A Brake Caliper Assembly for Resurfacing Brake disc to Enhance Brake Optimization and Method Thereof

Abstract

ABSTRACT: Title: A Brake Caliper Assembly for Resurfacing Brake disc to Enhance Brake Optimization and Method Thereof The present disclosure proposes a brake caliper assembly (100) that is adapted to provide a real-time resurfacing of a brake disc (12) when a vehicle is in motion, thereby ensuring uniform and continuous optimization of the brake disc (12) for improved vehicle safety and performance. The brake caliper assembly (100) comprises a caliper housing (102), a pair of frame sections (106A, 106B), and cylinder housings (112A, 112B). The cylinder housings (112A, 112B) are adapted to adjust on the brake disc (12) through adjustable rods (114A, 114B) to accommodate the circumference of the brake disc (12) for performing a surface grinding operation. The proposed brake caliper assembly (100) is integrated with the snap-fit mechanism and allows for quick and easy replacement of resurfacing pads (124A, 124B) without the need for specialized tools, making maintenance user-friendly and accessible.

Specification

Description:DESCRIPTION:
Field of the invention:
[0001] The present disclosure generally relates to the technical field of a brake disc resurfacing, in specific, and relates to a brake caliper assembly that is adapted to provide a real-time resurfacing of a brake disc when a vehicle is in motion, thereby ensuring uniform and continuous optimization of the brake disc for improved vehicle safety and performance.
Background of the invention:
[0002] A disc brake is a type of braking system that uses a disc, or rotor, to slow down or stop a vehicle. The disc, usually made of metal, is attached to the wheel. When a brake pedal is pressed, brake pads clamp onto the disc, thereby creating friction that slows the wheel's rotation. The main advantages of disc brakes include their superior stopping power and performance, particularly in wet and high-temperature conditions. They dissipate heat more effectively than drum brakes, thereby reducing the risk of brake fade and providing better overall control, which makes them popular in modern vehicles for enhanced safety and reliability.

[0003] Disc resurfacing, also known as rotor resurfacing, is a process in which the surface of a brake disc (rotor) is machined to restore a smooth and even surface. Over time, brake discs may develop grooves, uneven wear, or warping due to friction or heat. Furthermore, the heat might be created during the regular usage of the brake discs. Resurfacing is adapted to remove a thin layer of the disc's material, thereby eliminating imperfections and restoring the disc's flatness. This process might help to improve braking performance and extend the life of the brake disc.

[0004] The tools used for resurfacing brake discs, such as lathe machines or dedicated brake rotor resurfacing equipment, have several drawbacks. These tools require precise calibration and maintenance to ensure they produce a uniform surface, and any malfunction or misalignment can result in uneven resurfacing. Additionally, the equipment can be expensive to purchase and maintain, placing a financial burden on smaller shops. The process also generates fine metal particles and dust that must be managed to avoid contamination or damage to other components. Furthermore, resurfacing tools might only for correct surface imperfections to a certain extent. If the disc is excessively worn or damaged, the resurfacing process might not restore it to optimal condition, potentially leading to continued brake performance issues.

[0005] Resurfacing the brake disc typically requires removing the wheel or disc from the vehicle to access it properly. This process can be labour-intensive and time-consuming, as it involves lifting the vehicle, removing the wheel, and sometimes detaching a brake caliper and rotor. In some cases, where removing the wheel or disc is impractical, alternative methods are used. For example, some specialized resurfacing equipment is designed to work with the disc still attached to the vehicle, though these systems are less common and may not provide as precise results. These methods often involve replacing the brake pads with a surfacing plate or tool that can grind the disc surface while it remains mounted.

[0006] However, this approach has limitations, such as less accurate resurfacing and the potential for damage to other brake components if not performed correctly. Additionally, these tools might not effectively address deeper imperfections or warping, which can compromise braking performance if the disc is significantly worn or damaged.

[0007] Therefore, there is a need for a brake caliper assembly that provide consistent and uniform contact between the resurfacing pads and the brake disc, leading to a smoother surface finish, better braking performance, and reduced vibrations. There is also a need for a brake caliper assembly that reduces the formation of metal particles and dust during resurfacing, reducing pollution and making the process more environmentally friendly. Furthermore, there is also a need for a brake caliper assembly that allows for the use of different types of resurfacing pads (e.g., smoothing, glazing), enabling the user to adapt the innovative brake caliper for various maintenance needs and brake conditions.
Objectives of the invention:
[0008] The primary objective of the present invention is to provide a brake caliper assembly that is adapted to provide a real-time resurfacing of a brake disc when a vehicle is in motion, thereby ensuring uniform and continuous optimization of the brake disc for improved vehicle safety and performance.

