Abstract: An electromechanical actuator package for actuating a brake assembly configured to operate a vehicle brake comprises: a motor; a differential operably connected to the motor, the differential comprising a pulley and an output connectable to the brake assembly; and a locking mechanism configured to lock the pulley of the differential, the locking mechanism comprising: a base configured to be movable, a plurality of projections projecting from the movable base, the projections comprising first and second projections, wherein at least a part of the pulley is positioned between the first and second projections projected from the movable base, an electromagnet assembly disposed adjacent to at least one of the projections, the electromagnet assembly operably associated with at least one of the projections, and one or more springs operably coupled to the movable base and/or at least one of the projections.

Abstract: A piston configured for use in a brake system is disclosed. The piston can comprise: a body; and a footing; the footing positioned adjacent an end of the body, and having a recess that receives a central portion of the end; during operation of the brake system, the footing extends along a brake pad, and is configured to exert force on the brake pad during actuation of the disk brake system; and the footing having a face configured to contact the brake pad, the face having a length and a width, wherein the length is longer than an outside width of the body, and the length is greater than the width, and/or the face having a cross-sectional area normal to a direction of travel of the piston that is larger than a cross-sectional area of the piston body that is normal to the direction of travel of the piston.

Abstract: A brake piston is described. The brake piston is configured for use in a disk brake system, the piston comprising: a body having an outside width perpendicular to a central axis; a footing disposed at a distal end of the piston; wherein the footing is configured to exert force on a brake pad during actuation of the disk brake system; the footing having a face configured to contact the brake pad, the face having a length and a width, wherein the length is longer than the outside width of the body, and the length is greater than the width.

Abstract: Brake calipers, molds and method of producing brake calipers are disclosed including a brake caliper mold for molding a brake caliper, the brake caliper mold comprising: a first mold section; a second section half; a core member configured to form a piston bore, the core member comprising: a tower configured to form a tower window in a bridge of the brake caliper and a piston bore extension to form a piston bore of the brake caliper; and four locator forming surfaces located on the tower, each of the four locator forming surfaces configured to form a separate lateral data reference surface on the brake caliper, the lateral data reference surfaces capable of being used for subsequent machining of the brake caliper to predetermined tolerances.

Abstract: An electromechanical actuator package for actuating a brake assembly configured to operate a vehicle brake comprises: a motor; a differential operably connected to the motor, the differential comprising a pulley and an output connectable to the brake assembly; and a locking mechanism configured to lock the pulley of the differential, the locking mechanism comprising: a base configured to be movable, a plurality of projections projecting from the movable base, the projections comprising first and second projections, wherein at least a part of the pulley is positioned between the first and second projections projected from the movable base, an electromagnet assembly disposed adjacent to at least one of the projections, the electromagnet assembly operably associated with at least one of the projections, and one or more springs operably coupled to the movable base and/or at least one of the projections.

Abstract: A piston configured for use in a brake system is disclosed. The piston can comprise: a body; and a footing; the footing positioned adjacent an end of the body, and having a recess that receives a central portion of the end; during operation of the brake system, the footing extends along a brake pad, and is configured to exert force on the brake pad during actuation of the disk brake system; and the footing having a face configured to contact the brake pad, the face having a length and a width, wherein the length is longer than an outside width of the body, and the length is greater than the width, and/or the face having a cross-sectional area normal to a direction of travel of the piston that is larger than a cross-sectional area of the piston body that is normal to the direction of travel of the piston.

Abstract: A brake piston is described. The brake piston is configured for use in a disk brake system, the piston comprising: a body having an outside width perpendicular to a central axis; a footing disposed at a distal end of the piston; wherein the footing is configured to exert force on a brake pad during actuation of the disk brake system; the footing having a face configured to contact the brake pad, the face having a length and a width, wherein the length is longer than the outside width of the body, and the length is greater than the width.

Abstract: A brake piston is described. The brake piston is configured for use in a disk brake system, the piston comprising: a body having an outside width perpendicular to a central axis; a footing disposed at a distal end of the piston; wherein the footing is configured to exert force on a brake pad during actuation of the disk brake system; the footing having a face configured to contact the brake pad, the face having a length and a width, wherein the length is longer than the outside width of the body, and the length is greater than the width.

