Composite brake caliper

Abstract

A composite brake caliper, a vehicle having a brake caliper, and a method for adjusting the stiffness of a brake caliper are provided. A method for adjusting brake caliper stiffness for a vehicle includes determining a vehicle position envelope of a selected brake caliper; modeling the designed composite brake caliper to conform to a vehicle position envelope and to have increased stiffness or to conform to a reduced vehicle position envelope; forming an insert member having a selected stiffness; and casting the outer shell component around the insert component to form a composite brake caliper having an increased stiffness of the designed composite brake caliper and configured to fit within a vehicle position envelope or configured to conform to a reduced vehicle position envelope.

Description

Technical Field

[0001] The present disclosure relates to a brake caliper for a vehicle and may specifically relate to a brake caliper having increased stiffness for applying a braking force to a disc brake rotor of a vehicle. Background Art

[0002] A motor vehicle disc brake system typically utilizes a disc brake rotor at each respective wheel, and each disc brake rotor typically includes a rotor cap for a hub that is connected to a rotatable shaft of the motor vehicle, and at least one annular rotor cheek plate that is connected to the rotor cap, wherein the rotor cheek plate has a pair of opposing braking surfaces to which brake pads are selectively applied when braking is desired.

[0003] The disc brake system typically also includes a caliper that supports a pair of opposing brake pads, with one brake pad disposed to overlay a respective rotor cheek plate braking surface. Typically, the caliper keeps the brake pads separated from the braking surfaces of one or more rotor cheek plates. Braking of the motor vehicle occurs by extending a caliper piston from the caliper to press the brake pads against the braking surfaces of the rotor cheek plates. Typically, hydraulic fluid is used to cause the extension of the caliper piston. The frictional interaction between the rotating rotor cheek plates and the non-rotating brake pads causes braking of the motor vehicle, and the braking rate depends on the pressure of the brake pads against the braking surfaces.

[0004] The braking force may be limited by the stiffness or material strength of the brake caliper. Specifically, the caliper must withstand the outward force of the caliper piston and the force of the hydraulic fluid. A caliper with insufficient stiffness may leak hydraulic fluid and / or may undesirably extend away from each other during braking, thereby limiting the amount of braking force.

[0005] In addition, when braking occurs, undesirable brake squeal may be generated. Brake squeal is the result of modal excitation of the braking components by the frictional interaction during braking.

[0006] Accordingly, it is desirable to provide new and improved methods for adjusting the stiffness of a brake caliper for a vehicle (such as in automotive manufacturing), as well as new and improved brake calipers having increased stiffness and / or a desired natural frequency. A cost-effective and efficient method for adjusting the stiffness of a brake caliper for a vehicle. Further, other desired features and characteristics of the present disclosure will become apparent from the following detailed description and the appended claims in conjunction with the accompanying drawings and the foregoing technical field and background art. Summary of the Invention

[0007] In one embodiment, a method for adjusting the stiffness of a brake caliper for a vehicle is provided. The method includes: determining a vehicle position envelope for a selected brake caliper; modeling a designed composite brake caliper to conform to the vehicle position envelope and have increased stiffness or to conform to a reduced vehicle position envelope; forming an insert member having a selected stiffness; and casting a housing member around the insert member to form a composite brake caliper that has the increased stiffness of the designed composite brake caliper and is configured to fit within the vehicle position envelope or is configured to conform to the reduced vehicle position envelope.

[0008] In certain embodiments, the method includes modeling a designed composite brake caliper to conform to the vehicle position envelope and have increased stiffness; and casting a housing member around the insert member to form a composite brake caliper that has the increased stiffness of the designed composite brake caliper and is configured to fit within the vehicle position envelope.

[0009] In certain embodiments, the method includes modeling a designed composite brake caliper to conform to a reduced vehicle position envelope; and casting a housing member around the insert member to form a composite brake caliper that is configured to conform to the reduced vehicle position envelope.

[0010] In certain embodiments of the method, the housing member includes aluminum, iron, aluminum alloy, or iron alloy. In certain embodiments of the method, the insert member includes ceramic, ceramic foam, metal foam, an additive manufacturing metal skeleton insert, a cast metal insert, a powered metal insert, or a machined metal insert.

