Brake node

Abstract

Aspects for vehicle structures are provided herein. The vehicle structure may include a caliper portion configured to apply a braking force, the caliper portion including an inner housing, an outer housing, and a bridge portion, where the bridge portion connects the inner housing and the outer housing. In various embodiments, the outer housing may include an inner surface configured to face the rotor, where the inner surface includes a swept region configured to allow the rotor to tilt during installation and removal of the rotor. The vehicle structure may further include a pillar portion configured to be coupled to a wheel of the vehicle, the pillar portion connected to the inner housing. Further, the vehicle structure may include a reinforcement portion connecting the pillar portion to at least the bridge portion or the outer housing. In various embodiments, the vehicle structure may be 3D printed.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 392,823, filed on July 27, 2022, entitled “Brake Nodes,” and U.S. Non-Provisional Patent Application No. 18 / 360,716, filed on July 27, 2023, entitled “Brake Nodes,” the contents of which are incorporated herein by reference as if fully set forth herein. Technical Field

[0003] The present disclosure relates generally to brake and suspension systems for land vehicles, such as automobiles, and more particularly to the integration of brake calipers with suspension components, such as wheel uprights. Background Art

[0004] Automobiles are complex machines with many independent and specialized systems. For example, an automobile has a braking system whose function is to apply braking force to the wheels to stop the automobile. The braking system may include components such as rotors and brake pads, and may include associated brake calipers that seat the brake pads and apply the brake pads to the rotors with friction to slow down and stop the rotors and wheels attached to the rotors. Automobiles also have a suspension system that bears the weight of the automobile and the various dynamic loads that the automobile experiences during driving, turning, stopping, etc. The suspension system may include, for example, a wheel post (also referred to as a wheel carrier, a steering knuckle, or simply a post) that is attached to the wheel and allows the wheel to rotate. For example, when driving over a bumpy road, various other suspension components may be attached to the post (such as control arms and other links) to allow the post to rotate the wheel and move with the up and down movement of the wheel.

[0005] Traditionally, the brake caliper and the column are separate components. The brake caliper (particularly the inner housing of the brake caliper) is bolted to the column, and the rotor is positioned between the brake pads. When the brakes need to be serviced, the brake caliper is unscrewed from the column and lifted to allow removal of the rotor and brake pads. Summary of the invention

[0006] In the present disclosure, it can be appreciated that the brake caliper and the column can be formed as an integral structure. In various embodiments, various advantages can be achieved, as described in more detail below for various embodiments. For example, the benefits can include weight reduction, rigidity, fewer parts, reduced assembly, built-in functionality, improved vehicle dynamics, etc. In various embodiments including an integrated vehicle structure, fewer parts can allow for easier or faster maintenance or repair of the brakes.

[0007] However, integrating a brake caliper and stud presents challenges. For example, because the brake caliper cannot be unscrewed or removed from the stud, during brake servicing, it may be difficult or impossible to remove the rotor without removing the entire integrated brake caliper and stud. In this case, servicing the brakes may be very difficult and time consuming. Various embodiments of the present disclosure may mitigate or eliminate this problem. For example, the integrated caliper and stud may include a swept area on the inner surface of the outer housing that allows the rotor to tilt so that the portion of the rotor connected to the wheel can be disconnected and the rotor can be removed.

[0008] Various embodiments disclosed herein are vehicle structures. In one aspect, the vehicle structure includes a caliper portion configured to apply a braking force. For example, the caliper portion may include an inner housing, an outer housing, and a bridge portion, wherein the bridge portion connects the inner housing and the outer housing. In one or more embodiments, the vehicle structure includes a pillar portion configured to be coupled to a wheel of the vehicle. For example, the pillar portion may be connected to the inner housing of the caliper portion.

[0009] In addition, in one or more embodiments, the vehicle structure may include a reinforcement portion that connects the pillar portion to at least the bridge portion or the outer shell. For example, the reinforcement portion may include an external reinforcement structure configured to connect the pillar portion to the outer shell. In another example, the reinforcement portion includes a bridge reinforcement structure configured to connect the pillar portion to the bridge portion. These exemplary reinforcement portions may further include a cross reinforcement structure that connects the pillar portion to the external reinforcement structure. In one or more embodiments, the reinforcement portion may include a cross reinforcement structure configured to connect the external reinforcement structure to the bridge reinforcement structure. In one or more embodiments, the reinforcement portion may be configured to reduce noise, vibration and harshness (NVH).