[0009] Another objective of the present invention is to provide a brake caliper assembly that adjusts the resurfacing process of the brake disc by using torque hinges and a screw shaft, thereby allowing pads to be lifted according to user requirements.

[0010] Another objective of the present invention is to provide a brake caliper assembly that continuous perform the resurfacing process to prevent excessive wear, thereby extending a lifespan of the brake disc and minimizing the need for costly replacements.

[0011] Another objective of the present invention is to provide a brake caliper assembly that utilizes a spring-piston mechanism ensures to consistent contact with the brake disc, thereby promoting uniform resurfacing and resulting in improved and reliable braking performance.

[0012] Another objective of the present invention is to provide a brake caliper assembly that integrated with a snap-fit mechanism allows for quick and easy replacement of resurfacing pads without the need for specialized tools, making maintenance user-friendly and accessible.

[0013] Another objective of the present invention is to provide a brake caliper assembly that provides consistent and uniform contact between the resurfacing pads and the brake disc, leading to a smoother surface finish, better braking performance, and reduced vibrations.

[0014] Another objective of the present invention is to provide a brake caliper assembly that reduces the formation of the metal particles and dust during resurfacing, thereby lowering pollution and making the process more environmentally friendly.

[0015] Yet another objective of the present invention is to provide a brake caliper assembly that allows for the use of different types of resurfacing pads (e.g., smoothing, glazing), thereby allowing the user to adapt the innovative brake caliper for various maintenance needs and brake conditions.

[0016] Further objective of the present invention is to provide a brake caliper assembly that eliminates the need for external equipment and professional intervention, thereby reducing maintenance costs for vehicle owners and increasing the overall efficiency of brake servicing.
Summary of the invention:
[0017] The present disclosure proposes a brake caliper assembly for resurfacing brake disc to enhance brake optimization and method thereof. The following presents a simplified summary in order to provide a basic understanding of some aspects of the claimed subject matter. This summary is not an extensive overview. It is not intended to identify key/critical elements or to delineate the scope of the claimed subject matter. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.

[0018] In order to overcome the above deficiencies of the prior art, the present disclosure is to solve the technical problem to provide a brake caliper assembly that is adapted to provide a real-time resurfacing of a brake disc when a vehicle is in motion, thereby ensuring uniform and continuous optimization of the brake disc for improved vehicle safety and performance.

[0019] According to one aspect, the invention provides the brake caliper assembly for resurfacing brake disc. In one embodiment, the brake caliper assembly comprises a caliper housing, a pair of frame sections, and cylinder housings. In one embodiment, the caliper housing having brake pads is mounted on the brake disc. The caliper housing is configured to contact with the brake disc for decelerating its rotation when a vehicle is in motion.

[0020] In one embodiment, the pair of frame sections is adaptably mounted at one end of the caliper housing. In one embodiment, the pair of frame sections are securely coupled through a connecting member to ensure the performance of a surface grinding operation. In one embodiment, the cylinder housing is pivotally coupled to each frame section through torque hinges. The cylinder housing is configured to enable a user to rotate a screw shaft from a rest position and an operative position for allowing a resurfacing pad to contact with the brake disc via a piston cylinder so as to perform the surface grinding operation.

[0021] In one embodiment, the cylinder housing is adapted to adjust the brake disc through the adjustable rod to accommodate the brake disc's circumference for performing the surface grinding operation. In one embodiment, the adjustable rod is operably coupled to the cylinder housing. The adjustable rod is configured to enable precise positioning of the resurfacing pad relative to the brake disc for allowing the resurfacing pad to be manually raised and lowered into contact with the brake disc, thereby facilitating controlled resurfacing while ensuring uniform pressure distribution throughout the surface grinding operation.

[0022] In one embodiment, the screw shaft having a hand-operated screw knob at one end that is configured to be operated by the user to adjust the movement of the piston cylinder within the cylinder housing, thereby adjusting pressure applied to the resurfacing pad in contact with the brake disc. In one embodiment, the piston cylinder is coupled to the screw shaft at one end and the resurfacing pad at the other end. The piston cylinder is configured to move forward and backward within the cylinder housing, thereby applying the controlled pressure to the resurfacing pad during the surface grinding operation.

