Decorative brake caliper cover kit for calipers

Abstract

A vehicle caliper cover kit includes multiple caliper covers. Each caliper cover includes an inner surface that is sized and configured to be morphologically complementary to the outer surface of one of the multiple calipers. Each caliper cover also includes an outer surface having a near-center portion and an outer portion positioned opposite to the near-center portion. The inner and outer surfaces define a thickness between them of 0.015 inches and 0.150 inches. Each caliper cover also includes a polygonal opening extending from the inner surface to the outer surface, the polygonal opening being positioned between the near-center and outer portions of the outer surface.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Application No. 63 / 033,124, filed June 1, 2020, the contents of which are expressly incorporated herein by reference.

[0003] Statement: Federally funded research / development

[0004] not applicable Technical Field

[0005] The disclosure of this invention generally relates to automotive caliper cover kits, and more specifically to vehicle / caliper-specific decorative brake caliper cover kits for enhancing the vehicle owner experience by providing the appearance of a high-end caliper disc braking system to vehicles originally equipped with a basic caliper disc braking system. Background Technology

[0006] Most vehicles use disc brake systems. Almost all cars have disc brakes (front disc brakes and rear disc brakes), which interact with the vehicle's wheels and control their rotation. Each disc (or rotor) in a disc brake system can rotate in sync with its corresponding wheel during travel. Disc brake systems may require calipers fixed to the vehicle. Each caliper controls two internally positioned brake pads that interact with each rotating rotor during vehicle braking or deceleration.

[0007] When the driver depresses the brake pedal, one or more hydraulically displaced pistons within each caliper generate friction by pushing each brake pad against each side of the rotor. This friction affects vehicle motion; it slows a moving vehicle or prevents a stationary vehicle from accelerating. The friction generated between the rotating rotor and the fixed brake pads against each side of the rotor produces heat. This heat is transferred in two ways: through thermal conduction to the engaging parts within the caliper, and through thermal convection of air passing through the wheel well.

[0008] Automakers typically offer different versions of disc brake systems for a given vehicle brand and model as a way to differentiate their base models from higher-end or high-performance versions. Base caliper disc brake systems are less expensive than higher-end or high-performance caliper disc brake systems and, unsurprisingly, hold a lower status among car enthusiasts. The caliper specifications of a disc brake system are the most obvious way this differentiation occurs. Disc brake systems can include (a) fixed calipers, (b) floating calipers, or (c) a combination of both.

[0009] Regarding the calipers of a vehicle's disc brake system, the calipers are specified by the vehicle manufacturer and are designed for a specific vehicle model and any selected braking system option. The vehicle's calipers are equipped and oriented in two pairs: a front caliper pair and a rear caliper pair.

[0010] For non-performance vehicles, floating (or sliding) calipers are more often specified. Floating calipers represent the basic type of caliper and utilize a single piston acting from within the sliding caliper frame onto the inner surface of the rotor. Unlike the monolithic design of fixed calipers, floating calipers consist of a static (non-moving) caliper bracket and a dynamic (moving) caliper frame. The caliper frame is mounted on the static caliper bracket, which is installed in the vehicle. When hydraulic pressure is applied by pressing the brake pedal, the displaced piston forces the inner brake pad against the inside of the rotor in one direction (outwards), while simultaneously causing the dynamic caliper frame to be pulled in the opposite direction (inwards). This inward movement of the caliper frame simultaneously forces the outer brake pad against the opposite outer surface of the rotor. This combination of relative movements (piston and caliper frame) results in the rotor being "squeezed" by the opposing brake pads. Considering the multi-part appearance resulting from the floating aspect of this type of low-performance caliper, it is generally considered less aesthetically pleasing compared to the single-part appearance offered by the monolithic design of fixed calipers.

[0011] In summary, advanced automotive braking systems typically include fixed calipers. Furthermore, advanced braking systems employ performance markings when the calipers are painted and marked. Therefore, vehicles equipped with performance-enhanced OEM braking components typically include: (a) fixed (monoblock) calipers (front and rear calipers), which are (b) painted and (c) marked.

[0012] Understandably, caliper cover kits have been in use for many years. Typically, caliper cover kits include aftermarket metal-faced and aftermarket plastic-faced caliper cover kits. Other options for improving the appearance of calipers include applying vinyl-coated sheets and permanently altering the calipers by painting them on an aftermarket basis.

[0013] A common problem with traditional automotive caliper cover kits is that, in the case of metal and plastic caliper cover kits, they are stylistically generic and fail to closely follow the eye-catching industrial design of the vehicle's calipers. Instead, these types of covers simply obstruct the view of the calipers being obscured. Metal caliper cover kits require metal fasteners to attach to the vehicle's calipers, while plastic caliper cover kits require high-temperature adhesives to attach directly to the front surface of the calipers. While each option is a reversible option that allows the vehicle to return to its stock state, none of them achieve the look of an OEM premium-painted caliper due to the "one-size-fits-all" approach employed by each. Therefore, neither option effectively produces the look of a premium brake caliper system when installed on a vehicle equipped with a base caliper system. Upon installation, neither option integrates with the surface contours of the calipers they obscure, making them unappealing add-ons in the aftermarket.

[0014] Another problem with traditional automotive caliper cover kits is that applying vinyl-coated sheets (or vinyl coatings) to a vehicle's calipers is an extremely challenging task, given the varying contours of the caliper surface. Vinyl coatings work best on smooth and flat vehicle surfaces. Given the limits of how vinyl can stretch across surface contours, using this type of product on calipers is often unsuccessful. Those attempting to apply vinyl coatings to calipers typically give up or end up with a poorly coated caliper surface that doesn't last. Even when successful application of vinyl coatings is achieved, it often requires many hours of effort from the installer, making it physically demanding. Another issue with traditional automotive caliper cover kits is that, given the availability of aftermarket options for painting vehicle calipers, this permanent solution eliminates any possibility of returning the vehicle to its unaltered (or stock) condition. In many cases, doing so can void the vehicle warranty and / or become a financial liability when attempting to resell the vehicle. Furthermore, regarding the appearance of calipers painted based on the aftermarket, it's important to remember that painting is an art form, and painting installed calipers is a challenging task that specifically relies on the painter's skill. This is especially challenging considering the environmental drawbacks associated with painting calipers that are already installed on a vehicle and exposed to the environment. Conversely, OEM caliper suppliers use repeatable processes in controlled environments to paint new, clean calipers, ensuring high-quality results. Therefore, calipers painted based on the aftermarket often fail to meet expectations.

