DESC:FORM 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules, 2005

COMPLETE SPECIFICATION
(See Section 10 and Rule 13)

TITLE OF THE INVENTION
“CALIPER ASSEMBLY FOR BRAKING SYSTEM OF A VEHICLE”

Endurance Technologies Limited
E-92, M.I.D.C. Industrial Area, Waluj,
Aurangabad – 431136, Maharashtra, India

The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed.
Field of Invention

[001] The present invention is related to a braking system of a two-wheeled vehicle. More particularly, the invention is related to a caliper assembly for disc brake of two-wheeled vehicles, preferably bikes and scooters.

Background of the Invention

[002] Braking is one of the important systems employed on the two wheeled vehicles. Recent trend is employing the disc type braking systems on the vehicles due to its better braking performance, less efforts for braking and other merits over the conventional braking systems. Generally, the disc brakes are of two types viz. floating caliper disc brake and the fixed caliper disc brake. In case of fixed caliper disc brake, the caliper assembly is rigidly fitted with the corner module of the suspension unit. While in case of floating caliper disc brake, the caliper assembly moves relative to a support bracket between a brake on position and a brake off position. The floating caliper system may have one or more pins to move brake pads in contact with a disc rotor to create a braking force. The floating caliper systems typically slides over the pins of the bracket so that the floating caliper is movable relative to the bracket and said bracket is suitably mounted on the suspension unit (fork leg) of a vehicle.

[003] Conventionally the caliper holding brackets are made up of aluminum casting. These caliper holding brackets have two guide pins that are projected out from the body of the bracket in the same direction. These projected guide pins are slidably sleeved inside the insertion cavities meant therefor on the caliper body. This arrangement of the caliper assembly is more prone to vertical deflection of the caliper body when the brake is applied leading to poor braking performance.

[004] To address the above-mentioned drawback, the subsequent prior art solution of caliper assembly was introduced wherein the caliper holding bracket made in casting is provided with one guide pin and one insertion cavity and the casted caliper body is provided with one guide pin and one insertion cavity. The guide pin of the holding bracket is slidably inserted inside the insertion cavity of the caliper body, and the guide pin of the caliper body is slidably inserted inside the insertion cavity of the holding bracket. This solution of caliper assembly successfully addressed the drawback of vertical deflection of the caliper body but led to another problem of restricting its usage on the vehicle for only for higher caliper offset (i.e. the distance from the caliper mounting to the brake disc center). This solution completely failed on the vehicles where the caliper offset is less due to its inability to withstand the desired torque and the complexity involved in manufacturing of the holding bracket in casting.

[005] Therefore, to address the aforementioned problem of the prior art, there is a long pending unmet need to provide an intelligent solution of caliper assembly that nullifies / minimizes the vertical deflection of the caliper body, makes it effectively usable on the vehicles having lower caliper offset without any limitation and at the same time addresses the issue of packaging constraint and effective space management.

Objectives of the Invention

[006] The main objective of the present invention is to provide a caliper assembly for disc brake of a two wheeled vehicle.
[007] Another objective of the present invention is to provide a caliper assembly for disc brake of a vehicle wherein the bracket is made of sheet metal having a unique profile.

[008] Still another objective of the present invention is to provide a caliper assembly efficiently workable on the vehicles with low caliper offset, viz. Ntorq Scooter, Apache bike, Jupiter scooter, iQube Electric Scooter, and like.

[009] Yet object of the present invention is to nullify / minimize the vertical deflection of the prior art caliper assemblies.

[0010] Still the objective of the present invention is to provide caliper assembly made in sheet metal and aluminum casting that withstand the desired torque for the low caliper offset.

[0011] Further, objective of the present invention is to provide caliper assembly for the disc brakes that is effectively usable on the vehicles having lower caliper offset without any limitation and at the same time addresses the issue of packaging constraint and effective space management.

[0012] Yet objective of the present invention is to enhance the braking performance of the disc brake by addressing the drawbacks of the prior art by providing a cost effective solution using simple manufacturing process/es.

[0013] Yet objective of the present invention is to provide a unique construction of the bracket assembly (BA) that is very easy to assemble without requiring any specialized processes and easy to manufacture at a low cost.
Brief Description of the Drawings

[0014] Figure 1 discloses an exploded view of the caliper assembly in accordance with the present invention.

