Abstract: The drum-in-hat assembly (10) comprises a disc brake (12) mounted slidably relative to a backing plate (18) which includes an opening (19) through which extends a reverse scissors actuator (40) for the drum brake (30) of the assembly (10). The drum brake (30) includes a pair of arcuate drum brake shoes (32, 34) supported relative to the backing plate (18), with the shoes (32, 34) having a pair of opposed brake shoe ends (36, 38) engaged by the actuator (40). The actuator (40) comprises a pair of levers (42, 46) pivotably attached to one another with each lever (42, 46) having a second lever end (48, 58) engaging a respective end (38, 36) of an associated brake shoe, wherein the second lever end (48, 58) has either a slot (49) or an edge (59) located laterally away from the other and engaging the associated brake shoe end (38, 36). The actuator (40) is free to float relative to the backing plate (18), and the levers (42, 46) are located within a housing (70) attached to the backing plate (18).

Abstract: A duo-servo drum brake (10) includes an application adjuster mechanism (50). The application adjuster mechanism (50) comprises a threaded member (51) anchored to one brake shoe end (34), a socket member (61) anchored to the other brake shoe end (32), an opening (63) in the socket member (61) which freely receives a threaded shaft (53) of the threaded member (51), a starwheel (70) rotatedly mounted on the threaded member (51) and abutting an adjacent end (65) of the socket member (61), the socket member (61) having an axially extending button (64) and a torsion spring (90) disposed about its outer surface, the torsion spring having a hook end (95)engaging the button (64). A cable mechanism (60) has one end connected to the anchor pin (40) of the duo-servo drum brake (10) and the other end has a spring member (44) connected with a lever (80) of the adjuster mechanism (50).

Abstract: The drum brake wheel cylinder (20) comprises a longitudinal through bore (16) having therein a pair of opposed pistons (22, 24) with each piston (22, 24) engaging a respective web (12, 14) of an adjacent drum brake shoe. A first piston (22) includes a longitudinal opening (32) receiving therein one end (62) of a friction rod (60), and the second piston (24) includes a recess opening (27) receiving therein the second end (64) of the friction rod. A friction latch adjusting lever (50) has a central opening (52) receiving therethrough the friction rod (60) and is located diagonally relative to a longitudinal axis of the friction rod (60). A spring (70) is located about the friction rod (60) with one end biasing the friction latch adjuster lever (50) against a wall (34) of the first piston (22) and the other end of the spring engaging an abutment (27B) in the recess opening (27 ).

Abstract: The automatic adjuster (5) for the drum brake (6) comprises first and second oppositely disposed end members (30, 40) each having slots (32, 42) for receiving nonrotatably brake shoe webs (10, 14) and a parking lever (22). The first end member (30) includes a radially expanded end portion (34) defining an interior cavity (36) with a conically shaped surface (38). The second end member (40) is connected with a rotatable starwheel flange (44) of a longitudinally extended shaft (48) having therein a threaded opening (49), the starwheel flange (44) immobilized by a return spring (16) of the brake (6). An intermediate member (50) has at one end a threaded shaft (52) which is received threadedly within the threaded opening (49) of the shaft (48) and at the other end a conically shaped member (54) which engages the conically shaped surface (38) of the first end member (30).

Abstract: The vehicle brake with brake cylinder bore insert (30, 130) comprises a cast disc brake cylinder (12, 112) which includes a bore (14, 114) into which the bore insert (30, 130) may be disposed. The bore (14, 114) may have an opening (22, 118) at either one (20, 120) of the opposite axial ends for inserting the bore insert (30, 130). The insert has lock ribs (34) disposed about the perimeter (32) thereof, and at opposite axial ends a pair of perimeter extensions or crush ribs (36) which tightly engage the surface (21, 121) of the bore (14, 114) when the insert (30, 130) is disposed within the bore (14, 114). The insert (30, 130) has opposite flat sides (50) which permit an adhesive material to be disposed between the lock ribs (34) and the surface (21, 121) of the bore (14) in order to fix the insert (30) within the bore (14). The insert (30, 130) contains a central opening (39, 139) which may be of different diameters or shapes for receiving a piston (40) and seals disposed about the piston (40).

Abstract: A drum brake shoe is provided by fine blanking the brake shoe web (50) so that the web (50) has radially extending weld projections (60) at a circumferential edge (52), with a radial recess (62) disposed on each side of a weld projection (60). As a brake shoe rim (40) is fed through a welding and forming mechanism (65), a flat surface (41) of the rim (40) engages a radially extending weld projection (60) and a weld is effected. Welding wheels (90, 100) of the mechanism (65) rotate to bend the rim (40) and engage the rim (40) with the next weld projection as a weld is effected between the rim (40) and web (50). The manufacturing method will provide a more consistent welding process that will result in a higher percentage of quality welds and less scrappage.