[0015] While these devices may be suitable for their specific purpose, they are not suitable for enhancing the vehicle owner experience by giving vehicles that originally came equipped with basic caliper disc brakes the look of advanced caliper disc brake systems. As described herein, this disclosure is designed as an aftermarket product that can be easily installed for use and easily removed, such as returning the vehicle to its unaltered (or stock) state if necessary. Summary of the Invention

[0016] In view of the aforementioned drawbacks inherent in existing known types of automotive caliper cover kits and other caliper appearance modification methods, this document discloses a novel vehicle / caliper-specific decorative brake caliper cover kit construction, which can be used to enhance the vehicle owner experience by providing the appearance of an advanced caliper disc braking system to a vehicle originally equipped with a basic caliper disc braking system. Various embodiments of the cover kit described herein have been designed as aftermarket products that are easy to install for use and easy to remove, allowing the vehicle to be returned to its unmodified (or stock) state if possible.

[0017] According to one embodiment, two types of caliper cover pairs are provided: a pair of fixed caliper covers for mounting to a fixed caliper pair, and a pair of floating caliper covers for mounting to a floating caliper pair. Each cover in the automotive caliper cover kit closely conforms to the profile of the vehicle-specific caliper it is designed for.

[0018] By considering the two types of calipers within the scope, the design concepts disclosed herein can be applied to caliper designs for any conceivable automotive disc brake system. Therefore, an automotive caliper cover kit comprising a pair of fixed caliper covers and a pair of floating caliper covers can be an aftermarket product that enhances the vehicle owner experience by providing the appearance of a high-end brake caliper system to vehicles initially equipped with the basic caliper system. This can be achieved through the following steps: (a) replicating the appearance of the monolithic industrial design when mounted on floating calipers and highlighting the appearance of the monolithic industrial design when mounted on fixed calipers; (b) replicating the high-performance upgrade color options when mounted on either fixed or floating calipers; and (c) replicating the brand characteristics of the OEM high-performance monolithic caliper on the most visible surface when mounted on either fixed or floating calipers.

[0019] Each cover can be molded from silicone resin with a hardness of 80A (measured by a rubber hardness tester) into a single component with a nominal wall thickness of 0.050 inches. The hardness can range from 60A to 100A, and the wall thickness can range from 0.015 inches to 0.150 inches.

[0020] A pair of fixed caliper covers can have symmetrical physical properties to facilitate their manufacture. Similarly, a pair of floating caliper covers can have symmetrical physical properties to facilitate their manufacture.

[0021] Caliper cover kits can be sized and constructed to be installed by hand without tools.

[0022] Caliper cover kits can be custom-designed to fit specific floating and / or fixed caliper designs associated with a particular vehicle brand and model.

[0023] Caliper cover kits can be sized and constructed to improve the aesthetic appearance of both fixed and floating automotive brake calipers in terms of color and industrial design.

[0024] Caliper cover kits can be sized and constructed relative to the surface profile of the specific caliper targeted by each cover design to ensure direct contact with an aesthetically pleasing fixed surface and surface profile, while separating from surfaces that do not have a preferred design aesthetic and surfaces that need to be separated to allow caliper movement.

[0025] Caliper cover kits can be configured to withstand the operating environment exposed to a vehicle's disc brake system, including automotive chemicals and extreme temperatures.

[0026] At least one cover in the caliper cover kit may be formed of a material that facilitates the flexibility required for installation and preloads the rigidity required by the design (like a spring against a specific surface), thereby ensuring a precise fit while preventing separation from the caliper during use.

[0027] Caliper cover kits can be sized and constructed to adhere to critical surfaces of the caliper and reduce the likelihood of interference with adjacent rotating wheels.

[0028] Caliper cover kits are available in the aftermarket and can be easily installed for use or easily removed, allowing the vehicle to be returned to its unmodified (or stock) state if needed.

[0029] According to another embodiment, a vehicle caliper cover kit is provided for use with a caliper disc braking system on a vehicle, comprising a pair of fixed calipers and a pair of floating calipers. The vehicle caliper cover kit includes a pair of fixed caliper covers. Each fixed caliper cover includes an inner surface sized and configured to be shape-complementary to the outer surface of one of the fixed calipers in the pair. Each fixed caliper cover also includes an outer surface having a median portion and a lateral portion positioned opposite to the median portion. The inner and outer surfaces define a thickness between 0.015 inches and 0.150 inches therebetween. Each fixed caliper cover also includes a quadrilateral opening extending from the inner surface to the outer surface, the quadrilateral opening being positioned between the median and lateral portions of the outer surface. The vehicle caliper cover kit also includes a pair of floating caliper covers, each floating caliper cover including an inner surface sized and configured to be shape-complementary to the outer surface of one of the floating calipers in the pair. Each floating caliper cover also includes an outer surface having a near-center portion and an outer portion positioned opposite to the near-center portion. An inner surface and an outer surface define a thickness between 0.015 inches and 0.150 inches therebetween. Each floating caliper cover also includes a pair of loops extending from the near-center portion of the outer surface, each of the loops being capable of extending around a corresponding portion of one of the floating calipers in a pair of floating calipers.

[0030] Each fixed caliper cover may include a hole sized to receive a bleed screw on a corresponding fixed caliper of a pair of fixed calipers.

[0031] A pair of fixed caliper covers and a pair of floating caliper covers can be made of materials with Shore hardness in the range of 60A to 100A.

[0032] Each of the fixed caliper covers in a pair of fixed caliper covers and each of the floating caliper covers in a pair of floating caliper covers can be flexible and can be arranged in a tensioned manner.

[0033] Each of the fixed caliper covers in a pair of fixed caliper covers and each of the floating caliper covers in a pair of floating caliper covers can extend between a neutral configuration and a curved configuration, wherein each of the fixed caliper covers in a pair of fixed caliper covers and each of the floating caliper covers in a pair of floating caliper covers is biased toward the neutral configuration.

