Abstract: A brake pad retractor system, comprising, a torsional mount and an adjustable torsion arm having an angular relation with the torsional mount, wherein the torsion arm is sprung responsively to at least some movement of a brake pad and the torsional mount being operative such that upon movement of a brake pad by a first distance, the torsion arm is sprung and communicates an action upon the brake pad through a contact between the torsion arm and the brake pad, the communicated action sufficient to positively retract the brake pad upon release of the brake system, the torsional mount further operative such that upon further movement of a brake pad beyond the first distance the angular relation between the torsion arm and the torsional mount is adjusted responsively to the further movement. Further aspects include a novel a brake caliper and method.

Abstract: A brake pad retractor system, comprising, a torsional mount and a torsion arm having an angular relation with the torsional mount, wherein the torsion arm is sprung responsively to at least some movement of a brake pad and the torsional mount being operative such that upon movement of a brake pad by a first distance, the torsion arm is sprung and communicates an action upon the brake pad through a contact between the torsion arm and the brake pad, the communicated action sufficient to positively retract the brake pad upon release of the brake system, the torsional mount further operative such that upon further movement of a brake pad beyond the first distance the angular relation between the torsion arm and the torsional mount is adjusted responsively to the further movement. Further aspects include a novel a brake caliper and method.

Abstract: A floating disc brake assembly, and method of assembly, comprising a disc brake rotor comprising an outer friction ring, an inner circumferential flange having a plurality of rotor tabs spaced about the flange and a circumferential groove about the inner circumferential flange, a hat comprising a cylindrical axial body, an outer circumference, a rotor mounting flange extending radially about the outer circumference and having a plurality of rotor mounting tabs spaced about the rotor mounting flange and forming slots interspersed therebetween structured and arranged for receiving the rotor tabs, and a circumferential groove about the outer circumference of the axial body, structured and arranged to align with the circumferential groove of the disc brake rotor, and at least one expander ring structured and arranged to fit within the circumferential grooves of both the rotor and the hat.

Abstract: A brake caliper is provided with a timing and retraction controller, a brake pad and a lock-connection comprising an engaging component and a locking component. The timing and retraction controller adjusts brake timing, eliminates parasitic brake losses and dampens out-of-plane vibration between the brake pad and rotor. The brake caliper includes a housing disposed over a brake rotor; first and second opposing brake pads extendably and retractably mounted on opposite sides of the caliper housing, brake pistons that extend and retract the brake pads into and out of frictional engagement with the rotor, and brake pad timing and retraction controllers disposed on opposite sides of the caliper housing. Each controller includes a Belleville spring or other resilient member with a short compression travel limited to between about 1.50 mm and 0.025 mm.

Abstract: A floating disc brake assembly having a disc brake rotor secured to a hub with a retention ring structured and arranged to fit within retention ring flanges of a plurality of rotor mounting tabs extending from the hub. A method of uniformly transferring braking forces from a rotor of a brake assembly about a hub of the brake assembly and a kit of parts are also provided.

Abstract: A floating disc brake assembly having a disc brake rotor secured to a mounting assembly, such as a hat or a hat with a retention ring structured and arranged to fit within retention ring flanges of a plurality of rotor mounting tabs uniformly distributed about the mounting assembly. A method of uniformly transferring braking forces from a rotor of a brake assembly about a wheel hat component of the brake assembly and a kit of parts are also provided.

Abstract: A brake caliper is provided with a timing and retraction controller that that adjusts brake timing, eliminates parasitic brake losses and dampens out-of-plane vibration between the brake pad and rotor. The brake caliper includes a housing disposed over a brake rotor; first and second opposing brake pads extendably and retractably mounted on opposite sides of the caliper housing, brake pistons that extend and retract the brake pads into and out of frictional engagement with the rotor, and brake pad timing and retraction controllers disposed on opposite sides of the caliper housing. Each controller includes a Belleville spring or other resilient member with a short compression travel limited to between about 1.50 mm and 0.025 mm.

Abstract: A brake rotor assembly for use with an anti-lock braking system. The brake rotor assembly includes a brake rotor having a pair of braking surfaces; a tone ring having a first end having a plurality of spaced sensing formations disposed thereon and a second end for circumferentially contacting a surface of the brake rotor assembly, the first end thermally insulated from the brake rotor; and a snap ring for connecting the tone ring to the brake rotor assembly. A method of forming a brake rotor assembly is also provided.

Abstract: A parking brake actuator for a disc brake caliper. The parking brake actuator includes a tapered collet having an axial bore, the tapered collet slidably positionable within a bore of the disc brake caliper; an actuator rod having a first end and a second end, the actuator rod slidably positionable within the axial bore of the collet; means for receiving a force for placing the parking brake actuator in a non-actuated condition; and a first biasing means structured and arranged to apply a force sufficient to place the parking brake actuator in an actuated condition when the force for placing the parking brake in a non-actuated condition is reduced or eliminated.

Abstract: A disc brake assembly includes a rotor with an ABS tone ring insert assembly that functions as a rotation indicator in an anti-lock braking system. The insert is positioned in the hat of a rotor disc in a spaced relationship and is mounted to the mounting flange of the rotor disc. Forming the ring insert separately from the rotor disc also allows different coating materials to be used on the tone ring that may be more heat resistant. The ring insert assembly can be made of powder metal or made as a cast iron cylinder with a toothed cap made of powder metal having a corrosion resistant coating. Cost savings can be realized along with high performance when only a portion of the assembly if made of powder metal and coated.

Abstract: The floating brake drum and hat assembly includes a brake drum (12) having a braking surface (14) and an attachment flange (16), a hat (18) having an outer diameter (20) and a brake drum mounting flange (22) for mounting to the attachment flange (16) of the brake drum, and means for coupling (24) the attachment flange of the brake drum to the brake drum mounting flange of the hat, the means for coupling structured and arranged to allow radial thermal expansion and contraction of at least a portion of the attachment flange of the brake drum and/or at least a portion of the brake drum mounting flange of the hat.