Abstract: An automatically adjustable strut (60) is mounted adjacent a drum brake (10) wheel cylinder (20) and strut forks (62, 66) bear against a pair of brake shoes (12, 14) and a parking brake lever (50). The strut (60) extends automatically according to wear of the brake shoes (12, 14) and comprises a nut-and-bolt system operated by a pawl (75) engaging teeth (84) of a nut (80). The pawl (75) is part of a clip-on automatic adjuster strut lever (100) mounted resiliently upon a body (68) of the strut (60). The strut lever (100) includes a loading arm (108) which resiliently engages the body (68) of the strut (60), so that proper operational loading is effected by the pawl (75) upon the nut (80). The strut lever (100) also includes a spring lever arm (120) which engages a rocker lever (90) that moves the lever arm (120) and pawl ( 75) when the brake (10) is released toward an at-rest position, and then permits movement of the pawl (75) in an opposite direction when the brake (10) is applied.

Abstract: The electrically operated drum brake (10) comprises an electric motor assembly (80, 180) disposed between opposing ends (62, 72) of two brake shoes (12, 14), the electric motor assembly (80, 180) replacing both the hydraulic wheel cylinder and the parking brake strut and lever. The electric motor assembly (80, 180) comprises a housing (82, 182) having an interior opening (84, 184) in which is disposed an electric motor (86, 186). The electric motor (86) drive a planetary gear assembly (91) which operates a screw mechanism (102) that engages an end (72) of an adjacent brake shoe (14), the housing (82) engaging the other brake shoe (12). An alternative embodiment includes an electric motor (186) which drives a bearing drive member (198), the bearing drive member (198) having a bearing track (200) which receives a plurality of bearing balls (205). The bearing balls (205) engage a fixed bearing track (187) on the housing ( 182) and also a curved surface (202) on a rotatable bearing member (201).

Abstract: The electrically operated drum brake (10) comprises an electric motor assembly (80, 180) disposed between opposing ends (62, 72) of two brake shoes (12, 14), the electric motor assembly (80, 180) replacing both the hydraulic wheel cylinder and the parking brake strut and lever. The electric motor assembly (80, 100) comprises a housing (82, 182) having an interior opening (84, 184) in which is disposed an electric motor (86, 186). The electric motor (86) drives a planetary gear assembly (91) which operates a screw mechanism (102) that engages an end (72) of an adjacent brake shoe (14), the housing (82) engaging the other brake shoe (12). An alternative embodiment includes an electric motor (186) which drives a bearing drive member (198), the bearing drive member (198) having a bearing track (200) which receives a plurality of bearing balls (205). The bearing balls (205) engage a fixed bearing track (187) on the housing ( 182) and also a curved surface (202) on a rotatable bearing member (201).

Abstract: The retainer assembly (10) comprises a longitudinally extending retainer body (12) having an enlarged diameter or head member (14) at one end and an arrow-shaped or flared member (16) at the other end. A V-shaped leaf spring (20) has an opening (24) at the bottom of the V-shaped opening (22) which receives the retainer body (12) so that the spring (20) is disposed between the head member (14) and a surface (31) of a first member (30). The retainer body (12) extends through an opening (32) in the first member (30) and the flared member (16) is resiliently captured within a resilient receiving member (50) disposed within an opening (46) of the second member (40). The opening (46) in the second member (40) is in a second surface (44) disposed apart from a first surface (42) of the second member (40) which engages the first member (30).

Abstract: A brake control mechanism (14) includes a housing (20) with a stepped bore (22). A valve member (44) cooperates with a seat (46) to close communication from a master cylinder (10) to a brake assembly (12) when a vehicle is going up a hill. An actuator assembly (78) is operatively coupled to a clutch assembly (16) and is comprised of a plate (50) to control operation of the valve assembly in response to actuation of the clutch assembly (16). The plate (50) includes a relatively small axial dimension and forms a central opening (54) for receiving the valve member (44).

Abstract: A rotor for a disc brake assembly includes at least two members (40, 42) opposing a pair of friction elements (16, 18). The members are stamped to form projections (46) in abutment with each other to join the members together. The projections (46) also space the members from each other to form a clearance (58) and a connecting portion (44) cooperates with some of the projections (46) to prevent rotation between the connecting portion (44) and the two members (40, 42).

Abstract: A floating-caliper disc brake (1) includes a non-rotating torque member (36) which carries the caliper (22) in fixed radial position relative to the disc (12) via a pair of pins (56, 58). The torque member and caliper each have matching grooves (44, 46, 48, 50) which, when placed in registry, define a pair of apertures (52, 54) between the caliper and the arms (38, 40) of the torque member. The pins are complementary in cross-section to the shape of these apertures so as to space apart the caliper and the torque member when the pins are inserted into the apertures. Brake torque is transferred from the caliper to the torque member solely through the pins. Sliding of the caliper along the pins provides for axial movement of the caliper relative to the torque member and brake rotor, but the caliper is otherwise restrained from movement in the radial and circumferential directions. One of the pins (58) includes a pair of opposed wedge-defining members (66, 68).