[0034] Each of the fixed caliper covers in a pair of fixed caliper covers and each of the floating caliper covers in a pair of floating caliper covers is formed from a corresponding monolith.

[0035] Each of a pair of floating caliper covers includes a body and a pair of O-rings connected to the body, the pair of O-rings defining a pair of ring portions.

[0036] According to another embodiment, the vehicle caliper cover kit includes a pair of fixed caliper covers and a pair of floating caliper covers. Each fixed caliper cover includes an inner surface sized and configured to be shaped to complement the outer surface of one of the fixed calipers in the pair. Each fixed caliper cover also includes an outer surface having a proximal portion and an outer portion positioned opposite to the proximal portion. A quadrilateral opening extends from the inner surface to the outer surface, located between the proximal and outer portions of the outer surface. Each fixed caliper cover also includes a hole sized to receive a bleed screw on the corresponding fixed caliper in the pair.

[0037] According to another embodiment, a vehicle caliper cover kit including multiple caliper covers is provided. Each caliper cover includes an inner surface sized and configured to be shaped complementary to the outer surface of one of the multiple calipers. Each caliper cover also includes an outer surface having a near-center portion and an outer portion positioned opposite to the near-center portion. The inner and outer surfaces define a thickness between 0.015 inches and 0.150 inches therebetween. Each caliper cover also includes a quadrilateral opening extending from the inner surface to the outer surface, the quadrilateral opening being located between the near-center and outer portions of the outer surface.

[0038] This disclosure will be best understood by referring to the following specific embodiments when read in conjunction with the accompanying drawings. Attached Figure Description

[0039] These and other features and advantages of the various embodiments disclosed herein will be better understood with reference to the following description and accompanying drawings, in which:

[0040] Figure 1A This is a top view of the driver's side of the pair of fixed caliper covers at the front;

[0041] Figure 1B yes Figure 1A Front view of the fixed caliper cover;

[0042] Figure 1C yes Figure 1A A bottom view of the fixed caliper cover;

[0043] Figure 1D yes Figure 1A Rear view of the fixed caliper cover;

[0044] Figure 1E yes Figure 1A First side view of the fixed caliper cover;

[0045] Figure 1F yes Figure 1A Second side view of the fixed caliper cover;

[0046] Figure 2A This is a rear upper perspective view of the first side of the front caliper cover;

[0047] Figure 2B This is the rear upper perspective view of the second side of the front caliper cover;

[0048] Figure 2C This is a front upper perspective view of the first side of the front caliper cover;

[0049] Figure 2D This is the front upper perspective view of the second side of the front caliper cover;

[0050] Figure 3A This is a top view of the floating caliper cover;

[0051] Figure 3B yes Figure 3A A front view of the floating caliper cover;

[0052] Figure 3C yes Figure 3A A bottom view of the floating caliper cover;

[0053] Figure 3D yes Figure 3A Rear view of the floating caliper cover;

[0054] Figure 3E yes Figure 3A Side view of the floating caliper cover;

[0055] Figure 4A This is a rear upper perspective view of the first side of the floating caliper cover;

[0056] Figure 4B This is the rear upper perspective view of the second side of the floating caliper cover;

[0057] Figure 4C This is the front top perspective view of the first side of the floating caliper cover;

[0058] Figure 4D This is the front upper perspective view of the second side of the floating caliper cover;

[0059] Figure 5 This is a perspective view of the construction of a car disc brake (caliper on the rotor);

[0060] Figure 6 This is an exploded view of an exemplary automotive caliper cover kit and automotive disc brake construction;

[0061] Figure 7A This is an exploded front-up perspective view of the fixed caliper cover and the fixed caliper on the rotor;

[0062] Figure 7B It is an exploded rear-upper perspective view of the fixed caliper cover and the fixed caliper on the rotor;

[0063] Figure 8A This is an exploded front-top perspective view of the floating caliper cover and the floating caliper on the rotor.

[0064] Figure 8B It is an exploded rear-upper perspective view of the floating caliper cover and the floating caliper on the rotor;

[0065] Figure 9A This is a perspective view of the upper first side of the retaining caliper cover on the retaining caliper mounted on the rotor;

[0066] Figure 9B This is a perspective view of the upper second side of the retaining caliper cover on the retaining caliper mounted on the rotor;

[0067] Figure 9C This is a top perspective view of the first side of the floating caliper cover on the floating caliper mounted on the rotor;

[0068] Figure 9D This is a perspective view of the upper second side of the floating caliper cover on the floating caliper mounted on the rotor;

[0069] Figure 10A This is an exploded perspective view of the upper part of the first side of the fixed caliper cover and the fixed caliper on the rotor;

[0070] Figure 10B This is an exploded perspective view of the upper second side of the fixed caliper cover and the fixed caliper on the rotor;

[0071] Figure 10C This is an exploded perspective view of the upper part of the first side of the floating caliper cover and the floating caliper on the rotor;

[0072] Figure 10D This is an exploded perspective view of the upper second side of the floating caliper cover and the floating caliper on the rotor;

[0073] Figure 11A This is a rear upper perspective view of the first side of the retaining caliper cover on the retaining caliper mounted on the rotor;

[0074] Figure 11B This is an upper perspective view of the second side of the retaining caliper cover on the retaining caliper mounted on the rotor;

[0075] Figure 11C This is an upper perspective view of the first side of the floating caliper cover on the floating caliper mounted on the rotor;

[0076] Figure 11D This is an upper perspective view of the second side of the floating caliper cover on the floating caliper mounted on the rotor;

[0077] Figure 12A This is a front view of the asymmetrical fixed caliper cover on the driver's side;

[0078] Figure 12B This is a front view of a symmetrical fixed caliper cover;

[0079] Figure 12C This is a front view of the asymmetrical fixed caliper cover on the passenger side;

[0080] Figure 13A This is a rear upper perspective view of the first side of the O-ring variant of the floating caliper cover;

[0081] Figure 13B This is the rear upper perspective view of the second side of the O-ring variant of the floating caliper cover;

[0082] Figure 13C This is the front upper perspective view of the first side of the O-ring variant of the floating caliper cover;

[0083] Figure 13D This is the front upper perspective view of the second side of the O-ring variant of the floating caliper cover;

[0084] Figure 14A This is an exploded perspective view of the lower side of the first side of an optional variant of the fixed caliper cover and the corresponding automotive disc brake.