[0010] In one or more embodiments, the caliper portion, the column portion and the reinforcement portion can be an integral structure. In one or more embodiments, the caliper portion, the column portion and the reinforcement portion can be a 3D printed structure. In addition, in one or more embodiments, the caliper portion includes a printed-in fluid channel that is configured to provide brake fluid to the inner shell and the outer shell. In other embodiments, the column portion or the reinforcement portion includes a portion of the printed-in fluid channel. In one or more embodiments, the caliper portion, the column portion or the reinforcement portion can be at least partially hollow.

[0011] In one or more embodiments, the vehicle structure includes a cooling element configured to increase cooling of at least a portion of the vehicle structure. For example, the cooling element includes at least a 3D printed heat sink, a channel for airflow, a channel for airflow from a wheel well, an air intake, a diffuser, or a cross-bridge cooling duct.

[0012] In one or more embodiments, the caliper portion, the column portion, or the reinforcement portion includes a printed channel for mounting at least wiring or sensors. For example, the printed channel can be configured for at least a pad wear warning sensor, a temperature sensor, or a smart brake pad sensor.

[0013] On the other hand, the vehicle structure includes a caliper portion configured to apply a braking force. The caliper portion may include an inner housing, an outer housing, and a bridge portion, wherein the bridge portion connects the inner housing and the outer housing. In addition, the outer housing may include an inner surface configured to face the rotor, wherein the inner surface includes a swept area configured to allow the rotor to tilt during installation and removal of the rotor. The swept area may include a curved surface. In one or more embodiments, the vehicle structure includes a column portion configured to be coupled to a wheel of the vehicle, the column portion being connected to the inner housing.

[0014] In one or more embodiments, the vehicle structure further includes a seat configured to seat a pad stop. For example, the seat may be arranged on the front side of the caliper portion. The pad stop may be configured to transfer force from a portion of the brake pad to the vehicle structure, wherein the portion of the brake pad is an area of ​​the brake pad that does not contact the vehicle structure during braking due to the swept area. For example, the seat may be configured to seat a plate-shaped pad stop. In addition, the seat may include a slot. In one or more embodiments, the seat may be configured to seat a pad stop including a stopper portion for an inner brake pad and an outer brake pad. In one or more embodiments, the seat may be configured to seat a pad stop including a stopper portion only for an outer brake pad. In one or more embodiments, the vehicle structure may include a second seat configured to seat a second pad stopper seat, wherein the second seat may be arranged on the rear side of the caliper portion.

[0015] In one or more embodiments, the caliper portion may be a 3D printed structure and the caliper portion includes a printed fluid channel configured to provide brake fluid to the inner housing and the outer housing. For example, the column portion or a reinforcement portion connecting the column portion to at least the bridge portion or the outer housing may be a 3D printed structure and may include a portion of the printed fluid channel.

[0016] In one or more embodiments, the vehicle structure further includes a cooling element configured to increase cooling of at least a portion of the vehicle structure. For example, the cooling element may include at least a 3D printed heat sink, a channel for airflow, a channel for airflow from a wheel well, an air intake, a diffuser, or a cross-bridge cooling duct.

[0017] In one or more embodiments, at least the caliper portion, the column portion, or a reinforcement portion connecting the column portion to at least the bridge portion or the outer shell can include a printed channel for mounting at least wiring or sensors. For example, the printed channel can be configured for at least a pad wear warning sensor, a temperature sensor, or a smart brake pad sensor.

[0018] Other aspects will become apparent to those skilled in the art from the following detailed description, wherein only a few embodiments are shown and described by way of illustration. As will be appreciated by those skilled in the art, the concepts herein are capable of other and different embodiments, and several details are capable of being modified in various functional other aspects, all without departing from the present disclosure. Therefore, the drawings and detailed description are to be regarded as illustrative rather than restrictive in nature. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Various aspects will now be described in detail by way of example and not by way of limitation in the accompanying drawings in which:

[0020] Figure 1 A side perspective view of an example vehicle structure is shown in accordance with an embodiment.

[0021] Figure 2 Shows Figure 1 A top view of an example vehicle structure.

[0022] Figure 3 Shows Figure 1 Bottom view of an example vehicle structure.

[0023] Figure 4 Shows Figure 1 A rear view of an example vehicle structure.

[0024] Figure 5 Shows Figure 1 A second rear view of the example vehicle structure, wherein the vehicle structure is rotated toward the front.

[0025] Figure 6 Shows Figure 1 A front view of an example vehicle structure.

[0026] Figure 7 Shows rotating between top and front views Figure 1A view of an example vehicle structure.

[0027] Figure 8 A front cross-sectional view of an example vehicle structure is shown according to another embodiment.

[0028] Fig. 9 The rotor is shown Figure 8 A front cross-sectional view of an example vehicle structure.

[0029] Fig.10 Shows Figure 8 A front cross-sectional view of an example vehicle structure with the rotor tilted for installation.