Abstract: Brake systems and methods of their operation are disclosed, including a brake system comprising: a rotor comprising: a hub configured for attachment to a vehicle; and a first and a second contact surfaces; and a web connecting the first and second contact surfaces to the hub; a first and a second brake pad located adjacent to the respective first and second contact surfaces of the brake rotor, wherein the first and the second brake pads are configured to press on the respective first and second contact surfaces during operation of the brake system; a first brake piston configured to push the first brake pad against the first contact surface of the rotor during operation of the brake system; wherein upon operation of the brake system in a first operation mode, the first piston moves the second contact surface toward the second piston by deflection of the rotor at the web.

Abstract: Brake calipers, molds and method of producing brake calipers are disclosed including a brake caliper mold for molding a brake caliper, the brake caliper mold comprising: a first mold section; a second section half; a core member configured to form a piston bore, the core member comprising: a tower configured to form a tower window in a bridge of the brake caliper and a piston bore extension to form a piston bore of the brake caliper; and four locator forming surfaces located on the tower, each of the four locator forming surfaces configured to form a separate lateral data reference surface on the brake caliper, the lateral data reference surfaces capable of being used for subsequent machining of the brake caliper to predetermined tolerances.

Abstract: Brake systems and methods of their operation are disclosed, including a brake system comprising: a rotor comprising: a hub configured for attachment to a vehicle; and a first and a second contact surfaces; and a web connecting the first and second contact surfaces to the hub; a first and a second brake pad located adjacent to the respective first and second contact surfaces of the brake rotor, wherein the first and the second brake pads are configured to press on the respective first and second contact surfaces during operation of the brake system; a first brake piston configured to push the first brake pad against the first contact surface of the rotor during operation of the brake system; wherein upon operation of the brake system in a first operation mode, the first piston moves the second contact surface toward the second piston by deflection of the rotor at the web.

Abstract: A brake piston assembly is described. The brake piston assembly includes a brake piston, the brake piston comprising: a front face and a back surface, the front face opposite the back surface and the front face configured to exert pressure on a brake pad; a cavity extending into the brake piston from the rear surface; and a projection located within a cavity of the brake piston at a position intermediate the front face and the rear surface; a brake piston nut receivable into the cavity; and a flexible retainer, the flexible retainer located in a groove in an outer wall of the brake piston nut; wherein, when the piston nut is fully inserted into the cavity, the flexible retainer will be located between the projection and the front face.

Abstract: A brake clip is described. The brake clip can include a U-shaped body; a clip channel; and a return spring, wherein the clip channel is defined by: a clip base comprising a stop tab; a pad tensioner; and the channel side tab; wherein, the clip base is connected to the pad tensioner and the channel side tab to form a channel; the return spring is connected to the clip channel at a rotor side edge of the clip channel and extends over the clip base; the clip channel is configured to fit into a channel on the brake pad carrier and to receive a brake pad; and the stop tab extends into the clip channel and is configured to press on a brake pad backing plate when a portion of the brake pad backing plate is located in the clip channel.

Abstract: A brake piston is described. The brake piston is configured for use in a disk brake system, the piston comprising: a body having an outside width perpendicular to a central axis; a footing disposed at a distal end of the piston; wherein the footing is configured to exert force on a brake pad during actuation of the disk brake system; the footing having a face configured to contact the brake pad, the face having a length and a width, wherein the length is longer than the outside width of the body, and the length is greater than the width.

Abstract: A brake piston assembly is described. The brake piston assembly includes a brake piston, the brake piston comprising: a front face and a back surface, the front face opposite the back surface and the front face configured to exert pressure on a brake pad; a cavity extending into the brake piston from the rear surface; and a projection located within a cavity of the brake piston at a position intermediate the front face and the rear surface; a brake piston nut receivable into the cavity; and a flexible retainer, the flexible retainer located in a groove in an outer wall of the brake piston nut; wherein, when the piston nut is fully inserted into the cavity, the flexible retainer will be located between the projection and the front face.

Abstract: A disk brake piston having a spindle nut, and a load bearing column within a piston body. The load bearing column includes a footing configured to push against a brake pad and a core extending from the metal footing and slidably located within the piston body, wherein the spindle nut is configured to contact and push the metal core which pushes the metal footing which pushes on the brake pad.