Patent Abstract:
A brake caliper cover system for existing brake caliper assembly in a vehicle. The brake caliper cover system has a front cover and a back cover. The front cover and back cover are disposed on the front and back sides of a brake caliper assembly, respectively. The front cover and back cover are fastened together about the brake caliper assembly.

Full Description:
FIELD OF THE INVENTION 
     This invention relates to the field of automotive accessories, in particular to brake covers. 
     BACKGROUND OF THE INVENTION 
     Typical automotive braking systems use brake calipers to engage the rotor when braking is desired. Most automotive braking systems consist of floating or sliding single or double piston type calipers. In some high performance vehicles, the vehicles have high performance braking systems utilizing four piston aluminum fixed brake calipers. Various aftermarket kits are available to allow automotive enthusiasts to install high performance braking systems in their vehicles. 
     However, many automotive enthusiasts do not need the high performance braking system provided by the aftermarket high performance braking kits, but are only interested in the aesthetics provided by the installation of four piston calipers, particularly when used with aftermarket high performance aluminum wheels. Therefore it would be advantageous to provide a brake caliper cover for typical automotive braking systems which allows the braking systems to exude the aesthetic appeal of a high performance brake caliper, without the need to install the costly high performance braking systems. 
     Brake calipers covers are currently available to enhance various visual aspects and useful aspects of an automotive braking system. U.S. Pat. No. 7,144,142 discloses an illuminated cover for a brake caliper. Brake calipers covers, such as ones disclosed in U.S. Patent Application Publication 2004/0074716, are used to reduce the build up of brake dust. U.S. Patent Application Publication 2009/0321198 discloses brake caliper covers with vent openings to provide beneficial dynamics such as cooling the brake caliper mechanisms. 
     The present inventor has recognized the need for a brake caliper cover with increased stability. 
     The present inventor has recognized the need for a brake caliper cover with minimal movement once installed. 
     The present inventor has recognized the need for a brake caliper cover which is easy to install and remove. 
     The present inventor has recognized the need for a brake caliper cover which does not require modification to the existing brake assembly for installation. 
     SUMMARY OF THE INVENTION 
     A brake caliper cover system for at least partially enclosing an existing brake caliper assembly in a vehicle is disclosed. The brake caliper cover system has a front cover and a back cover. The front cover and back cover are disposed on the front and back sides of a brake caliper assembly. The front cover and back cover are fastened together and secured to the brake caliper assembly. 
     In some embodiments the front cover has a cushioning layer on the inner surface to minimize vibration and movement of the front cover over the front side of the brake caliper assembly. The back cover may also include a layer of foam on an inner surface for the same purpose. 
     In some embodiments each cover has an inner surface facing the brake disc configured to enclose the contours of the brake caliper assembly such that each cover can be disposed securely over the brake caliper assembly. The covers are attached to a fixed portion of the caliper. The covers when attached to the fixed portion allow a moving part of the caliper, such as the hydraulic piston(s), to move along shafts within a spaced defined by the cover. 
     Numerous other advantages and features of the present invention will be become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims and from the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a brake caliper assembly and the brake disc. 
         FIG. 2  is a perspective view of the brake caliper assembly of  FIG. 1  with one exemplary embodiment of the brake caliper cover system. 
         FIG. 3  is an exploded view of the brake caliper cover system and the brake caliper assembly. 
         FIG. 4  is a back perspective view of the brake caliper covers on the brake disc caliper with the brake disk removed for clarity. 
         FIG. 5  is a perspective view of the back caliper cover engaging with the brake caliper assembly. 
         FIG. 6  is a perspective view of the back side of the brake caliper assembly with the back caliper cover. 
         FIG. 7  is a perspective view of the brake caliper assembly with the back caliper cover and the brake disc removed for clarity. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     While this invention is susceptible of embodiment in many different forms, there are shown in the drawings, and will be described herein in detail, specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated. 
       FIG. 1  illustrates a front perspective view of a conventional brake caliper assembly  10  in an automobile. The brake caliper assembly  10  includes a caliper housing  20  disposed over a bracket member  30 , for receiving brake pads  40 . Piston housing  50  ( FIG. 7 ) receives hydraulic fluid for actuating hydraulic cylinders (not shown) which compress the pair of brake pads  40  against the brake disc  60  when braking is desired. In some embodiments, the brake caliper assembly may be that shown in U.S. Pat. No. 4,775,034, which is incorporated by reference to the extent not inconsistent with the present description. It will further be recognized that in some embodiments, the brake caliper assembly may be any such brake assembly known in the art. 