[0011] In certain embodiments of the method, casting a housing member around the insert member to form a composite brake caliper includes: providing a mold; positioning the insert member into the mold; pouring molten metal around the insert member into the mold; cooling the mold; and removing the composite brake caliper from the mold.

[0012] In certain embodiments of the method, the insert member includes through holes, and the housing member includes columns extending through the through holes.

[0013] In certain embodiments of the method, the density of the insert member is less than that of the housing member. In certain embodiments of the method, the density of the composite brake caliper is less than that of the selected brake caliper.

[0014] In certain embodiments of the method, the selected brake caliper has a first natural frequency, and the composite brake caliper has an adjusted natural frequency greater than the first natural frequency.

[0015] In another embodiment, a brake caliper includes a housing member having a first stiffness; and an insert member located within the housing member, wherein the insert member has a second stiffness greater than the first stiffness.

[0016] In some embodiments of the brake caliper, the housing member comprises aluminum, iron, an aluminum alloy, or an iron alloy. In some embodiments of the brake caliper, the insert member comprises ceramic, ceramic foam, metal foam, an additive manufactured metal skeleton insert, a cast metal insert, a powered metal insert, or a machined metal insert.

[0017] In some embodiments of the brake caliper, the insert member comprises a through hole, and the housing member comprises a post extending through the through hole. In some embodiments of the brake caliper, the housing member is formed by casting molten metal around the insert member.

[0018] In another embodiment, a vehicle comprises: a wheel; and a brake configured to stop rotation of the wheel, wherein the brake comprises a brake caliper, and wherein each brake caliper comprises: a housing member having a first stiffness; and an insert member located within the housing member, wherein the insert member has a second stiffness greater than the first stiffness.

[0019] In some embodiments of the vehicle, the housing member comprises aluminum, iron, an aluminum alloy, or an iron alloy. In some embodiments of the vehicle, the insert member comprises ceramic, ceramic foam, metal foam, an additive manufactured metal skeleton insert, a cast metal insert, a powered metal insert, or a machined metal insert.

[0020] In some embodiments of the vehicle, the insert member comprises a through hole, and the housing member comprises a post extending through the through hole. In some embodiments of the vehicle, the housing member is formed by casting molten metal around the insert member. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The present disclosure will be described below in conjunction with the following drawings, in which like numerals represent like elements, and in which:

[0022] Figure 1 is a perspective schematic view of a vehicle having a braking system according to an exemplary embodiment;

[0023] Figure 2 is according to an exemplary embodiment of Figure 1 a cross-sectional schematic view of a portion of the braking system;

[0024] Figure 3 is according to an exemplary embodiment of Figure 2 a perspective schematic view of a brake caliper of the braking system;

[0025] Figure 4 is Figure 3 a top view schematic view of the brake caliper;

[0026] Figure 5 is Figure 3 an end view schematic view of the brake caliper;

[0027] Figure 6 yes Figure 3 A schematic side view of a brake caliper of ; and

[0028] Figure 7 FIG. 1 is a diagram showing a method for adjusting the stiffness of a brake caliper and / or for manufacturing a brake caliper (such as Figures 2 - 7 Flow chart of the method of clamp). DETAILED DESCRIPTION

[0029] The following detailed description is merely exemplary in nature and is not intended to limit the application and use of the embodiments herein. In addition, there is no intention to be bound by any express or implied theory presented in the foregoing introduction, brief overview, or detailed description below. As used herein, the term "module" refers to any hardware, software, firmware, electronic control unit or component, processing logic and / or processor device, alone or in any combination, including but not limited to: an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated or group) and memory that executes one or more software or firmware programs, a combinational logic circuit, and / or other suitable components that provide the described functions.

[0030] Embodiments of the present disclosure may be described herein in terms of functional and / or logical block components and various processing steps. It should be understood that such block components may be implemented by any number of hardware, software, and / or firmware components configured to perform specified functions. For example, embodiments of the present disclosure may employ various integrated circuit components, such as memory elements, digital signal processing elements, logic elements, lookup tables, etc., which may perform various functions under the control of one or more microprocessors or other control devices. In addition, those skilled in the art will appreciate that embodiments of the present disclosure may be practiced in conjunction with any number of autonomous driving systems, including cruise control systems, automatic driver assistance systems, and autonomous driving systems, and that the vehicle system described herein is merely an example embodiment of the present disclosure.