[0015] Figure 2 discloses an assembled isometric view of the caliper assembly in accordance with the present invention.

[0016] Figure 3 discloses an exploded view of caliper holding bracket with secondary anchor pin and guide sleeve in accordance with the present invention.

[0017] Figures 4 and 5 discloses an isometric rear and front views of caliper holding bracket with secondary anchor pin and guide sleeve in accordance with the present invention.

[0018] Figures 6 and 7 discloses an isometric view of a primary anchor pin and a secondary anchor pin of the caliper assembly in accordance with the present invention.

[0019] Figure 8 discloses section view of the floating caliper with holding bracket in accordance with the present invention.

Detailed Description of the Present Invention

[0020] Referring to Fig. 1, a caliper assembly (1000) for disc brake of a two wheeler comprises of a bracket assembly (BA), caliper unit (CU) and a brake pad assembly (PA) having two brake pads (70 and 80).
[0021] Referring to Figs. 1 to 5, the bracket assembly (BA) comprises of a bracket (10), a guide sleeve (20), a secondary anchor pin (40), a primary anchor pin (30) and a washer (11). The bracket (10) is made in a sheet metal and is configured to have a C-shape profile. The C-profiled bracket (10) has a pair of thorough insertion holes (10P and 10S) at its distal ends (12) and a pair of mounting holes (10H) on the main body (18) of the bracket (10). The said bracket (10) has a front face (10F) and a rear face (10R). The said pair of mounting holes (10H) on the main body (18) is specifically meant for mounting the bracket (10) with the front fork leg of suspension assembly of the vehicle and hence these holes (10H) are configured to receive the fastening means, preferably the bolts, for mounting the bracket.

[0022] The insertion holes (10P and 10S) are configured to have threads on its inner peripheral surface. The insertion hole (10P) is configured to mount the guide sleeve (20) from the rear face (10R) of the bracket (10). The insertion hole (10S) is configured to mount the secondary anchor pin (40) from the front face (10F) of the bracket (10). The guide sleeve (20) and the secondary anchor pin (40) are mounted at the distal ends (12) of the bracket (10) at the respective insertion holes (10P, 10S) in such a way that the said sleeve (20) and the anchor pin (40) are projecting out in opposite direction from the bracket (10). Further, the bracket (10) is configured to have a rectangular slot (16) and a projection (14) adjacent to the insertion hole (10P) at a concave portion (C) of the bracket (10). The said rectangular slot (16) is open from the front face (10F) of the bracket (10) and partially covered by a projection (14) from the rear face (10R) of the bracket (10). Thus, the projection (14) is an integral part of the bracket (10) and it overlaps the rectangular slot (16) of the bracket (10).

[0023] The guide sleeve (20) made in sheet metal is configured to have a top portion (20T), a bottom portion (20B), a hollow cylindrical body (24). A collar (26) separates the cylindrical body (24) from the bottom portion (20B) and said bottom portion (20B) is configured to have threads (28) on its outer peripheral surface. The top portion (20T) of the guide sleeve (20) is configured to have a hexagonal profile or allen head profile (22) and this profile (22) of the guide sleeve (20) is used to receive a spanner or any relevant torqueing tool for rotating the guide sleeve (20) in clockwise or anti-clockwise direction as per the requirement. The collar (26) is an integral part of the guide sleeve (20) and guide sleeve is made in sheet metal by machining.

[0024] The guide sleeve (20) is fitted with the bracket (10) at its rear face (10R) in the insertion hole (10P) through the threaded joinery in such a way that the threads (28) on the bottom portion (20B) of the guide sleeve (20) are rigidly meshed with the threads provided on the inner peripheral surface of the insertion hole (10P) of the bracket (10) and the collar (26) abuts against the rear face (10R) of the bracket (10) thereby projecting out the said sleeve (20) orthogonally from the rear face (10R) of the bracket (10). The insertion hole (10P) of the bracket (10) is configured to partially receive the boot (50) of the caliper unit (CU) from its front face (10F).