[0023] In one embodiment, the cylinder housing comprises a spring that is encircled around the screw shaft. The spring is configured to exert a forward force on the piston cylinder upon compression caused by the rotation of the screw shaft. The spring propels the piston cylinder towards the brake disc when it is decompressed, thereby applying controlled pressure to the resurfacing pad to achieve uniform contact with the brake disc throughout the surface grinding operation.

[0024] In one embodiment, the resurfacing pads are coupled to the piston cylinders through a snap-fit locking mechanism, thereby enabling quick and easy replacement of the resurfacing pads without requiring specialized tools. In one embodiment, the resurfacing pads are made up of materials that include at least one of tungsten carbide and silicon carbide. In one embodiment, the brake caliper assembly is adapted to perform the surface grinding operations on the brake disc with a material removal thickness of at least 0.1 mm, thereby extending the lifespan of the brake disc and enhancing overall braking performance without compromising its structural integrity.

[0025] According to another aspect, the invention provides a method for operating the brake caliper assembly for resurfacing the brake disc. At one step, the user positions at least one of the resurfacing pads relative to the brake disc by using the adjustable rod, thereby allowing precise alignment and controlled pressure distribution between the resurfacing pad and the brake disc.

[0026] At another step, the user rotates the screw shaft in a clockwise direction via the hand-operated screw knob to compress the spring, thereby moving the piston cylinder within the cylinder housing for applying controlled pressure to the resurfacing pad to ensure uniform contact with the surface of the brake disc. Further, at another step, the user drives the vehicle to rotate the brake disc in parallel with the applied pressure from the resurfacing pad to perform a surface grinding operation, thereby optimizing the smoothness of the brake disc's surface and enhancing braking performance.

[0027] Further, objects and advantages of the present invention will be apparent from a study of the following portion of the specification, the claims, and the attached drawings.
Detailed description of drawings:
[0028] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention, and, together with the description, explain the principles of the invention.

[0029] FIG. 1 illustrates an isometric view of a brake caliper assembly with a brake disc, in accordance to an exemplary embodiment of the invention.

[0030] FIG. 2 illustrates an exploded view of the brake caliper assembly, in accordance to an exemplary embodiment of the invention.

[0031] FIGs. 3A-3B illustrate isometric views of the brake caliper assembly that is adapted to adjust cylinder housings around the brake disc, in accordance to an exemplary embodiment of the invention.

[0032] FIG. 3C illustrates an isometric view of the brake caliper assembly that is adapted to secure a position around the brake disc, in accordance to an exemplary embodiment of the invention.

[0033] FIG. 3D illustrates an isometric view of the brake caliper assembly that is adapted to move resurfacing pads toward the brake disc to move a surface grinding operation, in accordance to an exemplary embodiment of the invention.

[0034] FIG. 3E illustrates an isometric view of the brake caliper assembly that is adapted to detach the resurfacing pads from the cylinder housings, in accordance to an exemplary embodiment of the invention.

[0035] FIG. 4 illustrates a flowchart of a method for operating the brake caliper assembly for resurfacing the brake disc, in accordance to an exemplary embodiment of the invention.
Detailed invention disclosure:
[0036] Various embodiments of the present invention will be described in reference to the accompanying drawings. Wherever possible, same or similar reference numerals are used in the drawings and the description to refer to the same or like parts or steps.

[0037] The present disclosure has been made with a view towards solving the problem with the prior art described above, and it is an object of the present invention to provide a brake caliper assembly 100 that is adapted to provide a real-time resurfacing of a brake disc 12 when a vehicle is in motion, thereby ensuring uniform and continuous optimization of the brake disc 12 for improved vehicle safety and performance.

[0038] According to one exemplary embodiment of the invention, FIG. 1 refers to an isometric view of the brake caliper assembly 100 with the brake disc 12. In one embodiment herein, the brake caliper assembly 100 continuous perform the resurfacing process to prevent excessive wear, thereby extending a lifespan of the brake disc 12 and minimizing the need for costly replacements. The brake caliper assembly 100 reduces the formation of the metal particles and dust during resurfacing, thereby lowering pollution and making the process more environmentally friendly.

