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An evaporable foam pattern assembly for use in a process of casting a one-piece article in a mold filled with flowable particulate molding material. A first foam pattern section includes a first recess pattern portion and an adhesive surface pattern adapted to be joined to an adhesive surface patter

An evaporable foam pattern assembly for use in a process of casting a one-piece article in a mold filled with flowable particulate molding material. A first foam pattern section includes a first recess pattern portion and an adhesive surface pattern adapted to be joined to an adhesive surface pattern of a second foam pattern section having a second recess pattern portion that is registered with the first recess pattern portion to define the article when the adhesive surface patterns of the first and second foam pattern sections are adheringly joined. The registered first and second recess pattern portions define an outer shaped surface pattern of the article, and an inner shaped surface pattern of the article. An inlet end section of a tubular passageway cavity pattern forms a fluid flow path from the inner shaped surface pattern through an outlet end section of the tubular passageway cavity pattern that extends openly and outwardly through the outer shaped surface pattern. A structural configuration at the inlet end section is effective to enhance movement of particulate molding material into the passageway cavity pattern during the casting process to form a passageway fluid connection section within the article. Molten material poured into the mold evaporates and replaces the evaporable pattern assembly to produce the article. The invention more specifically produces a novel one-piece brake caliper casting having a cast-in tubular passageway having an inner surface diameter of less than about 6.0 mm. The unique casting design minimizes the time required to machine and assembly the finished disc brake caliper of the invention.

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What is claimed is: 1. A disc brake caliper casting comprising: a) caliper housing means including a front section, a rear section, and a bridge section extending between said front and rear sections; b) said front, rear, and bridge sections form a cast one-piece structural configuration to integra

What is claimed is: 1. A disc brake caliper casting comprising: a) caliper housing means including a front section, a rear section, and a bridge section extending between said front and rear sections; b) said front, rear, and bridge sections form a cast one-piece structural configuration to integrally define an outer shaped surface and an inner shaped surface; c) said inner shaped surface including at least one inner cylindrical surface, first cast-in passageway means disposed on a first side of said cylindrical surface, and second cast-in passageway means disposed on an opposed second side of said cylindrical surface; d) each said first and second passageway means including a cylinder connecting section having an inner end portion that openly connects to said opposed sides of said cylindrical surface; e) each said cylinder connecting section being outwardly directed from said inner cylindrical surface and having an outer end portion that extends to said bridge section; f) means for forming a fluid connection section that intersects said cylinder connecting sections to produce a continuous fluid flow path between said front section and said rear section; g) said fluid connection section forming means including a bridge portion that extends through said bridge section to intersect each said cylinder connecting section, and an outlet end segment that extends outwardly from the bridge section through an outlet opening in said outer shaped surface. 2. A caliper casting as defined in claim 1 wherein said fluid connection section forming means includes a cast-in fluid connection passageway portion that extends outwardly from each said outer end portion of said cylinder connecting sections across said bridge section and opens outwardly from said outlet end segment. 3. A caliper casting as defined in claim 1 wherein said bridge section includes two bridge end portions each disposed at an outer end of said front and rear sections, said front, rear, and bridge sections each includes an inwardly facing surface that together define a friction brake pad support chamber having torque bearing surfaces that are disposed at opposing ends of the support chamber and are perpendicular to the inwardly facing surfaces of the front and rear sections, and said torque bearing surfaces include disc rotor grooves having a structural configuration that is effective to allow brake disc rotor means to rotate through the friction brake pad support chamber when a brake caliper that is produced from said caliper casting is mounted to a vehicle. 4. A caliper casting as defined in claim 3 wherein said front and rear sections each includes an inner cylindrical surface and an inwardly directed cast-in cylinder connecting section on opposing sides of each said inner cylindrical surface, and each said bridge end portion includes a cast-in fluid connection section extending therethrough with each end thereof intersecting a cast-in cylinder connecting section. 5. A caliper casting as defined in claim 4 wherein said inner cylindrical surfaces are disposed along a single longitudinal center axis that extends through said front and rear sections, and through said friction brake pad support chamber. 