Abstract: This invention relates to a pad spring for use in a disc brake assembly. According to one embodiment of the present invention, the disc brake assembly comprises an anchor bracket adapted to be secured to a vehicle component; a brake caliper adapted to be secured to the anchor bracket; an inboard friction pad and an outboard friction pad carried by the disc brake assembly and adapted to be disposed on opposite axial sides of an associated brake rotor; actuation means for selectively moving the inboard and outboard friction pads into frictional engagement with the rotor; and a pad spring carried by at least one end of one of the friction pads for moving the friction pads from engagement with the rotor when the actuation means is released; wherein the pad spring includes a first portion for applying a first retraction force and a second portion for applying a second retraction force which is different from the first retraction force.

Abstract: This invention relates to an improved brake shoe assembly and a disc brake assembly including such a brake shoe assembly. The disc brake assembly includes an anchor bracket adapted to be secured to a vehicle component; a brake caliper adapted to be secured to the anchor bracket; an inboard brake shoe and an outboard brake shoe carried by the disc brake assembly and adapted to be disposed on opposite axial sides of an associated brake rotor, each of the brake shoes including a pair of opposed ends; actuation means for selectively moving the shoes into frictional engagement with the rotor; and a first clip carried by at least one of the opposed ends of one of the brake shoes to thereby urge the one of the brake shoes against a trailing end of the anchor bracket to prevent caliper rotation when the disc brake assembly is actuated.

Abstract: This invention relates to a pad spring for use in a disc brake assembly. According to one embodiment of the present invention, the disc brake assembly comprises an anchor bracket adapted to be secured to a vehicle component; a brake caliper adapted to be secured to the anchor bracket; an inboard friction pad and an outboard friction pad carried by the disc brake assembly and adapted to be disposed on opposite axial sides of an associated brake rotor; actuation means for selectively moving the inboard and outboard friction pads into frictional engagement with the rotor; and a pad spring carried by at least one end of one of the friction pads for moving the friction pads from engagement with the rotor when the actuation means is released; wherein the pad spring includes a first portion for applying a first retraction force and a second portion for applying a second retraction force which is different from the first retraction force.

Abstract: This invention relates to an improved pad retraction spring (30) adapted for use in a disc brake assembly. The disc brake assembly includes an anchor bracket (12) adapted to be secured to a vehicle component, a brake caliper (108) adapted to be secured to the anchor bracket, a pair of brake shoes (18, 20) carried by the disc brake assembly and adapted to be disposed on opposite axial sides of an associated brake rotor (106), and an actuation device for selectively moving the brake shoes into frictional engagement with the rotor. The anchor bracket includes a pair of outwardly extending arms (14, 16) and at least one of the arms has an opening (60) formed therethrough. The pad retraction spring is carried by the disc brake assembly and is operative to move the brake shoes from engagement with the rotor when the brake shoes are in a non-braking position. The pad retraction spring includes a central mounting portion (32) and a pair of outermost spring arms (38, 38′).

Abstract: The invention relates to a composite brake caliper and method for producing the same. The method for producing the composite brake caliper comprises the steps of: (a) providing a molding apparatus having at least a pair of mold sections, at least one of the pair of mold sections including at least one projection extending from a surface thereof; (b) providing at least one reinforced preform formed from at least a first material, the preform having at least one opening formed at least partially therein; (d) positioning the preform in the molding apparatus with the projection of the mold section extending into the opening of the preform so as to orient the preform in a predetermined position within the molding apparatus; and (e) casting a caliper body formed from a second material in situ therewith to produce the composite brake caliper.