[0039] In another embodiment herein, the brake caliper assembly 100 is positioned around the brake disc 12. Additionally, the brake caliper assembly 100 comprises a caliper housing 102, a pair of frame sections (106A, 106B), and brake pads 104. The pair of frame sections (106A, 106B) are adaptably mounted at one end of the caliper housing 102. Additionally, the caliper housing 102 is configured to contact with the brake disc 12 for decelerating its rotation when a vehicle is in motion.

[0040] In one embodiment herein, the each frame section 106A having a cylinder housing 112A with an adjustable rod 114A. Additionally, the cylinder housing 112A is pivotally coupled to each frame section 106A through torque hinges (110A, 110B). The cylinder housing 112A is configured to enable a user to rotate a screw shaft 116A (as depicted in FIG. 2) from a rest position and an operative position for allowing a resurfacing pad 124A to contact with the brake disc 12 via a piston cylinder 122A (as depicted in FIG. 2) so as to perform a surface grinding operation.

[0041] In one embodiment herein, the torque hinges (110A, 110B) are configured to provide adjustable pivot motion of the cylinder housing 112A around the disc brake 12 for placing the resurfacing pad 124A within a circumference of the disc brake 12, thereby enabling to perform the surface grinding operation. In one embodiment herein, the brake caliper assembly 100 is adaptable to fit various types of vehicles having the brake disc. The brake caliper assembly 100 is adapted to perform the surface grinding operation on the brake disc 12 via the resurfacing pads (124A, 124B) with a material removal thickness of at least 0.1 mm, thereby extending the lifespan of the brake disc 12 and enhancing overall braking performance without compromising its structural integrity.

[0042] In one embodiment herein, the brake caliper assembly 100 is manufactured with at least one material including, cast iron, mild steel, carbon steel, and other composite materials. In one embodiment herein, the resurfacing pads (124A, 124B) are made up of materials that include at least one of tungsten carbide and silicon carbide.

[0043] According to another exemplary embodiment of the invention, FIG. 2 refers to an exploded view of the brake caliper assembly 100. In one embodiment herein, the pair of frame sections (106A, 106B) are securely mounted at one end of the caliper housing 102. The pair of frame sections (106A, 106B) are securely coupled through the connecting member 108. Additionally, the adjustable rods (114A, 114B) are pivotally coupled to the pair of frame sections (106A, 106B) through the torque hinges (110A, 110B), thereby enabling the user to adjust the cylinder housings (112A, 112B) around the brake disc 12 based on the user requirement. In one example, the brake disc 12 is made up of cast iron and is preferred for its durability, cost-effectiveness, and good heat dissipation properties.

[0044] In one embodiment herein, the cylinder housings (112A, 112B) comprise the screw shafts (116A, 116B), springs (120A, 120B), and the piston cylinders (122A, 122B), which are positioned within the cylinder housings (112A, 112B) in order to move the resurfacing pads (124A, 124B) towards the brake disc 12, thereby performing the surface grinding operation. In one embodiment herein, the springs (120A, 120B) are encircled around the screw shafts (116A, 116B). The springs (120A, 120B) are configured to exert a forward force on the piston cylinders (122A, 122B) compression caused by the rotation of the screw shafts (116A, 116B).

[0045] In another embodiment herein, the springs (120A, 120B) propel the piston cylinders (122A, 122B) towards the brake disc 12 when it is decompressed, thereby applying controlled pressure to the resurfacing pads (124A, 124B) to achieve uniform contact with the brake disc 12 throughout the surface grinding operation.

[0046] In one embodiment herein, the each piston cylinder 122A is coupled to the screw shaft 116A at one end and the resurfacing pad 124A at other end. The piston cylinder 122A is configured to move forward and backward within the cylinder housing 112A for applying the controlled pressure to the resurfacing pad 124A during the surface grinding operation. Similarly, another piston cylinder 122B having the same components and also performs the surface grinding operation to resurface the brake disc 12 during rotation.

[0047] In one example, the springs (120A, 120B) are manufactured with at least one material of ferrous, non-ferrous, and austenitic stainless. In one embodiment herein, the resurfacing pads (124A, 124B) are coupled to the piston cylinders (122A, 122B) through a snap-fit locking mechanism, respectively, thereby enabling quick and easy replacement of the resurfacing pads (124A, 124B) without requiring specialized tools.

[0048] In one embodiment herein, the hand-operated screw knobs (118A, 118B) are protruded from the screw shafts (116A, 116B), thereby allowing the user to rotate the screw shafts (116A, 116B) in at least one direction that allows to move the resurfacing pads (124A, 124B) for performing the surface grinding operation. The brake caliper assembly 100 is adapted to perform the surface grinding operation on the brake disc 12 with a material removal thickness of at least 0.1 mm, thereby extending the lifespan of the brake disc 12 and enhancing the overall braking performance without compromising its structural integrity.