[0030] Fig.11 A top view of an example vehicle structure having a cushion stop seat configured to receive a cushion stop according to another embodiment is shown.

[0031] Fig.12 Shows Fig.11 An example vehicle structure wherein a pad stopper is installed in a pad stopper seat.

[0032] Fig.13 An inset view of an example vehicle structure is shown with a pad stop and brake pads installed.

[0033] Fig.14 A front cross-sectional view of an example vehicle structure is shown according to another embodiment.

[0034] Fig.15 A top perspective view of an example vehicle structure having a cushion stop seat configured to receive a cushion stop according to another embodiment is shown.

[0035] Fig.16 Shows Fig.15 A top view of an example vehicle structure.

[0036] Fig.17 Shown with gasket stop installed Fig.15 A top view of an example vehicle structure.

[0037] Fig.18 Shown with gasket stop installed Fig.15 A cross-sectional top view of an example vehicle structure.

[0038] Fig.19 Shown with gasket stop installed Fig.15 An inset cross-sectional top view of an example vehicle structure.

[0039] Fig. 20 Shown with gasket stop installed Fig.15 A side perspective view of an example vehicle structure.

[0040] Fig.21 A side perspective view of an exemplary vehicle structure having printed internal fluid passages is shown according to another embodiment.

[0041] Fig. 22 Shows Fig.21 A side perspective view of an example vehicle structure.

[0042] Fig.23 An inset cross-sectional side perspective view of an example vehicle structure is shown according to another embodiment.

[0043] Fig.24 Shown is a diffuser and cross-bridge cooling duct Fig.23 An inset cross-sectional side perspective view of an example vehicle structure.

[0044] Fig.25 An inset side perspective view of an example vehicle structure having a printed cooling fin is shown according to another embodiment.

[0045] Fig.26 An inset side perspective view of an example vehicle structure having a printed channel according to another embodiment is shown.

[0046] Fig. 27 A bottom perspective view of an example vehicle structure is shown according to another embodiment.

[0047] Fig.28 A top side perspective view of an example vehicle structure is shown according to another embodiment.

[0048] Fig.29 A bottom side perspective view of an example vehicle structure is shown according to another embodiment.

[0049] Fig.30 A side perspective view of an example vehicle structure is shown according to another embodiment.

[0050] Fig.31 A top perspective view of an example vehicle structure is shown according to another embodiment.

[0051] Fig.32 A side view of an example vehicle structure is shown according to another embodiment.

[0052] Fig.33 A side perspective view of an example vehicle structure is shown according to another embodiment. DETAILED DESCRIPTION

[0053] Several solutions have been developed to maximize the structural rigidity of brake calipers, however all these known solutions maintain the typical architecture of a conventional disc brake caliper, in which an outer housing is connected to an inner housing and the inner housing is connected to the wheel upright. Such brake caliper architectures usually rely on two or more connecting bridges spanning the inner and outer housings, which bridges handle all the clamping forces generated across the brake rotor and the tangential forces exerted by the outer brake pads due to the action of friction. Therefore, the rigidity of the structure, or more generally, its weight-stiffness ratio is affected by the design of such connecting bridges, which in turn is constrained by the available space between the brake rotor and the wheel rim. At the same time, when it comes to addressing potential system dynamic instabilities and NVH phenomena such as brake squeal, those known solutions mentioned do not allow much freedom in adjusting the design of the brake caliper to fine-tune its vibration modes, especially the so-called torsion and shear modes, since the aforementioned connecting bridges do not contribute significantly to those vibration modes.

[0054] In order to overcome the above-mentioned limitations associated with traditional brake caliper designs, it is necessary to propose a brake caliper assembly having an inner shell and an outer shell independently interconnected by a main wheel pillar structure by means of a supporting structural element, thereby allowing the weight-stiffness ratio of the product to be improved and having the added ability to adjust its vibration mode to address brake NVH issues.

[0055] A brake node is a vehicle structure that includes: a wheel column portion (also referred to as a bracket or knuckle) adapted to hold and connect a wheel hub-bearing unit to a cinematic point of a suspension link (e.g., a strut link); and a disc brake caliper portion that includes an inner housing and an outer housing configured to face respective sides of a brake rotor and configured to contain a set of pistons, seals, and dust covers to convert hydraulic pressure into a clamping force on the rotor. The column portion and the caliper portion are formed as an integral structure, such as by 3D printing as one piece, and include a reinforcement structure between the column and the center (also referred to as a bridge) portion of the caliper and between the column and the outer housing. The brake node may include an internal hydraulic channel that distributes pressure within the structure, one or more bleed screws with dust covers that allow filling and bleeding of the hydraulic circuit. The brake node may include a removable pad stop to transfer tangential forces from one or more brake pads to the rest of the structure, the force generated by the braking action of applying the pads to the spinning rotor. The brake node may include a connecting rod to contain the deformation of the caliper housing. The brake node may be configured to house two brake pads, using removable retaining pins and clips to hold the brake pads in place, and using springs to avoid excessive rattling and squeaking of the assembly. In some applications, the brake node may also be equipped with an electric parking brake device (electric drum brake (Drum-In-Hat) or electric parking brake caliper).