[0025] The primary anchor pin (30) is configured to have a shank portion (30S), a threaded portion (30T) and a hexagonal collar (30H) and said hexagonal collar (30H) separates the shank portion (30S) from the threaded portion (30T). The shank portion (30S) of the pin (30) is configured to have a D-profiled or triangular profiled (32) cross section. Further, the shank portion (30S) may have a plurality of grooves (32G) in axial direction on its outer peripheral surface. The said hexagonal collar (30H) of the primary anchor pin (30) facilitate to receive a spanner / suitable torqueing tool for rotating the primary anchor pin (30) in clockwise or anti-clockwise direction as per the requirement for fitting the primary anchor pin (30) through its threaded portion (30T) with the mouth (104tm) of the pin housing (104t).

[0026] The secondary anchor pin (40) is configured to have a shank portion (40S), a threaded portion (40T) and a hexagonal collar (40H) in such a way that the said hexagonal collar (40H) separates the shank portion (40S) and the threaded portion (40T) of the secondary anchor pin (40). The shank portion (40S) of the pin (40) is configured to have a D-profiled or triangular profiled (42) cross section. Further, the shank portion (40S) may have a plurality of grooves (42G) in axial direction on the outer peripheral surface.

[0027] The secondary anchor pin (40) is fitted with the bracket (10) at its front face (10F) in the insertion hole (10S) through the threaded joinery in such a way that the threaded portion (40T) of the secondary anchor pin (40) is rigidly meshed with the threads provided on the inner peripheral surface of the insertion hole (10S) of the bracket (10) and the hexagonal collar (40H) abuts against the front face (10F) of the bracket (10) thereby projecting out the said anchor pin (40) orthogonally from the front face (10F) of the bracket. The washer (11) is fitted between the hexagonal collar (40H) and the insertion hole (10S) of the bracket (10) for better fitment. The said hexagonal collar (40H) of the secondary pin (40) facilitate to receive a spanner / torqueing tool for rotating the secondary anchor pin (40) in clockwise or anti-clockwise direction while fitting it with the bracket (10).

[0028] The sleeve (20) and the secondary anchor pin (40) are being purposely threaded to the bracket (10) projecting out orthogonally in opposite direction not only to ensure the manufacturing feasibility but to make the bracket assembly (BA) modular as well. This unique construction of the bracket assembly (BA) makes it very easy to assemble without requiring any specialized processes (as is required in the prior art solutions) and easy to manufacture at a low cost thereby imparting a significant economic significance.

[0029] The caliper unit (CU) comprises of a caliper body (100), a primary boot (50), a secondary boot (60) and a pivot pin (110) with a pair of locking clips (120). The caliper body (100) is configured to have three portions viz. a first portion (104), a second portion (106) and a connecting portion (108). The connecting portion (108) connects the first portion (104) with the second portion (106) while forming a single integrated unit in aluminium casting. The first portion (104) of the caliper body (100) has a piston housing (104h) carved therein, a pair of pin housing (104t and 104s) and an extended wing (104P) integrated to said first portion (104) with a mounting hole (104m) thereon. The piston housing (104h) is carved in the center of the first portion (104) in case of the single piston caliper unit. In case two or three piston caliper, the said piston housings will be carved in the first portion of the caliper body. The said piston housing (104h) in the caliper body (100) houses a piston assembly (90) therein in such a way that it forms a hydraulic chamber in between the piston assembly (90) and the bottom face of the piston housing (104h).

[0030] The pin housing (104t) is an integrally casted with the caliper body (100) in such a way that it is in axial alignment with the insertion hole (10P) of the sheet metal bracket (10). The mouth (104tm) of the pin housing (104t) is configured to have a plurality of threads on its inner peripheral surface so as to fit the primary anchor pin (30) of the bracket assembly (BA) therein through the threaded joinery. The pin housing (104s) of the first portion (104) of the caliper body (100) is an integrally casted with the caliper body (100) in such a way that it is in axial alignment with the insertion hole (10S) of the sheet metal bracket (10).

[0031] Both the ends of this pin housing (104s) are open and the outer open end of the pin housing (104s) is closed by press fitting a secondary boot (60) therein whereas the inner end of the pin housing (104s) is configured to slideably house the shank portion (40S) of the secondary pin (40). The secondary boot (60) restrict the entry of any foreign material in the pin housing (104s) and thereby protects the secondary anchor pin (40) from dirt and grime. The extended wing (104P) is laterally projected out from the first portion (104) and has a mounting hole (104m) thereon.