[0049] According to another exemplary embodiment of the invention, 3A-3B refer to isometric views of the brake caliper assembly 100 that is adapted to adjust the cylinder housings (112A, 112B) around the brake disc 12. In one embodiment herein, the brake caliper assembly 100 is configured to enable the user to oscillate the cylinder housing (112A, 112B) from an initial position to a final position around the brake disc 12. Firstly, the user ensures the brake caliper assembly 100 is installed on the vehicle and inspects the resurfacing pads (124A, 124B) to ensure they are in good condition. Secondly, the user manually oscillates the cylinder housing (112A, 112B) from its rest position towards the brake disc 12.

[0050] According to another exemplary embodiment of the invention, FIG. 3C refers to an isometric view of the brake caliper assembly 100 that is adapted to secure the position around the brake disc 12. Referring to FIGs. 3A-3B, the user ensures the resurfacing pads (124A, 124B) are aligned with the brake disc 12. The adjustable rods (114A, 114B) are configured to be used to fine-tune position to match the size and circumference of the brake disc 12. In one embodiment herein, the cylinder housing 112A is adapted to adjust on the brake disc 12 through an adjustable rod 114A to accommodate the disc's circumference for performing the surface grinding operation.

[0051] According to another exemplary embodiment of the invention, FIG. 3D refers to an isometric view of the brake caliper assembly 100 that is adapted to move the resurfacing pads (124A, 124B) towards the brake disc 12 to perform the surface grinding operation. Referring to FIG. 3C, the user ensures to rotate the screw shafts (116A, 116B) in a clockwise direction through the hand-operated screw knobs (118A, 118B), respectively, thereby compressing the springs (120A, 120B), which in turn moves the piston cylinders (122A, 122B) forward in order to apply pressure within the cylinder housings (112A, 112B). This movement pushes the resurfacing pads (124A, 124B) towards the brake disc 12, thereby contacting the surface of the brake disc 12.

[0052] Next, the user enables to adjust the applied pressure on the resurfacing pads (124A, 124B) by rotating the screw shafts (116A, 116B) to ensure the resurfacing pads (124A, 124B) maintain consistent contact with the brake disc 12 during the surface grinding operation. Next, the user drives the vehicle to rotate the brake disc 12. The friction between the resurfacing pads (124A, 124B) and the brake disc 12 grinds away surface imperfections, smoothing the brake disc 12.

[0053] Next, the user continues adjusting the screw shafts (116A, 116B) if necessary to ensure consistent pressure is maintained throughout the surface grinding operation. The resurfacing pads (124A, 124B) ensure contact with the brake disc 12 to gradually smooth its surface. The user monitors the surface of the brake disc 12 and accesses changes in the braking performance to determine the desired surface finish has been achieved. Next, the user adjusts the resurfacing pads (124A, 124B) though the brake disc 12 has uneven areas that require extra attention, the adjustable rods (114A, 114B) allow the user to reposition the cylinder housing (112A, 112B) and resurfacing pads (124A, 124B) for precise resurfacing at specific locations.

[0054] In one embodiment herein, the brake caliper assembly 100 is configured to remove a very thin layer of material (less than 0.1 mm) from the surface of the brake disc 12, thereby ensuring that the resurfacing operation smooths out imperfections without compromising the structural integrity of the brake disc 12. The resurfacing pads (124A, 124B) are typically made of abrasive materials such as tungsten carbide or silicon carbide, which are highly effective at grinding metal surfaces without excessive wear.

[0055] According to another exemplary embodiment of the invention, FIG. 3E refers to an isometric view of the brake caliper assembly 100 that is adapted to detach the resurfacing pads (124A, 124B) from the cylinder housings (112A, 112B). In one embodiment herein, the brake caliper assembly 100 allows for easy switching between different types of pads, such as the resurfacing pads (124A, 124B) for smoothing the brake disc 12 and glazing pads for polishing the surface. This versatility ensures that users can customize the resurfacing process based on the specific maintenance requirements of the brake disc 12. Whether it is resurfacing to remove surface imperfections and glazing for a finer finish.