Abstract: A brake caliper is provided with a timing and retraction controller that that adjusts brake timing, eliminates parasitic brake losses and dampens out-of-plane vibration between the brake pad and rotor. The brake caliper includes a housing disposed over a brake rotor; first and second opposing brake pads extendably and retractably mounted on opposite sides of the caliper housing, brake pistons that extend and retract the brake pads into and out of frictional engagement with the rotor, and brake pad timing and retraction controllers disposed on opposite sides of the caliper housing. Each controller includes a Belleville spring or other resilient member with a short compression travel limited to between about 1.50 mm and 0.025 mm.

Abstract: An air-cooled piston cap assembly is provided for use in a disc brake caliper that includes a piston cap, and a piston body having a proximal end and a distal end which is slidably movable within a caliper bore along an axis. The piston cap includes a retention portion mounted within the distal end of the piston body, a contact portion located opposite from the retention portion that contacts a brake pad assembly, and an intermediate portion connecting the retention portion with the contact portion. The outer surface of the intermediate portion defines an extended heat exchange path between the contact portion and the retention portion, and may for example hourglass-shaped. An air gap is provided between a top edge of the piston body and an undersurface of the contact portion of the piston cap that allows air to circulate over the extended heat transfer path defined by the outer surface of the contact portion and intermediate portion to cool the cap from frictional heat generated during braking.

Abstract: A brake assembly for use on vehicles includes a rotor having connection tabs and a hub having bobbins, integrally formed or separate, with the rotor connection tabs being positioned between the hub bobbins and clamped together with a top plate. An ABS tone ring is fastened to the hub and is circumscribed by the rotor. Alternatively, an ABS tone ring can be formed as part of the top plate. A spring clip can be used with the top plate to accommodate thermal expansion of the rotor and eliminate rotor rattling. Torque is transferred from the brake rotor to the hub in a common plane to prevent twisting in the fastener connection.

Abstract: The floating brake drum and hat assembly includes a brake drum (12) having a braking surface (14) and an attachment flange (16), a hat (18) having an outer diameter (20) and a brake drum mounting flange (22) for mounting to the attachment flange (16) of the brake drum, and means for coupling (24) the attachment flange of the brake drum to the brake drum mounting flange of the hat, the means for coupling structured and arranged to allow radial thermal expansion and contraction of at least a portion of the attachment flange of the brake drum and/or at least a portion of the brake drum mounting flange of the hat.

Abstract: A sliding caliper parking brake that positively retracts of both the outer and the inner brake pads upon de-actuation of the parking brake is provided. The parking brake includes a caliper body, a mounting assembly that slidably mounts the caliper body on the suspension of the vehicle so that is movable with respect to a brake rotor, and at least one piston assembly movably mounted in a bore in the caliper body and having an end connected to an inner brake pad. An outer brake pad is fixedly connected to the caliper body and is moved into engagement with an outer side of the brake rotor when the caliper body is moved along the mounting assembly as a result of the inner brake pad extending into engagement with the inner side of the brake rotor.

Abstract: A parking brake actuator for a disc brake caliper having at least one service piston. The parking brake actuator includes a tapered collet having an axial bore for receiving the service piston; a release piston, said release piston in axially alignment with the service piston and said tapered collet, said release piston having an internally disposed taper for co-acting with the taper of said tapered collet; and a biasing means, said biasing means structured and arranged to apply a force to said release piston sufficient to place the parking brake actuator in an actuated condition.

Abstract: A parking brake actuator for a disc brake caliper. The parking brake actuator includes a tapered collet having an axial bore, the tapered collet slidably positionable within a bore of the disc brake caliper; an actuator rod having a first end and a second end, the actuator rod slidably positionable within the axial bore of the collet; means for receiving a force for placing the parking brake actuator in a non-actuated condition; and a first biasing means structured and arranged to apply a force sufficient to place the parking brake actuator in an actuated condition when the force for placing the parking brake in a non-actuated condition is reduced or eliminated.

Abstract: A wheel bearing hub and disc brake rotor assembly for use on vehicles includes a rotor (14) and a wheel mount (24), formed as a package bearing, fastened to the rotor with a connection assembly that promotes in plane torque transfer. The rotor has a flange form as a series of spaced tabs (20), and the wheel bearing hub (14) has a shoulder with complementary spaced tabs (34). The rotor is connected to the bearing hub by clamping a bridge (42) that spans the shoulder tabs over the rotor tabs. A spring clip (50) can be use with the bridge to accommodate thermal expansion of the rotor and eliminate rattling. Torque is transferred from the brake rotor to the bearing hub in a common plane to prevent twisting. In one embodiment, the bearing hub shoulder tabs may be formed by milling or machining slots. In another embodiment, the bearing hub shoulder tabs may be formed by fine-blanking or stamping slots.

Abstract: An air-cooled piston cap assembly is provided for use in a disc brake caliper that includes a piston cap, and a piston body having a proximal end and a distal end which is slidably movable within a caliper bore along an axis. The piston cap includes a retention portion mounted within the distal end of the piston body, a contact portion located opposite from the retention portion that contacts a brake pad assembly, and an intermediate portion connecting the retention portion with the contact portion. The outer surface of the intermediate portion defines an extended heat exchange path between the contact portion and the retention portion, and may for example hourglass-shaped. An air gap is provided between a top edge of the piston body and an undersurface of the contact portion of the piston cap that allows air to circulate over the extended heat transfer path defined by the outer surface of the contact portion and intermediate portion to cool the cap from frictional heat generated during braking.