[0056] Figure 1 An example of a vehicle structure 100 according to one or more embodiments herein is shown. The vehicle structure 100 includes a caliper portion 110, a pillar portion 120, and a reinforcement structure including a front reinforcement structure 132 and a rear reinforcement structure 134. The caliper portion 110 includes an inner shell 140 and an outer shell 150 and a pad stop seat 160. The pad stop seat 160 is configured to receive a pad stop 165 in the seat. The inner shell 140 and the outer shell 150 include a piston cylinder 180 and are configured to accommodate a piston that is hydraulically activated to apply a braking force on a rotor (not shown). The reinforcement structure includes a front reinforcement structure 132 arranged at a front side of the caliper portion 110 (i.e., the side where the forward-driven rotor moves away from the caliper) and a rear reinforcement structure 134 arranged at a rear side of the caliper portion 110 (i.e., the side where the forward-driven rotor moves toward the caliper). From Figure 1 From the perspective shown, the rotor movement would be seen as counter-clockwise, ie the portion of the rotor passing through the caliper would be moving upwards in the figure.

[0057] In various embodiments, the reinforcement structure can provide stiffness for the connection of the caliper portion 110 and the pillar portion 120. In various embodiments, the reinforcement structure can reduce the noise, vibration and harshness (NVH) of the vehicle structure. In various embodiments, such as the vehicle structure 100 shown in the figure, the caliper portion 110, the pillar portion 120 and the reinforcement structure can be an integral structure, that is, formed as a single part. For example, in various embodiments, the vehicle structure 100 can be 3D printed. Due to the complex shapes that can be printed, the 3D printing vehicle structure 100 can allow several advantages. For example, compared with traditional caliper and pillar assemblies, the entire structure can be topologically optimized to provide the required performance characteristics (such as stiffness, NVH) at a reduced weight. The reduction in the weight of the vehicle structure 100 is equivalent to a reduction in non-suspension mass, which can improve the performance of the vehicle (such as vehicle dynamics). In addition, compared with traditional caliper and pillar assemblies, forming the vehicle structure 100 as an integral structure can reduce the number of parts, which in turn can reduce the costs associated with assembly time (that is, the integral vehicle structure does not require assembly) and the procurement of different parts, which can alleviate supply chain issues. As described in more detail herein, in various embodiments, having a unitary design may allow for built-in cooling elements.

[0058] Although various embodiments described herein refer to a unitary vehicle structure, it should be noted that the caliper portion 110, the pillar portion 120, and / or the reinforcement structure can be formed as separate parts that are assembled together. For example, the caliper portion, the pillar portion, and the reinforcement structure can be formed as separate parts and glued or bolted together. In this embodiment, portions of the vehicle structure 100 can be hollow, which can provide a better stiffness-to-weight ratio than a completely solid structure.

[0059] Figure 2 The example vehicle structure 100 is shown from a caliper top view (i.e., looking down on the caliper 110). Figure 2 As can be seen in the caliper portion 110, the caliper portion 110 also includes a bridge structure 210 (also referred to as a central structure). In this example, the bridge structure 210 includes two parts, namely, an upper part and a lower part as shown in the figure. In various embodiments, the bridge structure 210 can include one or more different parts.

[0060] Figure 3The example vehicle structure 100 is shown from a caliper bottom view (i.e., looking up at the caliper portion 110). As shown, the reinforcement structures 132, 134 can be connected to the outer shell 150 (outer shell connectors 220, 225) and can be connected to the bridge structure 210 (bridge structure connectors 230, 235). It should be noted that the bridge structure connector of the rear reinforcement structure 134 is partially obstructed by the pillar portion in the figure. The reinforcement structures 132, 134 can be connected to the pillar portion 120 at the pillar connectors 245, 250.