[0056] In one embodiment herein, the user ensures the vehicle is parked on a flat surface with the engine turned off and the parking brake is fully engaged. Next, the user adjusts the cylinder housings (112A, 112B) to move the resurfacing pads (124A, 124B) away from the brake disc 12 by reversing the rotation of the screw shaft 116A to decompress the spring 120A and retract the piston cylinder 122A, thereby raising the resurfacing pad 124A away from the brake disc 12.

[0057] Next, the user secures the cylinder housings (112A, 112B) and the screw shafts (116A, 116B) are positioned to the rest or initial position (as depicted in FIG. 3A). Next, the user switches the resurfacing pads (124A, 124B) using the snap-fit locking to replace the resurfacing pads (124A, 124B) as needed, thereby enabling quick and easy maintenance without removing the caliper or wheel from the vehicle. Next, the user pulls the old resurfacing pads (124A, 124B) and inspects their wear and damage to ensure they are functioning correctly before replacement. Finally, the user re-engages the resurfacing pads (124A, 124B) by using the torque hinges (110A, 110B) to hold the resurfacing pads (124A, 124B) in position, thereby allowing for on-the-go resurfacing during vehicle operation without needing external tools.

[0058] In one example, the brake caliper assembly 100 is a user-friendly design, which makes it possible for drivers to perform resurfacing themselves without needing to remove the wheel or caliper. Unlike traditional methods, which require the wheel and caliper to be removed before accessing the brake disc 12. This drastically reduces the time and effort required for maintenance, enabling quicker and more convenient brake optimization.

[0059] According to another exemplary embodiment of the invention, FIG. 4 refers to a flowchart 400 of a method for operating the brake caliper assembly 100 for resurfacing the brake disc 12. At step 402, the user positions at least one of the resurfacing pad 124A relative to the brake disc 12 by using the adjustable rod 114A, thereby enabling precise alignment and controlled pressure distribution between the resurfacing pad 124A and the brake disc 12.

[0060] At step 404, the user rotates the screw shaft 116A in a clockwise direction via the hand-operated screw knob 118A to compress the spring 120A, thereby moving the piston cylinder 122A within the cylinder housing 112A for applying controlled pressure to the resurfacing pad 124A to ensure uniform contact with the surface of the brake disc 12. Further, at step 406, the user drives the vehicle to rotate the brake disc 12 in parallel with the applied pressure from the resurfacing pad 124A to perform a surface grinding operation, thereby optimizing the smoothness of the brake disc's surface and enhancing braking performance.

[0061] Numerous advantages of the present disclosure may be apparent from the discussion above. In accordance with the present disclosure, the brake caliper assembly 100 is disclosed. The proposed brake caliper assembly 100 adjusts the resurfacing process of the brake disc 12 by using the torque hinges (110A, 110B) and the screw shafts (116A, 116B), thereby allowing pads to be lifted according to user requirements. The proposed brake caliper assembly 100 continuously performs the resurfacing process to prevent excessive wear, thereby extending the lifespan of the brake disc 12 and minimizing the need for costly replacements.

[0062] The proposed brake caliper assembly 100 is integrated with the snap-fit mechanism and allows for quick and easy replacement of resurfacing pads (124A, 124B) without the need for specialized tools, making maintenance user-friendly and accessible. The proposed brake caliper assembly 100 provides consistent and uniform contact between the resurfacing pads (124A, 124B) and the brake disc 12, leading to a smoother surface finish, better braking performance, and reduced vibrations. The proposed brake caliper assembly 100 reduces the formation of metal particles and dust during resurfacing, thereby lowering pollution and making the process more environmentally friendly.

[0063] The proposed brake caliper assembly 100 allows for the use of different types of resurfacing pads (124A, 124B) (e.g., smoothing, glazing), thereby allowing the user to adapt the innovative brake caliper assembly 100 for various maintenance needs and brake conditions. The proposed brake caliper assembly 100 eliminates the need for external equipment and professional intervention, thereby reducing maintenance costs for vehicle owners and increasing the overall efficiency of brake servicing. The proposed brake caliper assembly 100 utilizes a spring-piston mechanism that ensures consistent contact with the brake disc 12, thereby promoting uniform resurfacing and resulting in improved and reliable braking performance.

