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US-12618443-B2 - Caliper housing for a disk brake system and method for manufacturing a caliper housing

US12618443B2US 12618443 B2US12618443 B2US 12618443B2US-12618443-B2

Abstract

The application relates to a caliper housing for a disk brake system. In addition, the application relates to a method for manufacturing a caliper housing. The proposed caliper housing comprises an inner part, an outer part, and a bridge part. The bridge part connects the inner part and the outer part. The caliper housing is formed by additive manufacturing such that a first region of the caliper housing and a second region of the caliper housing are formed and such that the first region has different material properties than the second region.

Inventors

  • Hatem Shahin

Assignees

  • HL MANDO CORPORATION

Dates

Publication Date
20260505
Application Date
20230425
Priority Date
20220425

Claims (12)

  1. 1 . A caliper housing for a disk brake system, comprising an inner part, an outer part, and a bridge part connecting the inner part and the outer part, characterized in that the caliper housing is formed by additive manufacturing such that a first region of the caliper housing and a second region of the caliper housing are formed and such that the first region has different material properties than the second region, wherein the caliper housing is formed by additive manufacturing such that a hole region of the caliper housing is formed, wherein the hole region comprises at least one through hole, wherein the hole region is formed in the outer part, wherein the outer part comprises an interior surface that is configured to push against a back side of a brake pad.
  2. 2 . The caliper housing of claim 1 , characterized in that the first region has a different density than the second region.
  3. 3 . The caliper housing of claim 1 , characterized in that the first region has a higher thermal conductivity or higher specific heat than the second region.
  4. 4 . The caliper housing of claim 3 , characterized in that the first region is a central portion of the bridge part or a portion of the inner part, wherein the inner part is configured to receive a brake piston.
  5. 5 . The caliper housing of claim 1 , characterized in that the first region has a higher E modulus than the second region.
  6. 6 . The caliper housing of claim 5 , characterized in that the first region is formed in the bridge part or in a region of an interface between the inner part and the bridge part or in a region of an interface between the outer part and the bridge part.
  7. 7 . The caliper housing of claim 1 , characterized in that the first region has a higher G modulus than the second region.
  8. 8 . The caliper housing of claim 7 , characterized in that the first region is formed in a portion of the outer part or in a portion of the inner part, wherein the inner part is configured to receive a brake piston.
  9. 9 . The caliper housing of claim 1 , characterized in that the inner part is configured to receive a brake piston.
  10. 10 . The caliper housing of claim 1 , characterized in that the first region has a higher vibration loss factor than the second region, wherein the first region forms an interior surface of the outer part or wherein the first region forms an interior surface of the inner part configured for facing a brake piston.
  11. 11 . The caliper housing of claim 1 , characterized in that the first region and the second region are formed by selective laser sintering.
  12. 12 . A method for manufacturing a caliper housing according to claim 1 , characterized by a step: forming the caliper housing by additive manufacturing such that the first region of the caliper housing and the second region of the caliper housing are formed.

Description

CROSS-REFERENCE TO RELATED APPLICATION This application is based on and claims priority under 35 U.S.C. § 119 to German Patent Application No. 102022203988.2, filed on Apr. 25, 2022 in the German Patent and Trade Mark Office, the disclosures of which are incorporated herein by reference. TECHNICAL FIELD The application relates to a caliper housing for a disk brake system. In addition, the application relates to a method for manufacturing a caliper housing. BACKGROUND Brake calipers are typically used in disk brake systems of vehicles to support and carry two brake pads that are movable relative to a brake disk of the disk brake system upon brake application. Typical disk brake systems further comprise a caliper housing having an inner part, which receives a brake piston. The brake piston may be configured to push against a back side of one of the brake pads. The caliper housing may further comprise an outer part that is a caliper finger configured to push against a back side of the other one of the brake pads. In a generally known manner, the brake pads can thus clamp the braked member in between them to stop or slow down the vehicle. The inner part and the outer part are typically connected via a bridge part of the caliper housing. The caliper housing is typically formed by a metal part made by casting using cast iron. The inner and outer parts of the caliper housing may lie on opposite sides of the brake disk and may be spaced apart from one another along an axial direction, the axial direction corresponding to an axis of rotation of the brake disk. A prior art example of a brake caliper can be found in document KR20090077181A. During brake activation, relatively large forces may act on the caliper housing. The caliper housing may thus deform. This can be accompanied by a number of disadvantages. For example, an uneven wear of the brake pads and specifically of their brake linings may occur. This may result in further problems, such as the generation of drag torque or noise. Furthermore, a hydraulic volume absorbed by the caliper housing and more specifically by a hydraulic chamber, i.e., a cavity, comprised by the caliper housing may increase as a result of said deformation. This additional brake fluid volume absorption is generally undesired for brake performance reasons and hence safety reasons. When developing brake calipers, simulations and structural optimizations with the aid of computer implemented models of the caliper housing may be performed before the caliper housing is cast. So far, it requires a lot of experience and iterations until certain targets are met, e.g., with regard to elastic deformation. This approach is often inefficient as it does not always guarantee optimal outcomes. For example, the known methods may lead to non-optimal brake caliper designs with respect to other relevant parameters, such as weight and price. SUMMARY In view of the above-mentioned aspects, it is an object of the present application to provide an improved caliper housing for a disk brake system. In particular, it is an object of the application to provide a compact, robust, and lightweight caliper housing at a low cost, which does not lead to undesirable noise generation of the disk brake system. In addition, it is an object of the application to provide an improved method for manufacturing a caliper housing having these advantages. This objective is achieved by a caliper housing for a disk brake system comprising the features of claim 1 and by a method having the steps according to another claim. Optional further features and further developments will become apparent from the dependent claims and the detailed description in conjunction with the accompanying figures. The proposed caliper housing for a disk brake system comprises an inner part, an outer part, and a bridge part. The bridge part connects the inner part and the outer part. The caliper housing is formed by additive manufacturing such that a first region of the caliper housing and a second region of the caliper housing are formed and such that the first region has different material properties than the second region. In some examples, the different material properties may be at least one of a different E modulus, a different G modulus, a difference in Poisson's ratio, a different thermal expansion coefficient, a different specific heat, a different thermal conductivity and a different vibration loss factor. By providing the at least two different regions having different material properties, a compact, robust, and lightweight caliper housing may be fabricated at a comparatively low cost. The present invention takes into account that the requirements on the material properties are not the same in all regions of the caliper housing. E.g., the load, strain and stress exerted on the caliper housing is typically different in the different regions in realistic braking scenarios. As compared with known cast caliper housings, the proposed caliper housing e