[0061] Figure 4 and Figure 5 An example vehicle structure 100 is shown showing details of a rear reinforcement structure 134. The rear reinforcement structure 134 (shown in phantom) may include an outer (shell) reinforcement structure 410 connecting the pillar portion 120 to the outer shell 150, a bridge reinforcement structure 420 connecting the pillar portion to the bridge structure 210, and a cross reinforcement structure 430 connecting the outer reinforcement structure to the bridge reinforcement structure. For example, the cross reinforcement structure 430 may provide additional stiffness and / or NVH improvements. Although the cross reinforcement structure 430 is shown as connecting the outer reinforcement structure 410 and the bridge reinforcement structure 420, it should be noted that in various embodiments, the cross reinforcement structure may connect the pillar portion 120 to the outer reinforcement structure, connect the pillar portion to the bridge reinforcement structure, and / or connect the outer reinforcement structure to the bridge reinforcement structure. Various combinations of the cross reinforcement structure 430 are within the scope of the present disclosure. It should be noted that various embodiments may include the outer reinforcement structure 410 but not the bridge reinforcement structure 420, or only the bridge reinforcement structure but not the outer reinforcement structure. These various combinations of reinforcement structures may be applied to the front reinforcement structure 132 and the rear reinforcement structure 134 in similar or different combinations. Various embodiments may include only the front reinforcement structure but not the rear reinforcement structure, or may include only the rear reinforcement structure but not the front reinforcement structure.

[0062] Figure 6 and Figure 7 An example vehicle structure 100 is shown showing details of a front reinforcement structure 132. The front reinforcement structure 132 may include an outer (shell) reinforcement structure 610, a bridge reinforcement structure 620, and a cross reinforcement structure 630. Figure 6 As shown, the cross reinforcement structure 630 may start from the column portion 120 and extend continuously between the outer reinforcement structure 610 and the bridge reinforcement structure 620. In this example, the cross reinforcement structure 430 is not directly connected to the caliper portion 110. In various embodiments, the cross reinforcement structure 630 may be connected to the caliper portion 110 so as to extend continuously from the column portion 120 to the caliper portion, may be connected to the caliper portion but not to the column portion, or various other combinations.

[0063] Figure 8 A cross-sectional view of an exemplary vehicle structure 800 according to one or more embodiments herein is shown. The vehicle structure 800 includes a caliper portion 810 and a pillar portion 815. The caliper portion 810 includes an inner housing 840 and an outer housing 850 and a pad stop seat 160. The inner housing 840 and the outer housing 850 include a piston cylinder 880 and are configured to accommodate a piston that is hydraulically actuated to apply a braking force on the rotor. Figure 8 The outer shell 850 is also shown to include an inner surface that is configured to face the rotor when the rotor is installed in the vehicle structure 800, and the inner surface may include a swept area 820 that may allow the rotor to tilt during installation and removal of the rotor. For example, the swept area 820 may be a curved surface. Figure 8 Further shown is a cross section of a piston cylinder 880 , wherein brake fluid channel openings 830 , 835 of a fluid channel can be seen, which may be printed to the vehicle structure 800 , as described in more detail herein.

[0064] Fig. 9 and Fig.10 Shows Figure 8 Additional cross-sectional views of the exemplary vehicle structure 800 are shown. These figures illustrate the installation and removal of the rotor 910 from the vehicle structure 800. Specifically, Figure 9-10 It is shown how the swept area 820 can allow the rotor to tilt.

[0065] Fig. 9 An example vehicle structure 800 is shown with a rotor 910 installed. As can be seen, the rotor 910 fits tightly within the caliper portion, which can allow for effective operation of the brake system without requiring excessive displacement (e.g., brake pedal displacement) or excessive torque applied to the piston or pads.

[0066] Fig.10 An example vehicle structure 800 is shown in which the rotor 910 is tilted for removal, i.e., not installed (or installed if the steps are reversed). As shown, the swept area 820 can allow space for the rotor 910 to be tilted during installation or removal. In some embodiments, where the caliper portion 810 and the column portion 815 are formed as an integral part, the swept area 820 may be necessary to allow the rotor 910 to be removed (e.g., because the caliper portion cannot be detached from the column portion). In some embodiments, the swept area may simply make removal or installation of the rotor 910 easier.

[0067] Fig.11 and Fig.12An example vehicle structure 1100 is shown that includes a pad stop seat 1160 that is configured to seat a pad stop 1165 (shown in the figure as not installed and floating in space). It should be noted that typical caliper designs allow the leading edges of the brake pads 1170, 1175 to contact the surface of the caliper during braking. This can allow the lateral forces of the brake pads to be transferred to the surface of the caliper portion when the brake pads are located in the caliper portion, which is rigid and can accept the force without deforming. This blocking of the brake pads can be important because heavy braking can create significant forces on the brake pads in a lateral direction. The figure shows that the direction of rotation of the rotor 1110 is into the page at the location of the brake pads.

[0068] In one or more embodiments of the present invention, the addition of swept area 1120 may result in an area of ​​the outer brake pad being unobstructed by the caliper portion surface. Fig.11 The arrangement of the leading edge of the outer brake pad 1170 is shown (the brake pad is not shown for clarity). Such an unblocked area is shown. Under heavy braking, the unblocked area may allow the outer brake pad to rotate in its seat, which is undesirable and potentially dangerous. The caliper portion may include a pad stop seat (e.g., pad stop seat 1160) that may seat a pad stop (e.g., pad stop 1165).