[0032] The connecting portion (108) creates the space (108a) in between the first portion (104) and the second portion (106) while forming an integrated unit of caliper body (100) and said space (108a) is being created for housing brake pad assembly (PA) therein. The second portion (106) is configured to have two pawls (106w) projected upwards and an extended wing (106P) with a mounting hole (106m) thereon laterally projecting out. The extended wing (104P) of the first portion (104) and the extended wing (106P) of the second portion (106) are parallel to each other in such a way that the mounting hole (104m) and the mounting hole (106m) are coaxially overlapping each other.

[0033] The brake pad assembly (PA) comprises of two brake pads (70, 80). The brake pad (70) has a core plate (72) with a friction pad (73) pasted on its inner surface. The core plate (72) is configured to have a main body (74), a projecting arm (75) with a mounting hole (75m) and a jaw (76). The main body (74) of the core plate (72) has a thorough opening (H) at its center and said opening (H) facilitate the easy dissipation of heat from the friction pad (73) and also used for removing the used/damaged friction pad (73) from the main body (74) of the core plate (72). The projecting arm (75) is projected out from one distal end of the main body (74) of the core plate (72) and have a mounting hole (75m). The jaw (76) is projected out from other distal end of the main body (74) of the core plate (72).

[0034] The brake pad (80) is configured to have a core plate (82) with a friction pad (83) pasted on its inner surface in such a way that the friction pad (73) of the brake pad (70) and the friction pad (83) of the brake pad (80) are facing with each other to arrest the rotational movement of the brake disc. The core plate (82) is configured to have a main body (84) and a pair of projecting arms (85, 86). The main body (84) of the core plate (82) has a thorough opening (H) centrally drilled thereon and said thorough opening (H) facilitate the easy dissipation of heat from the friction pad (83) and also used for removing the used/damaged friction pad (83) from the main body (84) of the core plate (82). The projecting arm (85) is projected out from one distal end of the main body (84) of the core plate (82) and have a mounting hole (85m). The projecting arm (86) is projected out from other distal end of the main body (84) of the core plate (82) and have a mounting hole (86m).

[0035] The bracket assembly (BA) is screwed with the caliper unit (CU) and the brake pad assembly (PA) to form the caliper assembly (1000). During assembly of the bracket assembly (BA) with the caliper unit (CU) and the brake pad assembly (PA) to form the caliper assembly (1000) of the invention, the threaded portion (30T) of the primary anchor pin (30) of the bracket assembly (BA) is screwed inside the mouth (104tm) of the pin housing (104t) of the caliper body (100) by using a spanner over the hexagonal collar (30H) of the primary anchor pin (30) in such a way that the shank portion (30S) of the anchor pin is slideably moveable inside the hollow cylindrical body of the guide sleeve (20). The D-profiled or triangular profiled (32) cross section of the shank portion (30S) or the plurality of grooves (32G) on outer peripheral surface of the shank facilitate to retain the grease on the shank portion (30S) so as to effectively reduce the sliding friction in between the shank portion (30S) of the primary anchor pin (30) and the inner peripheral surface of the guide sleeve (20).

[0036] The first brake pad (70) is placed inside the space (108a) created between the first portion (104) and the second portion (106) of the caliper body (100) in such way that the main body (74) of the core plate (72) of the brake pad assembly (70) is in mechanical communication with the piston assembly (90). The mounting hole (75m) of the brake pad (70) is positioned parallel to the mounting hole (104m) of the extended wing (104P) of the caliper body (100). The jaw (76) of the first brake pad (70) is slidably guided over the primary anchor pin (30) to maintain the position of the first brake pad (70).