[0031] For the sake of brevity, conventional techniques related to other functional aspects of signal processing, data transmission, signaling, control, and systems (and the various operating components of the systems) may not be described in detail herein. In addition, the connecting lines shown in the various figures included herein are intended to represent example functional relationships and / or physical couplings between various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in the embodiments of the present disclosure.

[0032] Embodiments of the present disclosure provide brake calipers with increased stiffness, reduced density, and / or tuned modal characteristics while conforming to a given vehicle packaging envelope. As used herein, the "vehicle packaging envelope" of a caliper is the volume representing all the positions that the caliper may occupy during its normal range of motion. The brake calipers provided herein form composite parts by using insert parts located inside the housing parts to achieve the desired characteristics. Specifically, the desired stiffness, desired density, and / or specific desired modal characteristics can be identified and achieved by selecting and designing the insert parts and modeling the composite parts obtained by positioning the insert parts within the housing parts. In some embodiments, the housing part may be aluminum, aluminum alloy, iron, iron alloy, or other suitable cast metals. The insert part may be a ceramic; ceramic foam; metal foam; an additive manufacturing metal skeleton insert; a cast metal insert; a powered metal insert; a machined metal insert, such as steel; or another suitable material.

[0033] This provides the desired stiffness and has sufficient thermal properties to withstand the casting process.

[0034] Reference Figure 1 , shows certain features of vehicle 10 in the form of a functional block diagram. In some examples, vehicle 10 includes an automobile. In various examples, vehicle 10 can be any of a variety of different types of automobiles, e.g., such as a sedan, a van, a truck, or a sport utility vehicle (SUV), and in some examples can be two-wheel drive (2WD) (i.e., rear-wheel drive or front-wheel drive), four-wheel drive (4WD), or all-wheel drive (AWD) and / or various other types of vehicles or mobile platforms.

[0035] As Figure 1 depicted in, exemplary vehicle 10 generally includes a body 14 and wheels 16. Body 14 substantially encloses the components of vehicle 10. Each wheel 16 is rotatably coupled to vehicle 10 near a respective corner of body 14.

[0036] As shown, vehicle 10 includes a braking system 30 at each wheel 16.

[0037] Reference Figure 2 , the braking system 30 includes a brake caliper system 100. In the illustrated embodiment, brake caliper system 100 includes two brake calipers 101, such as a mounting half and a rim half, although other possible embodiments are also contemplated.

[0038] As shown, each brake caliper 101 is formed with a chamber 110. Further, a hydraulic piston 120 is located within each chamber 110. A pad backplate 130 is located at the end of each piston 120. Additionally, a brake pad 140 is mounted to the pad backplate 130.

[0039] The piston 120 is configured to move towards each other such that the brake pads 140 can compress the rotor to slow down the rotation of the wheel. Additionally, the piston 120 is configured to move away from each other to retract the brake pads 140 from the rotor. To drive the movement of the piston 120, hydraulic fluid is injected into or discharged from the piston chamber 110.

[0040] When the brake pads 140 contact the rotor, forces may cause the brake caliper 101 to expand. Additionally, forces may cause hydraulic fluid to leak from the piston chamber 110. In either case, the result is that some of the braking force generated by the foot pedal and the master cylinder is wasted, and the braking force is limited. The long-term results include increased pedal travel and tapered pad wear.

[0041] Although Figure 2 a braking system 100 having a fixed brake caliper (commonly referred to as an opposed piston caliper) is shown, other embodiments are also contemplated. For example, the braking system 100 may include a movable (commonly referred to as a sliding or floating) brake caliper.

[0042] Figure 3 is a perspective view of the brake caliper 101, which has increased stiffness sufficient to withstand a desired level of braking force. Figure 4 is a top view of the same brake caliper 101, Figure 5 is an end view, and Figure 6 is a side view.

[0043] Cross-reference Figures 3 - 6 , the brake caliper 101 includes an insert member 150 and a housing member 160.

[0044] The insert member 150 may be formed of ceramic, metal foam, or another suitable material that provides sufficient stiffness and can withstand the high temperatures of the following manufacturing process.