     As illustrated in  FIG. 2 , illustrates a front caliper cover  70  of the brake caliper cover system  65  is disposed over the front side of the brake caliper assembly  10 . The front caliper cover  70  encloses the front side of the caliper housing and the front brake bracket, and extends to enclose, the spine region  25  ( FIG. 1 ) of the caliper housing  20  and the spine region  35  of the brake bracket. The caliper cover system has an upper region  75  above, and a lower region  76  below, the spine regions  25 ,  35 . The upper and lower regions  75 ,  76  of the caliper cover system has shafts or bosses  77  ( FIG. 3 ) for receiving bolts  78 . The bosses  77  can be molded into the cover  70 . The bosses provides a holding feature for the bolts. As illustrated in  FIG. 2 , two bolts are disposed at the upper region  75 , and two bolts are disposed at the lower region  76  to fasten the front and back caliper covers together. The top of the shafts  77  are recessed to receive the top of the bolt such that the top of the bolts do not protrude from the cover. 
       FIG. 3  illustrates an exploded view of the brake caliper cover system and the brake caliper assembly. The back brake caliper cover  80  of the brake caliper cover system  65  has threaded shafts or bosses  88  for receiving the bolts  78 . The bosses  88  can be molded into the cover  80 . In some embodiments, bosses are not threaded and instead threads are created when the receiving bolts  78  are screwed into the bosses. As illustrated in  FIGS. 3 and 4 , the back caliper cover  80  does not enclose the piston housing. The back caliper cover  80  has a U-shaped contour  81  which conforms around the piston housing  50 . In some embodiments, the back of the cover  80  as well as the cover  70  will be of other shapes to conform to the various shapes of difference styles of caliper design. As illustrated in  FIG. 5 , the back caliper cover  80  has an upper  82  and lower  84  lip extension which allows the back cover to fit over a portion of the spine region  25  of the caliper housing. In some embodiments, the back cover  80  has upper  86  and lower  89  tabs which protrude into, and engage with, the region above and below the back brake bracket ( FIG. 6 ). 
     Without wishing to be bound by any particular theory, it is believed that the back caliper cover  80  provides mounting support for the front caliper cover  70 . Fastening the front caliper cover to the back caliper cover allows the front caliper cover to be secure against the front side of the caliper housing and the front side of the brake bracket. Upper and lower lips  82 ,  84 , which extend about the top and bottom of the piston housing ( FIG. 5 ) and upper and lower tabs  86 ,  89 , which protrude into the region above and below the back brake bracket, minimizes the movement of the back cover, and accordingly the movement of the front caliper cover, in both a vertical and horizontal direction. The back caliper cover  80  has portions with a recessed perimeter which forms a recessed edge  85  ( FIG. 5 ) to allow portions of the front cover  70  to receivingly engage with the back caliper cover. The covers are attached to a fixed portion of the caliper. The covers, when attached to the fixed portion, allow a moving part of the caliper, such as the hydraulic piston(s), to move along shafts within a spaced defined by the cover. This advantageous because as brake pads wear the position of the caliper moves to account for the fact that the brake pads have friction areas that are reduced compared to their new condition. In this way, the caliper cover not interfere with the braking operation of the caliper. 
       FIG. 7  illustrates a perspective view of the inner surface of the front brake cover  70  in position over the front brake bracket. As illustrated in  FIG. 7 , the inner surface of front brake cover is configured to at least cover, and/or to conform to the shape of the front brake bracket and the front brake caliper housing. The front and back brake covers extend above and below the brake bracket such that a portion of the brake disc is also covered by the front and back brake caliper covers. The front brake cover is configured to provide aesthetic appeal to an observer. The inner surface of the front caliper cover can comprise a layer  90  for cushioning the contact between the brake caliper assembly and the caliper cover. The cushioning layer may be a foam layer, or any other suitable material. The cushioning layer can assist in minimizing vibration and/or movement of the brake caliper cover against the brake caliper assembly. The foam layer may be disposed on a portion of the inner surface of the front brake caliper cover as illustrated in  FIG. 7 , or may be disposed such that the entire inner surface, including the surface enclosing the spine of the brake bracket and the spine of the caliper housing, of the front brake caliper is covered. Alternatively, only the front inner surface of the brake caliper cover may be covered in foam. The foam layer can be made of any suitable foam material which is preferably resistant to wear and tear, and deterioration due to exposure to braking conditions, including heat. The foam layer can be secured to the inner surface of the front brake cover using an adhesive. The inner surface of the back brake cover can also have a cushioning layer over the entire inner surface, or a portion thereof. 
     From the foregoing, it will be observed that numerous variations and is modifications may be effected without departing from the spirit and scope of the invention. It is to be understood that no limitation with respect to the specific apparatus illustrated herein is intended or should be inferred.

Technology Classification (CPC): 1