[0085] Figure 14B yes Figure 14A Exploded perspective view of the lower part of the fixed caliper cover and the second side of the automotive disc brake;

[0086] Figure 14C This is a lower perspective view of the first side of an optional variant of the fixed caliper cover mounted on the corresponding automotive disc brake;

[0087] Figure 14D This is a lower perspective view of the second side of an optional variant of the fixed caliper cover mounted on a car disc brake;

[0088] Figure 15A This is an exploded upper perspective view of an optional variant of the fixed caliper cover (driver's side); and

[0089] Figure 15B This is an upper perspective mounting view of an optional variant of the fixed caliper cover (driver's side).

[0090] Common reference numerals are used in all accompanying drawings and detailed descriptions to indicate the same elements. Detailed Implementation

[0091] The specific embodiments described below with reference to the accompanying drawings are intended to be descriptions of certain embodiments of a set of vehicle brake caliper covers, and are not intended to represent the only form that can be developed or utilized. This specification illustrates various structures and / or functions in conjunction with the illustrated embodiments; however, it should be understood that the same or equivalent structures and / or functions can be implemented by different embodiments, which are also intended to be included within the scope of this disclosure. It should also be understood that the use of related terms such as "first" and "second" is only for distinguishing one entity from another, and does not necessarily require or imply any actual such relationship or order between these entities.

[0092] Referring now to the accompanying drawings, in which the same reference numerals denote the same elements throughout all the views, the drawings illustrate a decorative brake caliper cover kit 10 specifically for vehicle / brake calipers. The caliper cover kit 10 comprises two types of caliper cover pairs: one pair for mounting to a fixed caliper pair and another pair for mounting to a floating caliper pair. Each cover, including the caliper cover kit 10, can closely conform to the profile of the vehicle-specific caliper to which its design is intended. Each cover can be molded from 80A hardness silicone into a single component with a nominal wall thickness of 0.050 inches. Each cover is a pre-molded and contoured silicone film cover with a nominal wall thickness of 0.050 inches.

[0093] It should be understood that the values ​​and dimensions provided herein are exemplary and not intended to limit the scope of the disclosure herein. In this regard, without departing from the spirit and scope of the disclosure herein, the hardness of the material used to form the cover kit 10 may vary, such as in the range of 60A to 100A, and the nominal wall thickness may vary between 0.025 inches and 0.150 inches.

[0094] The fixed caliper cover 12 is a 0.050-inch silicone film that can follow or mimic the precise contours of the outer surface of the fixed caliper 14. The fixed caliper cover 12 is designed based on or for the fixed caliper 14. In this respect, the fixed caliper cover 12 can be considered to be complementary in shape to the outer surface of the fixed caliper 14. The fixed caliper cover 12 can be sized and constructed to cover or extend more than 100% of all visible surfaces of the fixed caliper 14 once mounted on it. Surfaces of the fixed caliper 14 that cannot be covered by the fixed caliper cover 12 can be limited to one or more invisible surfaces on the wheel well-facing surface of the fixed caliper 14. By employing a design that covers less than 100% of the invisible surfaces, the fixed caliper cover 12 can be easier to install while also allowing for more efficient heat dissipation of the fixed caliper 14 via convection cooling during vehicle use / braking. The specific material (silicone resin with a hardness of 80A) of the fixed caliper cover 12 and the caliper / vehicle-specific design can be combined to allow a form-fitting engagement with the vehicle's fixed caliper 14. The flexibility of the selected material allows the fixed caliper cover 12 to bend along the geometric surface profile of the fixed caliper 14 during installation, thereby creating a "die-lock" state on many fixed caliper surfaces during vehicle use, thus securing the fixed caliper cover 12 to its fixed position. Fixed caliper surface portions lacking the contours to provide this "die-lock" state for securing the fixed caliper cover 12 to the fixed caliper 14 can be designed to be preloaded against these surfaces (Figures 1 and 2) to mitigate separation during use.

[0095] Regarding material selection, the silicone resin materials disclosed herein possess chemical and heat resistance properties to meet the environmental requirements of the caliper cover 12. However, other materials known in the art that can provide the desired heat resistance properties and meet environmental requirements may also be used.

[0096] The design of the fixed caliper cover 12 may include one or more visible non-circular, polygonal openings 16 (e.g., rectangular or quadrilateral) extending through the top (or top portion) of the fixed caliper, which may match or mimic the openings of the fixed caliper 14. Additionally, the fixed caliper cover 12 may include a circular opening 18 that allows a visible bleed screw of the fixed caliper 14 to protrude through the mounted fixed caliper cover 12. Each feature may be designed to enhance the authenticity of the disclosure herein, with the aim of replicating the appearance of a factory-painted premium fixed caliper (Figure 2).

[0097] The aforementioned fixed caliper cover 12 may represent a driver-side front configuration for a U.S.-configured vehicle having fixed calipers 14 on the front pair, wherein the front fixed caliper pair includes different styles of driver-side and passenger-side fixed calipers. Along these lines, although the driver-side and passenger-side fixed calipers may have minor differences, the same reference numeral (i.e., 14) has been used to refer to both the driver-side and passenger-side fixed calipers. The difference between the two fixed calipers 14 is that, although they are mirror images of each other on a vertical plane 20 that bisects the vehicle's length (...) Figure 5 However, neither of the two fixed caliper 14 is symmetrical with respect to a plane bisecting its own length (Figure 1). The symmetry of the calipers themselves provides a simplified product because it eliminates the need for two molds for producing the pair of calipers. Conversely, the lack of symmetry requires two separate tools (or molds) to manufacture a pair of front fixed caliper covers 12 (driver's side and passenger's side). Therefore, it is not possible to produce a single fixed caliper cover 12 to fit onto the two calipers 14 of the front caliper pair unless surface profile adjustments are made during the design of the fixed caliper cover 12 to force symmetry into the design; symmetry may not exist in the calipers 14 of the front pair.

