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 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 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 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: 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: 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 caliper assembly includes a caliper body connected to a torque plate via a mating protrusion and cavity that transfer torque through facing abutment surfaces to reduce twisting of the caliper. The mating protrusion and cavity provide a stiff connection and also allow use of a smaller, lighter connecting bolt. This arrangement eases removal and reinstallation of the caliper.

Abstract: A brake caliper assembly includes a caliper body connected to a torque plate via a mating protrusion and cavity that transfer torque through facing abutment surfaces to reduce twisting of the caliper. The mating protrusion and cavity provide a stiff connection and also allow use of a smaller, lighter connecting bolt. This arrangement eases removal and reinstallation of the caliper.

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: A brake caliper has a removable bridge that acts as a rigid mount for a pair of brake pad holders. The removable bridge is retained on the caliper body by spring loaded push button that allows quick removal for replacement of the brake pads, which is especially suited for automotive racing situations. The bridge is snapped in place and rigidly retained on caliper body when in use.

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: 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: A brake caliper assembly includes a caliper body connected to a torque plate via a mating protrusion and cavity that transfer torque through facing abutment surfaces to reduce twisting of the caliper. The mating protrusion and cavity provide a stiff connection and also allow use of a smaller, lighter connecting bolt. This arrangement eases removal and reinstallation of the caliper.

Abstract: A brake assembly for use on vehicles includes a rotor and a wheel mount, formed as a hat portion, fastened to the rotor with a bobbin assembly. The rotor has a flange formed as a series of spaced tabs, and the bobbin assembly is bolted to the hat portion with the rotor flange clamped therebetween. A spring clip can be used with the bobbin to accommodate thermal expansion of the rotor and eliminate rotor rattling. The bobbin has a binocular shape that receives a pair of bolts. A crush zone can be provided between the rotor and the bobbin yields to accommodate machining tolerances of the rotor and promote uniform torque transfer distribution to the hub. Torque is transferred from the brake rotor to the hat portion in a common plane to prevent twisting in the fastener connection.

Abstract: A brake assembly for use on vehicles includes a rotor and a wheel mount, formed as a hat portion, fastened to the rotor with a bobbin assembly. The rotor has a flange formed as a series of spaced tabs, and the bobbin assembly is bolted to the hat portion with the rotor flange clamped therebetween. A spring clip can be used with the bobbin to accommodate thermal expansion of the rotor and eliminate rotor rattling. The bobbin has a binocular shape that receives a pair of bolts. A crush zone between the rotor and the bobbin yields to accommodate machining tolerances of the rotor and promote uniform torque transfer distribution to the hub. Torque is transferred from the brake rotor to the hat portion in a common plane to prevent twisting in the fastener connection.

Abstract: A brake assembly for use on vehicles includes a rotor and a wheel mount, formed as a hat portion, fastened to the rotor with a bobbin assembly. The rotor has a flange formed as a series of spaced tabs, and the bobbin assembly is bolted to the hat portion with the rotor flange clamped therebetween. A spring clip can be used with the bobbin to accommodate thermal expansion of the rotor and eliminate rotor rattling. The bobbin has a binocular shape that receives a pair of bolts. A crush zone between the rotor and the bobbin yields to accommodate machining tolerances of the rotor and promote uniform torque transfer distribution to the hub. Torque is transferred from the brake rotor to the hat portion in a common plane to prevent twisting in the fastener connection.

Abstract: A rotor for use in an automobile braking assembly has a plurality of indentations or dimples formed on the brake pad contact surface of the rotor. The dimples may be arranged in a pattern on the surface. The pattern can be a series of aligned dimples that extend radially in groups around the circumference of the disk. The disk may be ventilated. The dimpled rotor provides enhanced friction, without increased noise, and promotes uniform temperature distribution.

Abstract: A brake caliper has a piston retained in a bore that abuts a brake pad for moving the brake pad into selective engagement with a rotor to effect braking. The piston has a composite cap that is formed of a cap piece made of strong material, such as steel, and an insulator, made of polyimide resin material, for example. The insulator is preferably in the form of a ring clamped between the cap piece and the piston to create a thermal break and minimize heat transfer from the brake pad to the piston and caliper assembly.

Abstract: A hub rotor assembly includes a hub, a rotor supported by the hub and a plurality of fasteners that connect the rotor to the hub. The hub includes a wheel mounting flange and rotor mounting flange to which a flange of the rotor is attached. The rotor mounting flange has a larger diameter than the wheel mounting flange, or other hub elements outboard of the rotor mounting flange, so that the rotor can be easily removed from the hub. Features of the invention also include floatation elements associated with a fastener to fasten the rotor to the hub while allowing the rotor to move or float relative to the hub. A spring clip may be used with the floatation elements to prevent the rotor from rattling. The assembly is particularly suited for commercial highway vehicles and high performance vehicles.

Abstract: A rotor has an array of grooves formed on the brake pad contact surface. The array is preferably formed as a repeating pattern of regularly spaced grooves. The repeating pattern of grooves creates a plurality of radially and circumferentially offset rings of grooves. The rings can radially overlap. The rotor is preferably ventilated having two brake pad contact surfaces separated by a plurality of vanes. The grooves are preferably arranged on the brake pad contact surfaces between the vanes. The grooves can have various configurations and shapes. The array of grooves increases friction between a brake rotor and brake pads, and decreases the thermal gradient and thermal distortion on the brake pad contact surfaces.