[0069] exist Fig.12 1, pad stop 1165 is shown mounted in pad stop seat 1160. As shown, pad stop 1165 can allow contact with the leading edge of outer brake pad 1170, which would not contact the caliper portion surface due to swept area 1120. Pad stop 1165 can allow lateral forces of the brake pad to be transferred to the surface of the pad stop when the brake pad is in the caliper portion, which can be rigidly seated in pad stop seat 1160 and can transfer the force to the caliper portion. In this manner, pad stop 1165 can prevent the brake pad from rotating in its seat under heavy braking, for example.

[0070] In one or more embodiments, the pad stopper seat 1160 is configured to seat a pad stopper 1165 that includes a stopper portion for the outer brake pad 1170 and the inner brake pad 1175. In various embodiments, the pad stopper seat 1160 may be configured to mount a pad stopper 1165 that includes a stopper portion only for the outer brake pad 1170 and not for the inner brake pad 1175. Fig.12As seen in FIG. 1 , for example, the inner surface of the inner housing may not require a swept area 1120 and the leading edge of the inner brake pad may contact a portion of the caliper surface during braking.

[0071] In one or more embodiments, a single pad stop seat is included at the front side of the caliper portion (i.e., the side where the forward rotating rotor moves away from the center of the caliper portion). In one or more embodiments, a second pad stop seat may be included at the rear side of the caliper portion (i.e., the side where the forward rotating rotor moves toward the center of the caliper portion). When braking during reverse (i.e., when the car is traveling backward), the pad stop located at the rear side may be effective.

[0072] Fig.13 An example vehicle structure 1300 is shown showing a pad stop 1365 installed in a pad stop seat and an outer brake pad 1370 and an inner brake pad 1375 installed. The figure shows the arrangement of the brake pads and pad stop, and how the pad stop allows contact with the leading edge of the outer brake pad 1370 during braking. The direction of rotation of the rotor during forward drive is shown by the arrow marked "A". The figure also shows a brake fluid port 1380, which can access a printed fluid channel for brake fluid, which will be described in more detail herein.

[0073] Fig.14 A cross-sectional view of an example vehicle structure 1400 is shown showing a swept area 1420 included on an inner surface of an outer shell 1450 at a rear side of a caliper portion 1410. As disclosed herein, a rear edge of an outer brake pad 1470 is shown showing that a portion of the rear edge may not contact the caliper portion surface. As disclosed herein, a pad stop seat and pad stop 1465 may be included at the rear side of the caliper portion to address braking in a reverse direction. In various embodiments, the speed of the reverse vehicle is less than the forward speed. In this case, a pad stop may not be required for the rear side of the brake caliper portion.

[0074] Figure 15-Figure 20 Various views and cross-sections of an example vehicle structure 1500 with a pad stop 1565 are shown.

[0075] refer to Figure 15-16, the example vehicle structure 1500 includes a pad stop seat 1560 located in a caliper portion, as disclosed herein. The pad stop seat 1560 can be a slot, channel, or other groove formed in the caliper portion. For example, the pad stop seat 1560 can be formed adjacent to an edge of a bridge or center portion of the caliper portion. The pad stop seat 1560 is configured to receive a pad stop 1565, which is shown removed from the vehicle structure 1500.

[0076] Figure 17-Figure 20 A vehicle structure 1500 is shown with a pad stop 1565 installed or seated in a pad stop seat 1560. When installed, the pad stop 1565 is positioned adjacent the rotor and the swept area 1520, permitting the rotor to be tilted along the swept area for installation or removal. The pad stop 1565 can transfer tangential forces from one or more brake pads to the rest of the vehicle structure 1500, the forces generated by the braking action of applying the pads to the spinning rotor. During forward motion of the vehicle, the direction of rotation of the rotor 1510 is shown by the arrow labeled "B".

[0077] Figure 21-22 An example vehicle structure 2100 is shown according to one or more embodiments, which shows a printed internal fluid channel 2120. The fluid channel 2120 can provide brake fluid to the piston cylinder 2130 of the caliper portion 2110. In this embodiment, the fluid channel 2120 can be included in a portion of the reinforcement structure and the caliper portion. In this way, for example, the brake fluid port 2125 can be positioned closer to the brake fluid source. For example, this can allow the brake fluid port 2125 to be positioned closer to the steering pivot point to reduce the slack or exposed length of the traditional brake hose, thereby reducing the dynamic compliance of the circuit and its exposure to external elements and the total volume of the brake fluid contained. In various embodiments, the printed fluid channel 2120 can be included only in the caliper portion, in the caliper portion and the reinforcement structure, in the caliper portion and the column portion, or any combination thereof.