[0098] Given this background, although the fixed caliper 14 targeted by the design of the fixed caliper cover 12 lacks symmetry, the following structural variant of the fixed caliper cover 12 design disclosed herein can achieve symmetry (Figure 12). Regarding the design process, this structural variant's symmetry is achieved by ensuring that the 3D inner surface 22 of the fixed caliper cover 12 is obtained through a comparison of various 3D outer surface regions on each side of the caliper 14, bisected by a plane passing through the caliper length. Using this comparison, a symmetrical design for the fixed caliper cover 12 is developed by using only the outermost outer surfaces of the two opposing surfaces of the fixed caliper (Figure 12). Although this design process may create cavities in some areas between the inner surface of the fixed caliper cover 12 and the fixed caliper 14 during installation, designing in this manner provides the desired symmetry of the design required to allow the use of a single mold when manufacturing a pair of front fixed caliper covers 12. Therefore, a single mold is capable of supporting the manufacture of both fixed caliper covers 12 in the pair. The fixed caliper 14 may also include an outer surface 23 opposite to the inner surface 22 to define a thickness therebetween.

[0099] One aspect of this variation in the molded fixed caliper cover 12, which may differ between driver-side and passenger-side styles, is the location of the 3 / 8-inch diameter bleed screw hole 18 on each fixed caliper cover 12. In some embodiments, for each caliper in the pair, the hole must be located on opposite ends. To account for this variation, the bleed screw hole 18 is formed where post-forming die-cutting is required to allow the corresponding fixed caliper cover 12 (FIG. 12) corresponding to each side of the pair of calipers to be manufactured from a common mold, or simply provided on both sides as an aesthetic compromise to ensure mating with either caliper 14. However, the floating caliper 24 may not have a visible bleed screw. Therefore, the same floating caliper cover 26 disclosed herein can be used for both calipers 24 including a rear pair without requiring post-forming processing to accommodate variations in the bleed screw position.

[0100] The floating caliper cover 26 may also include a 0.050-inch silicone film that conforms to the precise contours of the outer surface of the fixed caliper to which it is designed. As described above, without departing from the spirit and scope of this disclosure, the dimensions and materials provided herein are, for example, other dimensions such as 0.015 inches to 0.150 inches for the floating caliper cover 26, and other materials known in the art. The floating caliper cover 26 may also be sized and constructed to cover 100% of all visible caliper surfaces once installed. Similar to the fixed caliper cover 12, the surfaces of the caliper 24 not covered by the installed floating caliper cover 26 may be limited to one or more invisible surfaces on the wheel chamber-facing surface of the caliper 24. By employing a design that covers less than 100% of the invisible surfaces, the floating caliper cover 26 can be easier to install while also allowing for more efficient heat dissipation of the caliper 24 via convection cooling during vehicle use / braking.

[0101] The specific material (silicone resin with a hardness of 80A) of the floating caliper cover 26, combined with the caliper / vehicle-specific design, allows for a form-fitting engagement with the vehicle's floating caliper 24. Similar to the fixed caliper cover 12 described above, the hardness of the floating caliper cover 26 can vary between 60A and 100A.

[0102] As previously described, unlike the monolithic design of the fixed caliper 14, the floating caliper 24 comprises a static (non-moving) caliper bracket and a dynamic (moving) caliper frame (Figure 9). This is because the caliper bracket is mounted to the vehicle and therefore does not move relative to the vehicle. However, during braking, the caliper frame moves relative to the vehicle as a reaction to piston displacement. Thus, the floating caliper cover 26 can be designed to cover and securely attach to the caliper bracket, while simultaneously covering but allowing movement of the caliper frame beneath it. The design of the floating caliper cover 26 achieves this by engaging the opposing edges of the caliper 24 and maintaining the caliper cover 26 in a state of flexible tension on the surface and top of the caliper 24. Specifically, this interaction is achieved by designing the floating caliper cover 26 such that it allows engagement of opposing features to maintain the caliper cover 26 in a state of flexible tension on the surface and top of the caliper 24.

[0103] According to one embodiment, these opposing engagement features are: (a) the outer front portion of the caliper 24 along its entire length at the bottom edge of the caliper bracket near the rotor hub, and (b) the inner top portion of the caliper frame at the two bolt head locations (FIG. 8). The front bottom edge engagement with the static caliper bracket may include a snap-fit ​​channel engagement 25, while the inner top engagement with the two bolt heads 27 of the dynamic caliper frame consists of multiple resilient ring engagements. These opposing engagements secure the caliper cover 26 to the caliper surface via a flexible tension engagement. Although this type of engagement is depicted on a rear floating caliper, the same engagement is possible on any floating caliper, including those frequently positioned at the front of the vehicle.

[0104] Regarding the external front engagement, the channel engagement can be designed to extend along the entire length of the bottom and also extend upwards to a certain extent along both sides. By giving this channel engagement a U-shaped design, the flexible channel 29 is much stronger than an alternative straight channel design that extends only along the bottom length of the static caliper bracket without flipping upwards along each side (Figure 8). Regarding the internal top resilient ring engagement design, multiple resilient rings 28 engage with bolt heads 27, which are a common feature of the floating caliper frame (Figure 10). Considering that the caliper cover 26 can be constructed of a flexible material such as silicone, these resilient rings 28 are effectively integrated into the caliper cover 26 itself. Additionally, these resilient rings 28 can be designed with integrated clamping tabs 30 for use by the installer to help pull the rings 28 onto the bolt heads 27, thereby securing the cover 26 to the caliper 24 (Figure 11). Therefore, for the floating caliper cover 26, the main retaining features may involve holding the floating caliper cover 26 in a flexibly tensioned state via two opposing joints: (a) a leading edge caliper bracket joint spanning the front of the caliper, and (b) a plurality of elastic ring retaining features spanning the caliper frame bolt head located inside.

[0105] Additionally, similar to the fixed caliper cover 12, the flexibility of the selected material allows the floating caliper cover 26 to bend or stretch along the geometry of the floating caliper 24 during installation, thereby creating “mold-locked” states on many floating caliper surfaces. These “mold-locked” states provide supplementary fixation positions in addition to the previously described double-ring retaining features.

[0106] Regarding material selection, the silicone resin material disclosed herein possesses chemical and heat resistance properties to meet the environmental requirements of the floating caliper cover 26. Other materials known to those skilled in the art capable of withstanding the chemical and thermal environments experienced by calipers may also be used.

