Rockwell International Corporation

Joseph F Dernovshek

Patrick Michael Cadaret

A brake system having a caliper which defines a bore for slideably receiving a piston. The piston defines a hydraulic chamber at one end and generates a force in response to hydraulic pressure applied thereto. This force is then transmitted through the piston to a backing plate of a brake pad. The brake pad engages a rotor to retard rotation thereof. The piston is constructed as a vessel having a continuous circuit of sides which have an overall axial dimension. A first end of the circuit of sides is open, whereas the second end is closed defining a closed bore. The closed bore is filled with a plastic material which is bonded to the bore by the adhesive properties of the interface existing therebetween. The plastic material features a lower modulus of elasticity than that of the vessel in which it is molded. In addition, the plastic material extends axially beyond the axial dimension of the circuit of sides a predetermined dimension which is equal to the amount of deflection which occurs upon the piston transmitting a first range of forces. Upon reaching the limit of deflection of the predetermined dimension, the continuous circuit of sides engages the brake backing plate, and the combination of the continuous circuit of sides and the plastic material then conjunctively cooperate to transmit a second range of forces through the piston.

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Rock Hill, SC, United States of America

Joseph F Dernovshek