[0078] Fig. 22 An example vehicle structure is shown, highlighting only the printed fluid channels, without the piston cylinders highlighted in the previous figure.

[0079] Figure 23-Figure 25 An example vehicle structure 2300 is shown illustrating various cooling elements configured to increase cooling of at least a portion of the vehicle structure.

[0080] Fig.23A vehicle structure 2300 is shown having an air channel 2330 that directs airflow from the inner wheel well (i.e., from behind the wheel as viewed from the side of the vehicle). In one or more embodiments, the air channel 2330 can be a printed feature of the caliper portion 2310. In one or more embodiments, the air channel 2330 can be a printed feature of the pillar portion 2320, and the air channel 2330 can be configured as an intake for air that is directed through the caliper portion 2310 and toward the brake pads.

[0081] Fig.24 An example vehicle structure 2300 is shown showing a cross-bridge cooling duct 2350 and a diffuser 2340 disposed on one side of a caliper portion 2310. The diffuser 2340 and / or cross-bridge cooling duct 2350 may allow air to flow over the surface of a brake pad (not shown) or rotor. These features may be printed onto the caliper portion 2310.

[0082] Fig.25 An example vehicle structure 2500 is shown showing printed heat sinks 2560 for dissipating heat. The heat sinks 2560 may allow for better cooling of portions of the vehicle structure 2500. For example, the heat sinks 2560 may be printed on the inner housing 2540 and outer housing 2550 of the caliper portion to allow for cooling of the caliper portion 2510 and the brake fluid inside the caliper portion.

[0083] Fig.26 An example vehicle structure 2600 is shown showing a caliper portion 2610 having a printed channel 2620 for wiring and / or sensors 2630. For example, the printed channel 2620 may be configured to house a pad wear warning sensor, a temperature sensor, or a smart brake pad sensor. The printed channel may be used for wiring of sensors or other applications.

[0084] Figure 27-Figure 33 Example vehicle structures are shown from various perspectives and cross-sections. For example, Fig. 27 A bottom perspective view of a vehicle structure 2700 is shown having a brake fluid port 2780 located on a reinforced portion of a caliper portion 2710 .

[0085] The detailed description set forth above in conjunction with the accompanying drawings is intended to provide a description of various example embodiments of the concepts disclosed herein, and is not intended to represent the only embodiment in which the present disclosure may be practiced. The terms "exemplary" and "example" used in this disclosure mean "used as an example, embodiment, or illustration," and should not be interpreted as being more preferred or more advantageous than other embodiments introduced in this disclosure. In order to provide a thorough and complete disclosure that fully conveys the scope of the concepts to those skilled in the art, the detailed description includes specific details. However, the present disclosure may be practiced without these specific details. In some cases, well-known structures and components may be shown in block diagram form, or omitted entirely, in order to avoid blurring the various concepts introduced throughout this disclosure.

[0086] The previous description is provided to enable those skilled in the art to practice the various aspects described herein. Various modifications to these example embodiments introduced throughout this disclosure will be clear to those skilled in the art. Therefore, the claims are not intended to be limited to the example embodiments introduced throughout this disclosure, but to conform to the full scope consistent with the language claims. All structural and functional equivalents of the elements of the example embodiments described throughout this disclosure are intended to be covered by the claims, and all structural and functional equivalents are known to or will be known to those of ordinary skill in the art later. In addition, regardless of whether such disclosure is explicitly stated in the claims, nothing disclosed herein is intended to be committed to the public. Under the terms of 35 U.S.C. § 112 (f) or similar laws in the applicable jurisdiction, the elements of the claims will not be interpreted, unless the phrase "means for..." is used to explicitly state the claim elements, or in the case of method claims, the phrase "step for..." is used to state the claim elements, otherwise any claim elements shall not be interpreted according to the provisions of 35 U.S.C. § 112 (f) or similar laws in the applicable jurisdiction.

Claims

1. A vehicle structure comprising: a caliper portion configured to apply a braking force, the caliper portion comprising an inner housing, an outer housing, and a bridge portion, wherein the bridge portion connects the inner housing and the outer housing; a post portion configured to be coupled to a wheel of a vehicle, the post portion being connected to the inner housing; and A reinforcing portion connects the column portion to at least the bridge portion or the outer shell.

2. The vehicle structure according to claim 1, wherein: The caliper portion, the pillar portion and the reinforcement portion are an integral structure.

3. The vehicle structure according to claim 1, wherein: The caliper part, the pillar part and the reinforcement part are 3D printed structures.

