Composite caliper for a disc brake assembly and method for producing same

A method for producing a composite brake caliper adapted for use in a vehicle brake assembly comprising the steps of:

• (a) providing a molding apparatus having at least a pair of mold sections, at least one of the pair of mold sections including at least one projection extending from a surface thereof;
• (b) providing at least one reinforced preform formed from at least a first material, the preform having at least one opening formed at least partially therein;
• (d) positioning the preform in the molding apparatus with the projection of the mold section extending into the opening of the preform so as to orient the preform in a predetermined position within the molding apparatus;
• and
• (e) casting a caliper body formed from a second material in situ therewith to produce the composite brake caliper;
• wherein the opening in the preform extends completely therethrough, the other one of the pair of mold sections includes a recess formed therein, and the projection of the mold section extends through the opening and is disposed in a recess provided in the other one of the pair of mold sections.

A method for producing a composite brake caliper adapted for use in a vehicle brake assembly comprising the steps of:

• (a) providing a molding apparatus having at least a pair of mold sections, at least one of the pair of mold sections including at least one projection extending from a surface thereof;
• (b) providing at least one reinforced preformed formed from at least a first material, the preform having at least one opening formed at least partially therein;
• (d) positioning the preform in the molding apparatus with the projection of the mold section extending into the opening of the preform so as to orient the preform in a predetermined position within the molding apparatus;
• and
• (e) casting a caliper body formed from a second material in situ therewith to produce the composite brake caliper;
• wherein the preform forms at least a portion of an outer surface of the caliper body.

A composite brake caliper produced by a casting process utilizing a molding apparatus having at least a pair of mold sections, at least one of the pair of mold sections including at least one projection extending from a surface thereof, the composite brake caliper comprising:

• at least one reinforced preform formed from at least a first material, said preform having at least one opening formed at least partially therein;
• and
• a caliper body formed from a second material and cast in situ with said preform during the casting process, said caliper body including an inboard leg and an outboard leg interconnected by an intermediate bridge portion;
• wherein said preform is oriented in a predetermined position in said caliper body by positioning the projection of the mold section into said opening of said preform so as to orient said preform in said predetermined position in said caliper body subsequent to the casting process, and wherein said preform is formed from chopped alumina oxide fibers and is reinforced with a material selected from the group consisting of individual strands of ceramic fibers and chopped ceramic fibers.

A composite brake caliper produced by a casting process utilizing a molding apparatus having at least a pair of mold sections, at least one of the pair of mold sections including at least one projection extending from a surface thereof, the composite brake caliper comprising:

• at least one reinforced preform formed from at least a first material, said preform having at least one opening formed at least partially therein;
• and
• a caliper body formed from a second material and cast in situ with said preform during the casting process, said caliper body including an inboard leg and an outboard leg interconnected by an intermediate bridge portion;
• wherein said preform is oriented in a predetermined position in said caliper body by positioning the projection of the mold section into said opening of said preform so as to orient said preform in said predetermined position in said caliper body subsequent to the casting process and wherein said preform forms at least a portion of an outer surface of said caliper body.