65/0068

  Brake calipers · CPC title

• B22D25/02

  by its peculiarity of shape; of works of art {(cylinders, pistons B22D15/02)} · CPC title

• B22C9/22 Primary

  Moulds for peculiarly-shaped castings · CPC title

• B22C9/10

  Cores; Manufacture or installation of cores {(breaker cores B22C9/084)} · CPC title