6. A caliper casting as defined in claim 1 wherein said front, rear, and bridge sections each includes an inwardly facing surface that together define a friction brake pad support zone having a structural configuration effective to allow brake disc rotor means to rotate between friction brake pads mounted in said support zone when a brake caliper that is produced from said caliper casting is mounted to a vehicle, said fluid connection section forming means includes a cast-in fluid connection passageway portion that extends outwardly from each said outer end portion of said cylinder connecting sections and then extends across said bridge section and opens outwardly from said outlet end segment, said inner cylindrical surface is disposed in said rear section and has a longitudinal center axis that extends from said rear section and through said friction brake pad support zone with said front section including a front opening which is registered with said inner cylindrical surface and said longitudinal center axis, said outlet end segment includes an outlet opening having a longitudinal axis that is parallel to said longitudinal center axis of the inner cylindrical surface whereby any machining may be effected on one side of the casting within the inner cylindrical surface in said rear section, within the registered front opening, and along the longitudinal axis of and within said outlet opening. 7. A caliper casting as defined in claim 1 wherein said bridge section includes two bridge end portions each disposed at an outer end of said front and rear sections, said front, rear, and bridge sections each includes an inwardly facing surface that together define a friction brake pad support chamber around said support zone, said support chamber having torque bearing surfaces that are disposed at opposing ends of the support chamber and are perpendicular to the inwardly facing surfaces of the front and rear sections, said torque bearing surfaces include disc rotor grooves having a structural configuration that is effective to allow brake disc rotor means to rotate through the friction brake pad support chamber when a brake caliper that is produced from said caliper casting is mounted to a vehicle, said front and rear sections each includes an inner cylindrical surface and an inwardly directed cast-in cylinder connecting section located on opposing sides of each said inner cylindrical surface, and each said bridge end portion includes a cast-in fluid connection section extending therethrough with each end thereof intersecting a cast-in cylinder connecting section to produce a fluid flow path. 8. A caliper casting as defined in claim 7 wherein said outer shaped surface includes friction pad support means for mounting friction brake pad supports within said support chamber, and caliper support means for mounting a machined brake caliper cast housing to a vehicle, said friction pad support means and said caliper support means each includes a bore opening having a longitudinal axis that is parallel to said longitudinal center axis of the inner cylindrical surface. 9. A caliper casting as defined in claim 7 wherein said torque bearing surfaces are tapered inwardly and downwardly from a respective bridge end portion with a structural configuration which conforms to the shape of tapered friction brake pad members used in disc brake calipers. 10. A caliper casting as defined in claim 1 wherein said inner shaped surface includes a pair of inner cylindrical surfaces, each said first and second cast-in passageway means includes a fluid connection section outwardly directed from each said inner cylindrical surface and having an outlet end that extends openly and outwardly through said outer shaped surface, and each said first and second cast-in passageway means includes two opposing inwardly directed cylinder connection sections having inner ends that each openly connect to said pair of inner cylindrical surfaces; said first and second cast-in passageway means being effective to form a continuous fluid flow crossover path from a first open outlet side to a second closed side of the outer shaped surface so that said path extends through said outlet end of each said passageway means, and through said inner ends that openly connect to each said cylindrical surface. 11. A disc brake caliper casting comprising: a) caliper housing means including a front section, a rear section, and a bridge section extending between said front and rear sections; b) said front, rear, and bridge sections having a cast one-piece structural configuration to integrally define an outer shaped surface and an inner shaped surface; c) said front, rear, and bridge sections each includes an inwardly facing surface that together define a friction brake pad support zone for disposing friction brake pad means on opposing sides of disc brake rotor means; and d) friction pad support means for mounting said friction brake pad means within said brake pad support zone, e) said inner shaped surface including at least one inner cylindrical surface having a longitudinal center axis, first cast-in passageway means disposed on a first side of said cylindrical surface, and second cast-in passageway means disposed on an opposed second side of said cylindrical surface; f) each said first and second passageway means including a cylinder connecting section being outwardly directed from said inner cylindrical surface, and each having an inner end portion that openly connects to an opposed side of said cylindrical surface, and an outer end portion that extends to said bridge section; g) said outer shaped surface including a plurality of drilling surfaces each disposed in a respective plane that extends in a direction perpendicular to said longitudinal center axis of the inner cylindrical surface, and caliper support means for mounting a finished brake caliper produced from said brake caliper casting; h) said bridge section including a drilling surface so that the bridge section may be drilled into for forming a fluid outlet end portion that connects with a crossover fluid flow path that extends through the passageway means and inner cylindrical surface, and i) said caliper support means including a drilling surface so that said outer shaped surface may be drilled into for forming bore openings to mount said finished brake caliper to a vehicle. 