[0064] It will readily be apparent that numerous modifications and alterations can be made to the processes described in the foregoing examples without departing from the principles underlying the invention, and all such modifications and alterations are intended to be embraced by this application.
, Claims:CLAIMS:
I/We Claim:
1. A brake caliper assembly (100) for resurfacing brake disc (12), comprising:
a caliper housing (102) having brake pads (104) mounted on the brake disc (12), wherein the caliper housing (102) is configured to contact with the brake disc (12) for decelerating its rotation when a vehicle is in motion;
a pair of frame sections (106A, 106B) adaptably mounted at one end of the caliper housing (102); and
a cylinder housing (112A) pivotally coupled to each frame section (106A) through torque hinges (110A, 110B), wherein the cylinder housing (112A) is configured to enable a user to rotate a screw shaft (116A) from a rest position to an operative position for allowing a resurfacing pad (124A) to contact with the brake disc (12) via a piston cylinder (122A) so as to perform a surface grinding operation,
wherein the cylinder housing (112A) is adapted to adjust on the brake disc (12) through an adjustable rod (114A) to accommodate the disc's circumference for performing the surface grinding operation.
2. The brake caliper assembly (100) as claimed in claim 1, wherein the pair of frame sections (106A, 106B) are securely coupled through a connecting member (108) to ensure effective performance of the surface grinding operation.
3. The brake caliper assembly (100) as claimed in claim 1, wherein the screw shaft (116A) having a hand-operated screw knob (118A) at one end that is configured to enable the user to rotate in at least one direction, thereby providing movement to the piston cylinder (122A) within the cylinder housing (112A) for regulating the pressure applied to the resurfacing pad (124A) is in contact with the brake disc (12).
4. The brake caliper assembly (100) as claimed in claim 1, wherein the piston cylinder (122A) is coupled to the screw shaft (116A) at one end and the resurfacing pad (124A) at other end, wherein the piston cylinder (122A) is configured to move forward and backward directions within the cylinder housing (112A) for applying the controlled pressure to the resurfacing pad (124A) during the surface grinding operation.
5. The brake caliper assembly (100) as claimed in claim 1, wherein the resurfacing pads (124A, 124B) are coupled to the piston cylinders (122A, 122B) through a snap-fit locking mechanism, thereby enabling a user to easy replacement of the resurfacing pads (124A, 124B) without requiring specialized tools.
6. The brake caliper assembly (100) as claimed in claim 1, wherein the adjustable rod (114A) is operably coupled to the cylinder housing (112A), wherein the adjustable rod (114A) is configured to enable precise positioning of the resurfacing pad (124A) relative to the brake disc (12) for allowing the resurfacing pad (124A) to be manually raised and lowered into contact with the brake disc (12), thereby facilitating controlled resurfacing while ensuring uniform pressure distribution throughout the surface grinding operation.
7. The brake caliper assembly (100) as claimed in claim 1, wherein the cylinder housing (112A) comprises a spring (120A) that is encircled around the screw shaft (116A), and is configured to exert a forward force on the piston cylinder (122A) upon compression caused by the rotation of the screw shaft (116A),
wherein the spring (120A) propels the piston cylinder (122A) toward the brake disc (12) when it is decompressed, thereby applying controlled pressure to the resurfacing pad (124A) to achieve uniform contact with the brake disc (12) throughout the surface grinding operation.
8. The brake caliper assembly (100) as claimed in claim 1, wherein the resurfacing pads (124A, 124B) are made of materials that include at least one of tungsten carbide and silicon carbide.
9. The brake caliper assembly (100) as claimed in claim 1, wherein the brake caliper assembly (100) is adapted to perform the surface grinding operations on the brake disc (12) with a material removal thickness of at least 0.1 mm, thereby extending the lifespan of the brake disc (12) and enhancing overall braking performance without compromising its structural integrity.
10. A method for operating a brake caliper assembly (100) for resurfacing brake disc (12), comprising:
positioning, by a user, at least one of resurfacing pad (124A) relative to a brake disc (12) by using an adjustable rod (114A), thereby enabling precise alignment and controlled pressure distribution between the resurfacing pad (124A) and the brake disc (12);
rotating, by the user, a screw shaft (116A) in a clockwise direction via a hand-operated screw knob (118A) to compress a spring (120A), thereby moving a piston cylinder (122A) within the cylinder housing (112A) for applying controlled pressure to the resurfacing pad (124A) to ensure uniform contact with a surface of the brake disc (12); and
driving, by the user, a vehicle to rotate the brake disc (12) in parallel with the applied pressure from the resurfacing pad (124A) to perform a surface grinding operation, thereby optimizing a smoothness of the brake disc's surface and enhancing braking performance.

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