[0045] The housing member 160 may be formed via casting and may be a metal such as iron, iron alloy, aluminum, aluminum alloy, or other materials suitable for the brake caliper 101. For example, the housing member may be formed by casting molten metal around the insert member 150.

[0046] In certain embodiments, the density of the insert member 150 is less than that of the housing member 160. Thus, the density of the composite brake caliper 101 is less than that of a caliper of the same shape and size formed only of the housing member metal.

[0047] In certain embodiments, the insert member 150 has a greater stiffness than the housing member 160.

[0048] In some embodiments, the insert member 150 has a natural frequency different from that of the housing member 160 such that the composite brake caliper 101 has an adjusted natural frequency different from that of a caliper of the same shape and size formed solely of the housing member metal.

[0049] The insert member 150 may be completely surrounded by the housing member 160 such that the housing member 160 forms the entire outer surface 171 of the composite brake caliper 101.

[0050] In some embodiments, the insert member 150 includes a through-hole 151, i.e., a channel or opening that extends through the insert member 150 from one side to the other. In such an embodiment, the housing member 160 includes a post 161 that fills and extends through the through-hole 151 and connects opposite sides of the housing member 160.

[0051] The composite brake caliper 101 provides increased caliper strength and stiffness by casting a composite material in place within the caliper body without increasing the cross-sectional thickness and associated mass. Increasing the stiffness without increasing the size allows the caliper to be used in a smaller envelope without negatively impacting fluid consumption / performance targets. Generally, strength measures the stress or force applied to a material before it fractures (tensile strength) or permanently deforms (yield strength). However, the stiffness of a material defines how the material bends to resist an applied force while returning to its original shape after the force is removed. In some embodiments, the composite brake caliper 101 is provided with increased stiffness compared to a non-composite monolithic brake caliper of the same size and shape, i.e., an increased ability to resist deformation when an external force is applied. In some embodiments, the composite brake caliper 101 is provided with a higher Young's modulus compared to a non-composite monolithic brake caliper of the same size and shape, i.e., a higher ratio of the ability to resist deformation to the ability to return to the original shape when the external force is removed. In some embodiments, the composite brake caliper 101 is provided with a higher yield strength compared to a non-composite monolithic brake caliper of the same size and shape, i.e., a higher amount of force required to permanently deform the caliper. In some embodiments, the composite brake caliper 101 is provided with a higher tensile strength compared to a non-composite monolithic brake caliper of the same size and shape, i.e., a higher amount of tensile force required to break the caliper.

[0052] In addition to increasing strength and stiffness, the selection and design of the insert member can be used to tune the natural frequency of the composite brake caliper compared to an integral caliper of the same shape and size. Specifically, the modal characteristics of the brake caliper in terms of resonance frequency, mode shape, and structural damping can be selected and achieved through the selection and design of the insert member while still conforming to a given vehicle location envelope.

[0053] Reference Figure 7, The flowchart illustrates a method 700 for adjusting the stiffness of a brake caliper for a vehicle. As shown, method 700 includes determining, at operation 705, one or more parameters of a selected brake caliper. For example, method 700 can determine the vehicle position envelope of the brake caliper. Method 700 can also determine the stiffness of the selected brake caliper. For example, the stiffness of a cast monoblock caliper (i.e., a non-composite caliper) of the determined shape and size can be determined by modeling (such as by a processor). Method 700 can also determine the natural frequency of the selected brake caliper. For example, the natural frequency of a cast monoblock caliper (i.e., a non-composite caliper) of the determined shape and size can be determined by modeling (such as by a processor).

[0054] Method 700 can continue, at operation 715, by modeling a designed composite brake caliper to conform to the vehicle position envelope, i.e., to fit within the vehicle position envelope. A processor can model the designed composite brake caliper. The designed composite brake caliper can have increased stiffness, such as greater than the stiffness of the selected brake caliper. Additionally or alternatively, the designed composite brake caliper can conform to a reduced vehicle position envelope. For example, a proposed redesign or the proposed use of other components with increased dimensions may suggest using a reduced vehicle position envelope that is at least partially smaller than the original vehicle position envelope. Thus, the designed composite brake caliper can conform to a smaller vehicle position envelope while providing sufficient stiffness.