[0037] After positioning of the first brake pad (70) in the space (108a) of the caliper body (100), the shank portion (40S) of the secondary anchor pin (40) which is rigidly fitted on the bracket (10) is slidably sleeved inside the pin housing (104s) of the first portion (104) of the caliper body (100). The D-profiled or triangular profiled (42) cross section of the shank portion (40S) or the plurality of grooves (42G) on outer peripheral surface of the shank facilitate to retain the grease on the shank portion (40S) so as to

effectively reduce the sliding friction in between the shank portion (40S) of the secondary anchor pin (40) and the inner peripheral surface of the pin housing (104s). The shank portion (30S) of the primary anchor pin (30) is sleeved inside the opening (23) of the guide sleeve (20) where the guide sleeve (20) is rigidly screwed on the rear face (10R) of the bracket (10). The bracket (10) is positioned in such manner that the rectangular slot (16) receives an end of the friction pad (73) of the first brake pad (70) from the front face (10F) of the bracket (10) and is partially covered by the projection (14) from the rear face (10R) of the bracket (10) for avoiding the misalignment of the first brake pad (70).

[0038] The second brake pad (80) is placed inside the space (108a) created between the brake pad (70) and a second portion (106) of the caliper body (100) and the core plate (82) of the second brake pad (80) is supported by the pawls (106w) of the second portion (106) of the caliper body (100). The mounting hole (86m) of the second brake pad (80) is sleeved over the cylindrical body (24) of the guide sleeve (20), and the mounting hole (85m) of the brake pad assembly (80) is positioned parallel to the mounting hole (106m) of the extended wing (106P) of the caliper body (100). When the axis of the mounting holes (104m, 106m) of the caliper body (100) and the mounting holes (75m, 85m) of the brake pads (70, 80) are aligned, the pad pivot pin (110) is inserted therein to anchor the position of brake pad assembly (PA). The said pivot pin (110) has a pair of holes (110h) on its shank for receiving the lock clips (120). The locking clips (120) locks the anchored position of the brake pad assembly (PA) with the caliper unit (CU). A disc rotor is interposed in between the faces of the friction pads (73, 83) pasted on brake pads (70, 80) of the caliper body (100).

[0039] The present invention in accordance with the disclosed embodiment provides following technical advantages that contribute to the technical advancement of the caliper assembly for disc brake of two wheeled vehicles.
- The caliper assembly of the present invention is efficiently applicable for braking system on the vehicle having lower caliper offset.
- The caliper assembly of the present invention effectively nulify / minimizes the problem of vertical deflection of caliper body due to diagonal fitment of the primary and secondary anchor pin.
- The caliper assembly of the present invention is enhances the braking performace as the deflection of caliper body is being intelligently nulified / minimized.
- It provides a cost effective solution by using simple manufacturing process imparting the substantial economic significance.

[0040] The foregoing description of the specific embodiment of the invention will so fully reveal the general nature of the embodiment herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiment. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
,CLAIMS:We Claim

1. A caliper assembly (1000) for disc brake of a two wheeler comprising of a bracket assembly (BA), caliper unit (CU) and a brake pad assembly (PA) having two brake pads (70 and 80)
wherein,
- the bracket assembly (BA) is configured to comprise of a bracket (10), a guide sleeve (20), a secondary anchor pin (40), a primary anchor pin (30) and a washer (11); and said bracket (10) is made of a sheet metal forming a C-shape profile;
- the caliper unit (CU) is configured to comprise of a caliper body (100), a primary boot (50), a secondary boot (60) and a pivot pin (110) with a pair of locking clips (120); wherein the caliper body (100) has a first portion (104), a second portion (106) and a connecting portion (108); and said connecting portion (108) connects the first portion (104) with the second portion (106) to form a single integrated unit in aluminium casting of said caliper body (100);
- the brake pad assembly (PA) has two brake pads (70, 80) wherein each of the brake pads (70, 80) is configured to have a core plate (72, 82) with a friction pad (73, 83) pasted on its inner surface in such a way that the friction pad (73) of the brake pad (70) and the friction pad (83) of the brake pad (80) are facing to each other to arrest the rotational movement of a brake disc; and
- said the bracket assembly (BA) is screwed with the caliper unit (CU) and the brake pad assembly (PA) to form the caliper assembly (1000) in such way that the one end of the primary anchor pin (30) of the bracket assembly (BA) is received by the first portion (104) of the caliper body (100) and other end of said primary anchor pin (30) is slideably moveable inside the hollow cylindrical body of the guide sleeve (20) of the bracket assembly (BA).

