Brake caliper for disc brake assembly and method for producing same

1. A brake caliper adapted for use in a disc brake assembly including:

a brake caliper having an inboard leg portion and an outboard leg portion which are interconnected by an intermediate bridge portion, the brake caliper having a first locating surface provided on the inboard leg portion, a second locating surface provided on the outboard leg portion and a third locating surface provided on the outboard leg portion, the inboard leg portion including a pair of ears and a piston bore having an opened outer end, each ear having an opening formed therethrough, wherein the first locating surface provided on the inboard leg portion is an elongated groove formed wholly within the inboard leg of the caliper, the groove having first opened end located adjacent an innermost end of the inboard leg and extending toward the outboard leg and terminating at a second closed end located wholly within the inboard leg and not extending past at least one of the pair of ears and the opened outer end of the piston bore so as to not extend into the intermediate bridge portion of the caliper, the groove having a generally uniform cross-section along substantially the entire length thereof.

2. The brake caliper according to claim 1 wherein the elongated groove has one of a generally V-shape and a U-shape.

3. The brake caliper according to claim 1 wherein the groove has a generally U-shape and the second closed end of the groove has a generally partly conical shape.

4. The brake caliper according to claim 1 wherein the brake caliper is one of a vertically cast brake caliper and a horizontally cast brake caliper.

5. The brake caliper according to claim 1 wherein the groove has a generally V-shape and the second closed end of the groove includes a forward portion having a flat face.

6. The brake caliper according to claim 1 wherein the second closed end is located wholly within the inboard leg and does not extend past the pair of ears so as to not extend into the intermediate bridge portion of the caliper.

7. The brake caliper according to claim 1 wherein the second closed end is located wholly within the inboard leg and does not extend past the opened outer end of the piston bore so as to not extend into the intermediate bridge portion of the caliper.

8. The brake caliper according to claim 1 wherein the second closed end is located wholly within the inboard leg and does not extend past both of the pair of ears and the opened outer end of the piston bore so as to not extend into the intermediate bridge portion of the caliper.

9. A brake caliper adapted for use in a disc brake assembly including:

a brake caliper having an inboard leg portion and an outboard leg portion which are interconnected by an intermediate bridge portion, the brake caliper having a first locating surface provided on the inboard leg portion, a second locating surface provided on the outboard leg portion and a third locating surface provided on the outboard leg portion, the inboard leg portion including a pair of ears and a piston bore having an opened outer end, each ear having an opening formed therethrough, wherein the first locating surface provided on the inboard leg portion is an elongated groove formed wholly within the inboard leg of the caliper, the groove having first opened end located adjacent an innermost end of the inboard leg and extending toward the outboard leg and terminating at a second closed end located wholly within the inboard leg and not extending past at least one of the pair of ears and the opened outer end of the piston bore so as to not extend into the intermediate bridge portion of the caliper.

10. The brake caliper according to claim 9 wherein the groove extends a predetermined length and a predetermined uniform depth into the inboard leg of the caliper.

11. The brake caliper according to claim 9 wherein the groove has a generally uniform cross-section along substantially the entire length thereof.

12. The brake caliper according to claim 9 wherein the elongated groove has one of a generally V-shape and a U-shape.

13. The brake caliper according to claim 9 wherein the groove has a generally U-shape and the second closed end of the groove has a generally partly conical shape.

14. The brake caliper according to claim 9 wherein the groove has a generally V-shape and the second closed end of the groove includes a forward portion having a flat face.

15. The brake caliper according to claim 9 wherein the brake caliper is one of a vertically cast brake caliper and a horizontally cast brake caliper.

16. The brake caliper according to claim 9 wherein the second closed end is located wholly within the inboard leg and does not extend past the pair of ears so as to not extend into the intermediate bridge portion of the caliper.

17. The brake caliper according to claim 9 wherein the second closed end is located wholly within the inboard leg and does not extend past the opened outer end of the piston bore so as to not extend into the intermediate bridge portion of the caliper.

18. The brake caliper according to claim 9 wherein the second closed end is located wholly within the inboard leg and does not extend past both of the pair of ears and the opened outer end of the piston bore so as to not extend into the intermediate bridge portion of the caliper.

19. A brake caliper adapted for use in a disc brake assembly including:

a brake caliper selected from one of a vertically cast brake caliper and a horizontally cast brake caliper, said brake caliper having an inboard leg portion and an outboard leg portion which are interconnected by an intermediate bridge portion, the brake caliper having a first locating surface provided on the inboard leg portion, a second locating surface provided on the outboard leg portion and a third locating surface provided on the outboard leg portion, the inboard leg portion including a pair of ears and a piston bore having an opened outer end, each ear having an opening formed therethrough, wherein the first locating surface provided on the inboard leg portion is an elongated groove formed wholly within the inboard leg of the caliper, the groove having one of generally V-shape and a U-shape and extending a predetermined length and a predetermined uniform depth into the inboard leg of the caliper, the groove having first opened end located adjacent an innermost end of the inboard leg and extending toward the outboard leg and terminating at a second closed end located wholly within the inboard leg and not extending past at least one of the pair of ears and the opened outer end of the piston bore so as to not extend into the intermediate bridge portion of the caliper, the groove having a generally uniform cross-section along substantially the entire length thereof.

20. The brake caliper according to claim 19 wherein the groove has a generally U-shape and the second closed end of the groove has a generally partly conical shape.

21. The brake caliper according to claim 19 wherein the groove has a generally V-shape and the second closed end of the groove includes a forward portion having a flat face.

22. The brake caliper according to claim 19 wherein the second closed end is located wholly within the inboard leg and does not extend past the pair of ears so as to not extend into the intermediate bridge portion of the caliper.

23. The brake caliper according to claim 19 wherein the second closed end is located wholly within the inboard leg and does not extend past the opened outer end of the piston bore so as to not extend into the intermediate bridge portion of the caliper.

24. The brake caliper according to claim 19 wherein the second closed end is located wholly within the inboard leg and does not extend past both of the pair of ears and the opened outer end of the piston bore so as to not extend into the intermediate bridge portion of the caliper.