[0107] Because the floating caliper 24 is more suitable for the base model braking system than the fixed caliper 14, one purpose of one embodiment of the floating caliper cover 26 is to replicate the appearance of the fixed caliper 14 when mounted on the floating caliper 24. Therefore, unlike the design of the fixed caliper cover 12, which precisely follows the surface of the fixed caliper 14, the design of the floating caliper cover 26 can include a geometry similar to that of the fixed caliper cover 12, as provided by the gap between the static caliper bracket and the surface area of ​​the dynamic caliper frame (Figure 10). An important industrial design feature of the fixed caliper 14 (which the design of the floating caliper 24 may lack) is the multi-piston-shaped surface profile across the front visible surface of the fixed caliper 14. This geometry serves to provide structural support for the opposing pistons operating inside the fixed caliper 14. The resulting surface profile reflects the defining design features of the fixed caliper 14. Therefore, the design of the floating caliper cover 26 can include the multi-piston-shaped surface profile feature of the fixed caliper 14, even if the floating caliper 24 itself does not have this profile feature. In addition to this design feature, the floating caliper cover 26 similarly includes a visible rectangular opening 32 spanning the top surface. This opening 32 replicates a key design element feature of the fixed caliper 12, while also providing a vent for cooling the caliper during braking. Any changes made to improve the aesthetics of the floating caliper design are likely constrained by the rotational wheel close to the caliper according to the vehicle design. Therefore, according to one embodiment disclosed herein, no variation includes a design element protruding from the front surface of the floating caliper closely facing the inward side of the wheel to avoid interference during vehicle operation. The preferred embodiment of the floating caliper cover 26 disclosed herein is symmetrical. A single style of the floating caliper cover 26 can be used for both the driver-side floating caliper and the passenger-side floating caliper, as these two calipers are identical. A variation of the preferred embodiment of the floating caliper cover 26 disclosed herein is a variation suitable for asymmetrical floating caliper designs. This functional variation employs the same principles outlined in the fixed caliper variation for asymmetrical caliper pairs (Figure 12).

[0108] The preferred embodiment of the floating caliper cover 26 disclosed herein also includes a design where the front portion of the caliper 24 engages with the leading edge of the caliper bracket, and this design includes double-ring retaining features engaged at two locations on opposite inner sides of the caliper 24. These double-ring retaining features are integral with the caliper cover 26 itself and, during installation, extend and engage with each of the two bolt heads of the dynamic caliper frame (FIG. 11). A variation of the preferred embodiment of the floating caliper cover 26 disclosed herein achieves the same function as the integral resilient ring retaining feature by using separate O-rings 34 instead of the integral ring 28 (FIG. 13). This variation of design works by engaging the O-rings 34 with holes 36, which are integral with the caliper cover 26 near the integral ring of the preferred embodiment. Once the O-rings 34 are wrapped around the holes 36 and engaged with the caliper cover 26, each O-ring 34 can extend onto its respective bolt head to complete the installation of the caliper cover. Additionally, using a separate O-ring 34 provides a design where the O-ring 34 has a different stiffness than the caliper housing 26 as a whole (i.e., softer and more flexible). Therefore, while the preferred embodiment includes an integral ring 28 to affect the function of the double-ring retaining feature, a structural variation of this feature as described herein includes a double-hole 36 in which two separate O-rings 34 are used, passing through the holes 36 during installation and looping around the bolt head along the inside of the caliper frame.

[0109] Each of the caliper covers 12, 26 can be designed as a single-piece cover, engaging only with its specific caliper 14, 24. Thus, the vehicle-specific caliper design dictates the caliper cover design. As previously shown in the figures (Figure 10, etc.), the fixed caliper cover design differs from the floating caliper cover design based on the differences between the two types of calipers 14, 24. As a single component, each of the caliper covers 12, 26 may not have other interconnecting components, except for the components described in the functional variant of the floating caliper cover 26 having a separate O-ring 34 instead of an integral elastic ring 28.

[0110] As described in the preferred embodiments disclosed herein, the hole 18 can be incorporated into the fixed caliper cover 12 to allow the bleed screw fitting to pass through the surface of the fixed caliper cover 12 during installation onto the caliper 14, thereby making the bleed screw fitting of the caliper 14 a visible feature of the present invention during installation (FIG. 10). Similarly, the alternative variations disclosed herein incorporate different types of openings into the cover design to ensure the visibility of different features of the variations of the fixed caliper design disclosed herein. Specifically, unlike the fixed caliper disclosed herein that supports only the upper end of the caliper with a visible bleed screw fitting (two bleed screw fittings in total), many fixed caliper designs have a conduit assembly 38 that is also supported to the opposite end of the caliper by fittings of the same size (FIG. 14). This fixed caliper design uses an external conduit assembly 38 to allow the caliper itself (i.e., reducing the conduit assembly and bleed screw fitting) to be symmetrical, thereby eliminating the need for two forgings to manufacture both the driver-side and passenger-side versions. In other words, for the manufacture of the fixed caliper itself, the driver-side caliper or passenger-side caliper is achieved during the assembly process after forging / machining, depending on which end of the forged / machined caliper receives the bleed screw or pipe assembly. Considering this variation in fixed caliper design, the optional fixed caliper cover 12 variant disclosed herein accommodates this difference via two additional holes 40 (one of which is for each visible fitting of the pipe assembly 38) and a slit 42 between these two holes 40 for the pipe itself. Each opening in this variant allows each caliper feature to become visible during installation as it passes through the wall of the fixed caliper cover 12 (Figure 14). Furthermore, considering the die consolidation opportunities provided by the symmetry of the fixed caliper 14 using the pipe assembly 38, the holes 40 and slit 42 on the fixed caliper cover 12 are performed via a post-forming punching process, thus eliminating the need for two fixed caliper cover dies. The elements of this design variant (three holes and a slit between two of them) and the elements of the fixed caliper cover 12 disclosed herein (one hole) can be incorporated into their respective styles of single-piece silicone fixed caliper covers 12 to allow the respective design features of the fixed caliper 14 to pass through the fixed caliper cover 12 during installation. As mentioned above, how this is achieved in terms of symmetry offers opportunities for cost savings regarding mold consolidation, as symmetry allows for the use of a single-cavity mold.