2. The caliper assembly (1000) for disc brake of a two wheeler as claimed in claim 1, wherein
- the C-profiled bracket (10) is configured to have a main body (18) with a front face (10F), a rear face (10R), a pair of thorough insertion holes (10P and 10S) at its distal ends (12) and a pair of mounting holes (10H) on the body (18) of said bracket (10);
- said pair of mounting holes (10H) on the main body (18) is configured to mount the bracket (10) on the front fork leg of suspension assembly of the vehicle;
- the insertion hole (10P) is configured to have threads on its inner peripheral surface to mount the guide sleeve (20) from the rear face (10R) of the bracket (10);
- the insertion hole (10S) is configured to have threads on its inner peripheral surface to mount the secondary anchor pin (40) from the front face (10F) of the bracket (10);
- the guide sleeve (20) and the secondary anchor pin (40) are mounted at the distal ends (12) of the bracket (10) at the respective insertion holes (10P, 10S) in such a way that the said sleeve (20) and the anchor pin (40) are projecting out in opposite direction from the bracket (10); and
- said bracket (10) is configured to have a rectangular slot (16) and a projection (14) adjacent to the insertion hole (10P) at a concave portion (C) of the bracket (10); and said rectangular slot (16) is open from the front face (10F) of the bracket (10) and partially covered by a projection (14) from the rear face (10R) of the bracket (10).

3. The caliper assembly (1000) for disc brake of a two wheeler as claimed in claim 2, wherein
- the guide sleeve (20) made in sheet metal is configured to have a top portion (20T), a bottom portion (20B), a hollow cylindrical body (24) and a collar (26) separates said hollow cylindrical body (24) from the bottom portion (20B) and said bottom portion (20B) is configured to have threads (28) on its outer peripheral surface;
- the top portion (20T) of the guide sleeve (20) is configured to have a profile (22) selected from hexagonal and allen head profile; and said profile (22) is configured to receive the torqueing tool; and
- said sheet metal guide sleeve (20) is fitted with the bracket (10) at its rear face (10R) in the insertion hole (10P) through the threaded joinery in such a way that the threads (28) on the bottom portion (20B) of the guide sleeve (20) are rigidly meshed with the threads provided on the inner peripheral surface of the insertion hole (10P) of the bracket (10) and the collar (26) abuts against the rear face (10R) of the bracket (10) thereby projecting out the said sleeve (20) orthogonally from the rear face (10R) of the bracket (10).

4. The caliper assembly (1000) for disc brake of a two wheeler as claimed in claim 2, wherein
- the primary anchor pin (30) is configured to have a shank portion (30S), a threaded portion (30T) and a hexagonal collar (30H) and said hexagonal collar (30H) separates the shank portion (30S) from the threaded portion (30T);
- the shank portion (30S) of the pin (30) is configured to have at least a profiled groove (32G) selected from D-profiled and triangular profiled in axial direction on its outer peripheral surface; and
- the said hexagonal collar (30H) of the primary anchor pin (30) is configured to receive a torqueing tool to fit the said primary anchor pin (30) through its threaded portion (30T) with the mouth (104tm) of the pin housing (104t) of the caliper body (100).

5. The caliper assembly (1000) for disc brake of a two wheeler as claimed in claim 2, wherein
- the secondary anchor pin (40) is configured to have a shank portion (40S), a threaded portion (40T) and a hexagonal collar (40H) configured to separate the shank portion (40S) and the threaded portion (40T) of the secondary anchor pin (40);
- the shank portion (40S) of the pin (40) is configured to have at least a profiled groove (40G) selected from D-profiled and triangular profiled in axial direction on its outer peripheral surface;
- said secondary anchor pin (40) is fitted with the bracket (10) at its front face (10F) in the insertion hole (10S) through the threaded joinery in such a way that the threaded portion (40T) of the secondary anchor pin (40) is rigidly meshed with the threads provided on the inner peripheral surface of the insertion hole (10S) of the bracket (10) and the hexagonal collar (40H) abuts against the front face (10F) of the bracket (10) thereby projecting out the said anchor pin (40) orthogonally from the front face (10F) of the bracket; and
- the washer (11) is positioned between the hexagonal collar (40H) and the insertion hole (10S) of the bracket (10) for rigid fitment.