Abstract: A method for manufacturing a drum brake shoe comprises the steps of providing a strip of material, forming a plurality of connected blanks with the strip, bending each blank to form an arcuate surface with adjoining sides, cutting one of the blanks by serving a connecting link and trimming the one blank to form a contour for the adjoining sides. Thereafter, a friction lining is attached to the arcuate surface.

Abstract: A floating-caliper disc brake (10) includes a non-rotating torque member (36). A caliper (22) straddles the brake disc (12) and is carried in fixed radial and circumferential position by the torque member (36). Axial movement of the caliper (22) relative to the brake disc (22) is provided for by roller members (58) between the caliper (22) and the torque member (36). The torque member (36) and the caliper (22) both have axially-extending grooves (52, 54) which in registry cooperate to define axially-extending apertures (56) between the caliper and the torque member. The roller members (58) are received in the axially-extending apertures (56) between the caliper (22) and the torque member (36). The roller members (58) are the sole torque-transmitting structure between the caliper (22) and the torque member (36). Rolling of the caliper (22) on the roller members (58) provides for axial movement of the caliper (22) relative to the brake disc (12) and the torque member (36).

Abstract: A drum brake (10) includes a rotatable brake drum (16) and a pair of brake shoes (12, 14) which are engageable with the brake drum. A non-rotatable backing plate (24) slidably carries the pair of brake shoes. The brake shoes pivotally anchor at one end to a pin (32) secured to the backing plate. An extendible member (36) adjustably spaces apart the other ends of the brake shoes to maintain a desired running clearance between the brake shoes and the brake drum. One of the brake shoes carries a lever (48) which drivingly engages a ratchet wheel (46) of the extendible member. The lever carries a pin (60) which is slidably and rotatably received in an arcuate guide slot (58) of the backing plate. A brake application with forward brake drum rotation causes the lever to slide along the arcuate slot and to remain substantially stationary relative to the extendible member.

Abstract: A disc brake assembly includes a frame (28) which is movably disposed relative to a rotor (18) and a central opening (29) on the frame carries a pair of friction elements (30, 33) facing opposite sides of the rotor. An adjuster assembly (43) is disposed within the central opening to control the position of the pair of friction elements relative to the rotor. The adjuster assembly includes a lever (44) pivotally engaging the frame and an extendible assembly (48) cooperating with the lever and frame to control the pivotal position of the lever relative to the frame. An actuator (36) extends into the central opening and is engageable with one of the friction elements and the lever. Upon operation of the actuator, the one friction element separates from the lever to engage the rotor and the frame moves to engage the other friction element with the rotor. A pawl (50) is responsive to movement of the one friction element relative to the lever to control extension of the extendible assembly.

Abstract: A floating-caliper disc brake (10) includes a non-rotating torque member (38) which carries the caliper (22) in fixed radial position relative to the disc (12) via a pair of pins (50). The torque member and caliper each have matching grooves (46, 48) which, when placed in registry, define a pair of apertures (49) between the caliper and the arms (40, 42) of the torque member. The pins are complementary in cross-section to the shape of these apertures so as to space apart the caliper and the torque member when the pins are inserted into the apertures. Brake torque is transferred from the caliper to the torque member solely through the pins which may be made of a material resistant to corrosion. Sliding of the caliper along the pins provides for axial movement of the caliper relative to the torque member and brake rotor, but the caliper is otherwise restrained from movement in the radial and circumferential directions.

Abstract: A disc brake assembly provides a torque member which is juxtaposed with a rotor for the purpose of movably supporting a caliper. The caliper cooperates with a pair of friction elements to urge the latter into engagement with the rotor during a brake application as the caliper moves relative to the torque member. In order to movably support the caliper relative to the torque member, the torque member and caliper include a pair of matching slots for receiving a pair of pins. A pair of split cylindrical sleeves are also received within respective slots to engage the torque member and caliper. The sleeves define bores which receive the pins to form a clearance therewith. Consequently, during a braking application one of the sleeves is contracted radially to transmit braking torque from the caliper to the torque member via the one sleeve and its corresponding pin. The sleeves and pins maintain the caliper in spaced relation to the torque member at all times.

Abstract: A drum brake assembly includes a pair of brake shoes which are movable to a braking position by a hydraulic actuator. In order to maintain the pair of brake shoes adjacent the drum an adjuster is disposed between the pair of brake shoes opposite the hydraulic actuator. The adjuster carries a parking mechanism to manually move the pair of brake shoes to the braking position independently of the hydraulic actuator. The parking mechanism comprises a pair of levers which are pivotally connected to projections on the adjuster and the levers oppose one of the pair of brake shoes such that pivoting of the pair of levers moves the adjuster and the other brake shoe away from the one brake shoe. A spacer and a washer are disposed between the one brake shoe and abutment surfaces on each pair of levers and the adjuster movably supports the spacer and the washer.