[0055] At operation 725, method 700 includes forming an insert member having a selected stiffness. As described above, the insert member can be ceramic; ceramic foam; metal foam; an additive manufacturing metal skeleton insert; a cast metal insert; a powered metal insert; a machined metal insert, such as steel; or another suitable material.

[0056] At operation 735, method 700 includes providing a mold. Specifically, the mold can be designed and manufactured to form a cast part having a desired profile and dimensions. In some embodiments, the mold can be formed of sand or metal.

[0057] At operation 745, method 700 includes positioning the insert member in the mold.

[0058] Then, at operation 755, method 700 includes pouring molten metal into the mold and around the insert member. The molten metal can be iron, an iron alloy, aluminum, an aluminum alloy, or other suitable metal. Note that the insert member can include through holes or channels extending through the insert member, and the molten metal can fill the through holes. Additionally, the insert member is not deformed or otherwise damaged by the heat of the molten metal.

[0059] In operation 765, the method includes cooling the mold. Upon cooling, the molten metal solidifies to form a cast outer part around the insert part, i.e., a molded composite part. Additionally, the cast outer part can include posts that extend through the insert part.

[0060] After the metal has solidified to form the cast outer part, in operation 775, method 700 includes removing the molded composite part from the mold.

[0061] In operation 785, method 700 can include performing machining of the molded composite part to cut or remove material from the molded composite part, if necessary, to make the dimensions of the part more precise.

[0062] Operations 735, 745, 755, 765, 775, and / or 785 can together provide a process for casting a housing part around an insert part to form a composite brake caliper that has increased stiffness of the designed composite brake caliper and is configured to fit within a vehicle location envelope or is configured to conform to a reduced vehicle location envelope.

[0063] In operation 795, method 700 can further include installing the composite brake caliper in a vehicle.

[0064] Although at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that there are a large number of variations. It should also be understood that the exemplary embodiment or exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. Instead, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing the exemplary embodiment or exemplary embodiments. It should be understood that various changes can be made to the function and arrangement of the elements without departing from the scope of the present disclosure as set forth in the appended claims and their legal equivalents.

Claims

1. A method for adjusting the stiffness of a brake caliper for a vehicle, the method comprising: Determining a vehicle position envelope for a selected brake caliper; Modeling a designed composite brake caliper to conform to the vehicle position envelope and have increased stiffness or to conform to a reduced vehicle position envelope; Forming an insert member having a selected stiffness; And Casting a housing member around the insert member to form a composite brake caliper having the increased stiffness of the designed composite brake caliper and configured to fit within the vehicle position envelope or configured to conform to the reduced vehicle position envelope.

2. The method according to claim 1, comprising: Modeling the designed composite brake caliper to conform to the vehicle position envelope and have the increased stiffness; And Casting the housing member around the insert member to form the composite brake caliper having the increased stiffness of the designed composite brake caliper and configured to fit within the vehicle position envelope.

3. The method according to claim 1, comprising: Modeling the designed composite brake caliper to conform to the reduced vehicle position envelope; And Casting the housing member around the insert member to form the composite brake caliper configured to conform to the reduced vehicle position envelope.

4. The method according to claim 1, wherein: The housing member comprises aluminum, iron, aluminum alloy or iron alloy; and The insert member comprises ceramic, ceramic foam, metal foam, an additive manufacturing metal skeleton insert, a cast metal insert, a power metal insert or a machined metal insert.

5. The method according to claim 1, wherein Casting the housing member around the insert member to form the composite brake caliper comprises: Providing a mold; Positioning the insert member into the mold; Pouring molten metal around the insert member into the mold; Cooling the mold; and Removing the composite brake caliper from the mold.

6. A brake caliper, comprising: A housing member having a first stiffness; And An insert member located within the housing member, wherein the insert member has a second stiffness greater than the first stiffness.

7. The brake caliper according to claim 6, wherein, The housing member comprises aluminum, iron, aluminum alloy or iron alloy.

8. The brake caliper according to claim 6, wherein, The insert member comprises ceramic, ceramic foam, metal foam, an additive manufacturing metal skeleton insert, a cast metal insert, a power metal insert or a machined metal insert.

9. The brake caliper according to claim 6, wherein, The insert member comprises through holes, and wherein the housing member comprises posts extending through the through holes.

10. The brake caliper according to claim 6, wherein, The housing member is formed by casting molten metal around the insert member.

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