[0111] An alternative to making missing or hidden design features of a caliper design visible is by integrating one or more additional components designed to appear as missing or hidden features to present them on the outside of the caliper cover. An example of other ways to conceal design features is the hex head cap of a hex screw visible on the outer surface of a typical fixed caliper design (Figure 15). These hex screws work one after the other on each fixed caliper 14 to hold the brake pads and pad clamps in place. They are particularly visible on OEM-painted fixed calipers 14 because these calipers are painted before the assembly of the internal components of the calipers connected by the hex screws (appearing silver). While these hex head caps are visible on some fixed caliper designs, others, including those disclosed herein, do not have visible hex head caps. In these cases, a variation of the single-component design of the silicone fixed caliper cover 12 is a variation that incorporates a decorative cap 44 as an additional component to form the appearance of a hex head cap on its surface. Therefore, an alternative variation of the single-component design is to incorporate a barbed or threaded connector 46 protruding from the single-component cover 12 at a location adjacent to each hexagonal cap. Engaging with these barbed or threaded connector protrusions 46 are decorative caps 44, each designed to have the appearance of a normally visible hexagonal cap on one side and an internal thread on the other. The decorative caps 44 can be secured to the silicone cover detail by press-fitting on the barbed connector style or by threaded engagement on the threaded connector style. Alternatively, the engagement of either variation can be supplemented using adhesive. Alternatively, as an alternative to the protruding features on the silicone cover at the hexagonal cap locations, circular or slotted holes 48 stamped through the silicone cover 12 at these locations provide alternative engagement. These holes, combined with the style of the decorative hexagonal caps 44 with a retaining flange detail, allow for a shirt-to-button type engagement (Figure 15). Any of these options for securing the decorative hexagonal cap feature can be implemented by the manufacturer during the manufacturing process or by the installer during installation.

[0112] A third option for attaching the decorative hexagonal cap to the silicone fixed caliper cover 12 is to insert a flange-style decorative cap 44 into the silicone cover 12 itself. Alternatively, a variant of the floating caliper cover 26 disclosed herein is a floating caliper cover that similarly incorporates additional components such as the decorative hexagonal cap 44. The same concept using the same attachment method can be applied to a variant of the floating caliper cover 26, as previously described for a variant of the fixed caliper cover 12. When used with either the fixed caliper cover 12 or the floating caliper cover 26, these additional components create a specific appearance to enhance the authenticity of the disclosure, with the aim of replicating the appearance of a factory-painted premium fixed caliper. Specific materials for the decorative hexagonal cap used in any of the above variants are chrome-plated ABS or similar plastics (if molded), and chrome-plated steel, stainless steel, aluminum, or other rust-resistant alloys of similar color (if machined from bar stock).

[0113] This document discloses a design suitable for use with automotive disc brake systems, including combinations of both fixed and floating calipers (Figure 9). Regardless of the caliper type, the construction materials and design elements of the caliper cover allow the caliper cover to bend at the retaining edge of the caliper and then retract to its original shape, thereby securing itself firmly to the mounting surface of the caliper during installation (Figure 11).

[0114] Additionally, the engagement portions of the floating caliper cover 26 may include engaging relative features and hold the caliper cover 26 flexibly tensioned on the surface and top of the caliper 24. These engaging relative features are: (a) the outer front portion of the caliper along its entire length near the bottom edge of the caliper bracket close to the rotor hub, and (b) the inner top portion of the caliper frame at the two bolt head locations. Engaging the front bottom edge of the static caliper bracket is a snap-fit ​​channel engagement portion, while engaging the inner top portion of the two bolt heads of the dynamic caliper frame is a plurality of resilient ring engagement portions. These relative engagement portions secure the caliper cover to the caliper surface by flexibly tensioned engagement. Once installed, each of the caliper covers 12, 26 disclosed herein, whether fixed or floating, remains fully secured and fixed to its mating caliper 14, 24 (FIG. 11). Although more details are available regarding industrial design and very different application uses, each of the silicone caliper covers 12, 26 disclosed herein can function in a manner similar to a silicone smartphone housing. Each one is designed to be flexible to resist the forces it experiences during installation, while also allowing it to retract snugly into the fixed surface of the object it is designed to partially cover.

[0115] The details shown herein are provided as examples for illustrative purposes only and are not intended to provide a description of the principles and concepts of the various embodiments of this disclosure that is considered most useful and readily understood. In this regard, no further details are attempted to be shown except those necessary for a basic understanding of the different features of the various embodiments, and the description taken in conjunction with the accompanying drawings will enable those skilled in the art to understand how these can be implemented in practice.

Claims

1. A vehicle caliper cover kit for use with a disc brake system on a vehicle, comprising a pair of fixed calipers and a pair of floating calipers, the vehicle caliper cover kit comprising: A pair of fixed caliper covers, wherein each fixed caliper cover includes: The inner surface is sized and constructed to be complementary in shape to the outer surface of one of the pair of fixed calipers; An outer surface having a near-central portion and an outer portion positioned opposite to the near-central portion, the inner surface and the outer surface defining a thickness between 0.015 inches and 0.150 inches therebetween; and A polygonal opening extending from the inner surface to the outer surface, the polygonal opening being positioned between the near-center portion and the outermost portion of the outer surface; A pair of floating caliper covers, wherein each floating caliper cover comprises: The inner surface is sized and constructed to be complementary in shape to the outer surface of one of the floating calipers in the pair of floating calipers; An outer surface having a near-central portion and an outer portion positioned opposite to the near-central portion, the inner surface and the outer surface defining a thickness between 0.015 inches and 0.150 inches therebetween; and A pair of rings extending from the near-central portion of the outer surface, each of the pair of rings being capable of extending around a corresponding portion of one of the pair of floating calipers.

2. The vehicle caliper cover kit according to claim 1, wherein, Each fixed caliper cover includes a hole sized to receive a bleed screw on a corresponding fixed caliper of the pair of fixed calipers.

3. The vehicle caliper cover kit according to claim 1, wherein, The pair of fixed caliper covers and the pair of floating caliper covers are made of a material having a Shore hardness in the range of 60A to 100A.

4. The vehicle caliper cover kit according to claim 1, wherein, The pair of fixed caliper covers and the pair of floating caliper covers are made of silicone resin.