4. The vehicle structure according to claim 1, wherein: The reinforcement portion includes an outer reinforcement structure configured to connect the column portion to the outer shell.

5. The vehicle structure according to claim 4, wherein: The reinforcement portion further includes a cross reinforcement structure connecting the column portion to the outer reinforcement structure.

6. The vehicle structure according to claim 1, wherein: The reinforcement portion includes a bridge reinforcement structure configured to connect the column portion to the bridge portion.

7. The vehicle structure according to claim 6, wherein: The reinforcement portion further includes a cross reinforcement structure connecting the column portion to the bridge reinforcement structure.

8. The vehicle structure according to claim 1, wherein: The reinforcement portion includes a cross reinforcement structure configured to connect the outer reinforcement structure to the bridge reinforcement structure.

9. The vehicle structure according to claim 1, wherein: The reinforcement portion is configured to reduce noise, vibration and harshness (NVH).

10. The vehicle structure according to claim 1, wherein: At least the caliper portion, the pillar portion or the reinforcement portion is at least partially hollow.

11. The vehicle structure according to claim 1, wherein: The caliper portion is a 3D printed structure, and the caliper portion includes a printed fluid channel configured to provide brake fluid to the inner housing and the outer housing.

12. The vehicle structure according to claim 11, wherein: At least the pillar portion or the reinforcement portion is a 3D printed structure and includes a portion of the printed fluid channel.

13. The vehicle structure of claim 1, further comprising a cooling element configured to increase cooling of at least a portion of the vehicle structure.

14. The vehicle structure according to claim 13, wherein: The cooling elements include at least 3D printed fins, channels for airflow, channels for airflow from the wheel well, air intakes, diffusers or cross-bridge cooling ducts.

15. The vehicle structure of claim 1, wherein: At least the caliper portion, the pillar portion or the reinforcement portion includes a printed channel for mounting at least wiring or sensors.

16. The vehicle structure of claim 15, wherein: The printed channels are configured for at least a pad wear warning sensor, a temperature sensor or a smart brake pad sensor.

17. A vehicle structure comprising: a caliper portion configured to apply a braking force, the caliper portion comprising an inner housing, an outer housing, and a bridge portion, wherein the bridge portion connects the inner housing and the outer housing, the outer housing comprising an inner surface configured to face the rotor, wherein the inner surface comprises a swept area configured to allow the rotor to tilt during installation and removal of the rotor; and A post portion configured to be coupled to a wheel of a vehicle is connected to the inner housing.

18. The vehicle structure of claim 17, wherein: The swept area includes a curved surface.

19. The vehicle structure of claim 17, further comprising: A seat is configured to seat a pad stop configured to transfer force from a portion of the brake pad to the vehicle structure, wherein the portion of the brake pad is an area of ​​the brake pad that does not contact the vehicle structure during braking due to the swept area.

20. The vehicle structure of claim 19, wherein: The seat is configured to seat a plate-like gasket stopper.

21. The vehicle structure of claim 19, wherein: The seat includes a slot.

22. The vehicle structure of claim 19, further comprising a pad stopper mounted in the seat portion.

23. The vehicle structure of claim 19, wherein: The seat is configured to seat a pad stop including stopper portions for an inner brake pad and an outer brake pad.

24. The vehicle structure of claim 19, wherein: The seat is configured to seat a pad stop including a stopper portion for only the outer brake pad.

25. The vehicle structure of claim 19, wherein: The seat portion is arranged on the front side of the caliper portion.

26. The vehicle structure of claim 25, further comprising: A second seat is configured to seat a second pad stopper, wherein the second seat is disposed at a rear side of the caliper portion.

27. The vehicle structure of claim 17, wherein: The caliper portion is a 3D printed structure, and the caliper portion includes a printed fluid channel configured to provide brake fluid to the inner housing and the outer housing.

28. The vehicle structure of claim 27, wherein: At least the column portion or the reinforcement portion connecting the column portion at least to the bridge portion or the outer shell is a 3D printed structure and includes a portion of the printed fluid channel.

29. The vehicle structure of claim 17, further comprising: A cooling element is configured to increase cooling of at least a portion of the vehicle structure.

30. The vehicle structure of claim 29, wherein: The cooling elements include at least 3D printed fins, channels for airflow, channels for airflow from the wheel well, air intakes, diffusers or cross-bridge cooling ducts.

31. The vehicle structure of claim 17, wherein: At least the caliper portion, the column portion, or a reinforcement portion connecting the column portion at least to the bridge portion or the outer shell includes a printed channel for mounting at least wiring or sensors.

32. The vehicle structure of claim 31, wherein: The printed channels are configured for at least a pad wear warning sensor, a temperature sensor or a smart brake pad sensor.

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