6. The caliper assembly (1000) for disc brake of a two wheeler as claimed in claim 4, wherein
- the first portion (104) of the caliper body (100) has a piston housing (104h) carved therein, a pair of pin housing (104t and 104s) and an extended wing (104P) integrated to said first portion (104) with a mounting hole (104m) thereon;
- the said piston housing (104h) in the caliper body (100) is configured to house a piston assembly (90) therein forming a hydraulic chamber in between the piston assembly (90) and the bottom face of the piston housing (104h);
- the pin housing (104t) is an integrally casted with the caliper body (100) in such a way that it is in axial alignment with the insertion hole (10P) of the sheet metal bracket (10); and the mouth (104tm) of said pin housing (104t) is configured to have a plurality of threads on its inner peripheral surface so as to fit the primary anchor pin (30) of the bracket assembly (BA) therein through the threaded joinery; and
- the pin housing (104s) of the first portion (104) of the caliper body (100) is an integrally casted with the caliper body (100) in such a way that it is in axial alignment with the insertion hole (10S) of the sheet metal bracket (10).

7. The caliper assembly (1000) for disc brake of a two wheeler as claimed in claim 6, wherein
- the outer end of the pin housing (104s) is closed by press fitting a secondary boot (60) therein and the inner end of the pin housing (104s) is configured to slideably house the shank portion (40S) of the secondary pin (40); and said secondary boot (60) is configured to restrict the entry of any foreign material in the pin housing (104s) and thereby protects the secondary anchor pin (40) from dirt and grime; and
- the profiled groove (32G, 40G) on outer peripheral surface of the shank portion (30S, 40S) of the anchor pins (30, 40) is configured to retain the grease on the shank portion (30S, 40S) so as to effectively reduce the sliding friction in between the shank portion (30S, 40S) of the anchor pin (30, 40) and the inner peripheral surface of the guide sleeve (20).

8. The caliper assembly (1000) for disc brake of a two wheeler as claimed in claim 6, wherein
- the connecting portion (108) of the caliper body (100) is configured to create a space (108a) in between the first portion (104) and the second portion (106) while forming an integrated unit of caliper body (100);
- said space (108a) is configured to house the brake pad assembly (PA) therein;
- the second portion (106) is configured to have two pawls (106w) projected upwards and an extended wing (106P) laterally projecting out with a mounting hole (106m) thereon; and
- the extended wing (104P) of the first portion (104) and the extended wing (106P) of the second portion (106) are parallel to each other making the mounting hole (104m) and the mounting hole (106m) coaxially overlap each other.

9. The caliper assembly (1000) for disc brake of a two wheeler as claimed in claim 8, wherein
- the core plate (72) of the pad assembly (PA) is configured to have a main body (74), a projecting arm (75) with a mounting hole (75m) and a jaw (76) projected out from other distal end of the main body (74) of the core plate (72);
- the main body (74) of the core plate (72) has a thorough opening (H) at its center and said opening (H) is configured to dissipate the heat from the friction pad (73);
- the projecting arm (75) is projected out from one distal end of the main body (74) of the core plate (72) and have a mounting hole (75m);
- the core plate (82) is configured to have a main body (84) having a thorough opening (H) centrally drilled thereon and a pair of projecting arms (85, 86); and
- the projecting arm (85) is projected out from one distal end of the main body (84) of the core plate (82) and have a mounting hole (85m); and the projecting arm (86) is projected out from other distal end of the main body (84) of the core plate (82) and have a mounting hole (86m).
10. The caliper assembly (1000) for disc brake of a two wheeler as claimed in claim 9, wherein
- The first brake pad (70) of the pad assembly (PA) is positioned inside the space (108a) created between the first portion (104) and the second portion (106) of the caliper body (100) in a manner that the main body (74) of the core plate (72) of the brake pad assembly (PA) is in mechanical communication with the piston assembly (90);
- the second brake pad (80) of the pad assembly (PA) is placed inside the space (108a) created between the brake pad (70) and a second portion (106) of the caliper body (100) and the core plate (82) of the second brake pad (80) is supported by the pawls (106w) of the second portion (106) of the caliper body (100); and
- the brake disc is interposed in between the faces of the friction pads (73, 83) pasted on brake pads (70, 80) of the caliper body (100).

Dated this 11th day of Oct. 2024

(Sahastrarashmi Pund)
Head – IPR
Endurance Technologies Ltd.

To,
The Controller of Patents,
The Patent Office, at Mumbai