12. A caliper casting as defined in claim 11 wherein said friction pad support means including a drilling surface so that the outer shaped surface may be drilled into for forming a bore opening to mount said friction brake pad means in said brake pad support zone. 13. A caliper casting as defined in claim 11 wherein said inner shaped surface includes a pair of inner cylindrical surfaces, each said first and second cast-in passageway means includes a fluid connection section which is outwardly directed from each said inner cylindrical surface, and said fluid outlet end portion extends openly and outwardly through said outer shaped surface, and each said first and second cast-in passageway means includes two opposing inwardly directed cylinder connection sections having inner ends that each openly connect to said pair of inner cylindrical surfaces; said first and second cast-in passageway means being effective to form a continuous fluid flow crossover path from a first open outlet side to a second closed side of the outer shaped surface so that said path extends through said outlet end of each said passageway means, and through said inner ends that openly connect to each said cylindrical surface. 14. A caliper casting as defined in claim 11 wherein said bridge section includes two bridge end portions each disposed at an outer end of said front and rear sections, said front, rear, and bridge sections each includes an inwardly facing surface that together define a friction brake pad support chamber having torque bearing surfaces that are disposed at opposing ends of the support chamber and are perpendicular to the inwardly facing surfaces of the front and rear sections, and said torque bearing surfaces include disc rotor grooves having a structural configuration that is effective to allow brake disc rotor means to rotate through the friction brake pad support chamber when a brake caliper that is produced from said caliper casting is mounted to a vehicle. 15. A caliper casting as defined in claim 14 wherein said front and rear sections each includes an inner cylindrical surface and inwardly directed cast-in cylinder connecting sections on opposing sides of each said inner cylindrical surface, and each said bridge end portion includes a cast-in fluid connection section extending therethrough with each end thereof intersecting a cast-in cylinder connecting section. 16. A caliper casting as defined in claim 15 wherein said inner cylindrical surfaces are disposed along a single longitudinal center axis that extends through said front and rear sections, and through said friction brake pad support chamber whereby said inner cylindrical surfaces may be machined to form finished brake piston cylinders from the same side of said casting as the drilling surfaces are drilled into. 17. A caliper casting as defined in claim 11 wherein said inner cylindrical surface is disposed in said rear section and has a longitudinal center axis that extends from said rear section and through said friction brake pad support zone with said front section including a front opening which is registered with said inner cylindrical surface and said longitudinal center axis, said outlet end portion includes an outlet opening having a longitudinal axis that is parallel to said longitudinal center axis of the inner cylindrical surface whereby any machining may be effected on one side of the casting within the inner cylindrical surface in said rear section, within the registered front opening, and along said longitudinal axis of and within said outlet opening. 18. A caliper casting as defined in claim 11 wherein said bridge section includes two bridge end portions each disposed at an outer end of said front and rear sections, said front, rear, and bridge sections each include inwardly facing surfaces that define a friction brake pad support chamber around said support zone, said support chamber having torque bearing surfaces that are disposed at opposing ends of the support chamber and are perpendicular to the inwardly facing surfaces of the front and rear sections, said torque bearing surfaces include disc rotor grooves having a structural configuration that is effective to allow brake disc rotor means to rotate through the friction brake pad support chamber when a brake caliper that is produced from said caliper casting is mounted to a vehicle, said front and rear sections each includes an inner cylindrical surface and inwardly directed cast-in cylinder connecting sections on opposing sides of each said inner cylindrical surface, and each said bridge end portion includes a cast-in fluid connection section extending therethrough with each end thereof intersecting a cast-in cylinder connecting section. 19. A caliper casting as defined in claim 18 wherein said torque bearing surfaces are tapered inwardly and downwardly from a respective bridge end portion with a structural configuration which conforms to the shape of tapered friction brake pad members used in disc brake calipers.