5. The vehicle caliper cover kit according to claim 1, wherein, Each of the fixed caliper covers in the pair of fixed caliper covers and each of the floating caliper covers in the pair of floating caliper covers are flexible and can be arranged in a tensioned manner.

6. The vehicle caliper cover kit according to claim 1, wherein, Each of the pair of fixed caliper covers and each of the pair of floating caliper covers can extend between a neutral configuration and a curved configuration, and each of the pair of fixed caliper covers and each of the pair of floating caliper covers is biased toward the neutral configuration.

7. The vehicle caliper cover kit according to claim 1, wherein, Each of the fixed caliper covers in the pair of fixed caliper covers and each of the floating caliper covers in the pair of floating caliper covers are formed from a corresponding monolith.

8. A vehicle caliper cover kit for use with a disc brake system on a vehicle, comprising a pair of fixed calipers and a pair of floating calipers, the vehicle caliper cover kit comprising: A pair of fixed caliper covers, wherein each fixed caliper cover includes: The inner surface is sized and constructed to be complementary in shape to the outer surface of one of the pair of fixed calipers; An outer surface having a near-central portion and an outer portion positioned opposite to the near-central portion, the inner surface and the outer surface defining a thickness between 0.015 inches and 0.150 inches therebetween; and A polygonal opening extending from the inner surface to the outer surface, the polygonal opening being positioned between the near-center portion and the outermost portion of the outer surface; A pair of floating caliper covers, wherein each floating caliper cover comprises: The inner surface is sized and constructed to be complementary in shape to the outer surface of one of the floating calipers in the pair of floating calipers; An outer surface having a near-central portion and an outer portion positioned opposite to the near-central portion, the inner surface and the outer surface defining a thickness between 0.015 inches and 0.150 inches therebetween; and The body and a pair of O-rings connected to the body, the pair of O-rings being able to extend around a corresponding portion of one of the pair of floating calipers.

9. A vehicle caliper cover kit for use with a disc brake system on a vehicle, comprising a pair of fixed calipers and a pair of floating calipers, the vehicle caliper cover kit comprising: A pair of fixed caliper covers, wherein each fixed caliper cover includes: The inner surface is sized and constructed to be complementary in shape to the outer surface of one of the pair of fixed calipers; The outer surface has a near-center portion and an outer portion positioned opposite to the near-center portion; A polygonal opening extending from the inner surface to the outer surface, the polygonal opening being positioned between the near-central portion and the outermost portion of the outer surface; and The hole is sized to receive the vent screw on the respective retaining caliper of the pair of retaining calipers; A pair of floating caliper covers, wherein each floating caliper cover comprises: The inner surface is sized and constructed to be complementary in shape to the outer surface of one of the floating calipers in the pair of floating calipers; The outer surface has a near-central portion and an outer portion positioned opposite to the near-central portion; and A pair of rings extending from the near-central portion of the outer surface, each of the pair of rings extending around a corresponding portion of one of the pair of floating calipers.

10. The vehicle caliper cover kit according to claim 9, wherein, The pair of fixed caliper covers and the pair of floating caliper covers are made of a material having a Shore hardness in the range of 60A to 100A.

11. The vehicle caliper cover kit according to claim 9, wherein, The pair of fixed caliper covers and the pair of floating caliper covers are made of silicone resin.

12. The vehicle caliper cover kit according to claim 9, wherein, Each of the fixed caliper covers in the pair of fixed caliper covers and each of the floating caliper covers in the pair of floating caliper covers are flexible and can be arranged in a tensioned manner.

13. The vehicle caliper cover kit according to claim 9, wherein, Each of the pair of fixed caliper covers and each of the pair of floating caliper covers can extend between a neutral configuration and a curved configuration, and each of the pair of fixed caliper covers and each of the pair of floating caliper covers is biased toward the neutral configuration.

14. The vehicle caliper cover kit according to claim 9, wherein, Each of the fixed caliper covers in the pair of fixed caliper covers and each of the floating caliper covers in the pair of floating caliper covers are formed from a corresponding monolith.

15. A vehicle caliper cover kit for use with a disc brake system on a vehicle, comprising a pair of fixed calipers and a pair of floating calipers, the vehicle caliper cover kit comprising: A pair of fixed caliper covers, wherein each fixed caliper cover includes: The inner surface is sized and constructed to be complementary in shape to the outer surface of one of the pair of fixed calipers; The outer surface has a near-center portion and an outer portion positioned opposite to the near-center portion; A polygonal opening extending from the inner surface to the outer surface, the polygonal opening being positioned between the near-central portion and the outermost portion of the outer surface; and The hole is sized to receive the vent screw on the respective retaining caliper of the pair of retaining calipers; A pair of floating caliper covers, wherein each floating caliper cover comprises: The inner surface is sized and constructed to be complementary in shape to the outer surface of one of the floating calipers in the pair of floating calipers; The outer surface has a near-central portion and an outer portion positioned opposite to the near-central portion; and The body and a pair of O-rings connected to the body, the pair of O-rings being able to extend around a corresponding portion of one of the pair of floating calipers.

16. A vehicle caliper cover kit for use with a caliper disc braking system comprising multiple calipers on a vehicle, the vehicle caliper cover kit comprising: Multiple caliper covers, wherein each caliper cover includes: The inner surface is sized and constructed to be complementary in shape to the outer surface of one of the plurality of calipers; An outer surface having a near-central portion and an outer portion positioned opposite to the near-central portion, wherein the inner and outer surfaces are defined therebetween with a thickness between 0.015 inches and 0.150 inches; and A polygonal opening extends from the inner surface to the outer surface, the polygonal opening being positioned between the near-center portion and the outermost portion of the outer surface.

17. The vehicle caliper cover kit according to claim 16, wherein, The multiple caliper covers are made of a material with a Shore hardness in the range of 60A to 100A.

18. The vehicle caliper cover kit according to claim 16, wherein, Each of the plurality of caliper covers is flexible and can be arranged in a tensioned manner.

19. The vehicle caliper cover kit according to claim 16, wherein, Each of the plurality of caliper covers is extendable between a neutral configuration and a curved configuration, and each of the plurality of caliper covers is biased toward the neutral configuration.

20. The vehicle caliper cover kit according to claim 16, wherein, Each of the plurality of caliper covers is formed from a corresponding monolith.

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