Abstract: An electro-hydraulic brake assembly comprises a hydraulic control unit (HCU) body having a top surface and a bottom surface opposite the top surface and defining a master cylinder bore and a pressure supply bore. A fluid reservoir is disposed on the top surface. A primary piston is slidably disposed in the master cylinder bore and configured to supply brake fluid to a wheel brake in response to pressing of a brake pedal. A pressure supply unit includes: a pressure supply piston disposed within the pressure supply bore; a motor located on the bottom surface of the HCU body and having a motor shaft. An actuator mechanism includes a threaded shaft configured to be rotated by the motor shaft, and a nut coupled to the pressure supply piston, together causing the pressure supply piston to translate linearly through the pressure supply bore in response to rotation of the motor shaft.

Abstract: An electro-hydraulic brake assembly comprises a hydraulic control unit (HCU) body having a top surface and a bottom surface opposite the top surface and defining a master cylinder bore and a pressure supply bore. A fluid reservoir is disposed on the top surface. A primary piston is slidably disposed in the master cylinder bore and configured to supply brake fluid to a wheel brake in response to pressing of a brake pedal. A pressure supply unit includes: a pressure supply piston disposed within the pressure supply bore; a motor located on the bottom surface of the HCU body and having a motor shaft. An actuator mechanism includes a threaded shaft configured to be rotated by the motor shaft, and a nut coupled to the pressure supply piston, together causing the pressure supply piston to translate linearly through the pressure supply bore in response to rotation of the motor shaft.

Abstract: The invention provides a multi-disc brake for a vehicle. A knuckle supports a wheel of a vehicle. A hub is mounted for rotation on the knuckle about a rotation axis. A pair of discs are mounted for rotation with the hub and for sliding movement on the hub along the rotation axis. Each of the discs includes respective inboard and outboard engaging surfaces. Brake pad assemblies are disposed about the discs to engage the engaging surfaces. The brake pad assemblies slide along the rotation axis relative to the hub. A brake fist having a bridge portion extends outboard from the knuckle around the discs and the brake pad assemblies to an outboard wall supporting the outboard brake pad assembly against outboard movement along the rotation axis. An actuator urges the discs and the brake pad assemblies together against the outboard wall to slow rotation of the hub.

Abstract: A brake rotor assembly for a dual brake disc braking system includes an annular ring having a plurality of teeth. The teeth are disposed radially about a central axis of the annular ring, and extend inward toward the central axis. The teeth are for slideably engaging a hub (wheel end) having a plurality of channels. The annular ring includes a plurality of pins extending outwardly from the annular ring. A friction disc is disposed radially about the annular ring, and is in interlocking engagement with the plurality of pins. The annular ring and the plurality of teeth are integrally cast from a high strength corrosion resistant material having a tensile strength greater than 260 megapascals to resist fracture during high stress braking conditions and high thermal loads. The friction disc is cast around the annular ring from a grey cast iron.

Abstract: A brake rotor assembly for a dual brake disc braking system includes an annular ring having a plurality of teeth. The teeth are disposed radially about a central axis of the annular ring, and extend inward toward the central axis. The teeth are for slideably engaging a hub (wheel end) having a plurality of channels. The annular ring includes a plurality of pins extending outwardly from the annular ring. A friction disc is disposed radially about the annular ring, and is in interlocking engagement with the plurality of pins. The annular ring and the plurality of teeth are integrally cast from a high strength corrosion resistant material having a tensile strength greater than 260 megapascals to resist fracture during high stress braking conditions and high thermal loads. The friction disc is cast around the annular ring from a grey cast iron.

Abstract: A MR fluid formulation based upon a silicone liquid vehicle thickened with a treated fumed metal oxide and doped with one or more chemicals having hydrogen-bonding capability for use with natural rubber mounts. The MR fluid is resistant to settling of the magnetizable particles upon contact of the fluid with natural rubber. In one exemplary embodiment, the doping chemical is one or a combination of propylene glycol and a bifunctional ethoxylated amine.

Abstract: A hydraulic mount is provided having a body with first and second fluid chambers and a decoupler subassembly interposed between to partially define the first and second fluid chambers. The decoupler subassembly comprises first and second flexible decoupler members operatively sealed together to form a third fluid chamber. The first and second chambers may be substantially filled with a magneto-rheological fluid. The third chamber may be filled with a standard hydraulic fluid, like glycol.

Abstract: A magneto-rheological damping device comprises a core element for carrying a magnetic flux and a magnetic flux generator positioned adjacent to a portion of the core element and operable to generate a magnetic flux in the core element. A sleeve is positioned over the core element and magnetic flux generator and includes a plurality of protrusions extending generally radially outwardly from a center of the core element. A flux ring surrounds the core element and sleeve and defining a passage between flux ring and core element for the flow of a magneto-rheological fluid. The sleeve protrusions are configured to engage the flux ring and secure the flux ring in a concentric position around the core element and sleeve.

Abstract: A vehicle suspension damper assembly is provided which includes a cup member with a threaded opening formed therein. A piston rod includes a threaded portion, which is engaged in the threaded opening. An electrical connector including a terminal portion is received in an opening formed in the piston rod. The threaded engagement between the piston rod and the cup member is a predetermined length that reduces deflection of the cup member to reduce transfer of load to the terminal portion of the electrical connector.

Abstract: A magneto-rheological damping device comprises a core element for carrying a magnetic flux and a magnetic flux generator positioned adjacent to a portion of the core element and operable to generate a magnetic flux in the core element. A sleeve is positioned over the core element and magnetic flux generator and includes a plurality of protrusions extending generally radially outwardly from a center of the core element. A flux ring surrounds the core element and sleeve and defining a passage between flux ring and core element for the flow of a magneto-rheological fluid. The sleeve protrusions are configured to engage the flux ring and secure the flux ring in a concentric position around the core element and sleeve.

Abstract: A vehicle suspension damper assembly is provided which includes a cup member with a threaded opening formed therein. A piston rod includes a threaded portion, which is engaged in the threaded opening. An electrical connector including a terminal portion is received in an opening formed in the piston rod. The threaded engagement between the piston rod and the cup member is a predetermined length that reduces deflection of the cup member to reduce transfer of load to the terminal portion of the electrical connector.

Abstract: An improved magnetorheological fluid damper is provided which effectively provides a smooth transition, without a sharp break in the damper force/velocity curve, between very low damping forces near zero damper velocity to higher damping forces at higher piston velocities while maintaining desirable maximum force levels. The damper includes a piston assembly, including a magnet assembly and a flow gap extending through the piston assembly to permit fluid flow between the chambers. The force/velocity optimization feature includes a groove or passage open to the flow gap, positioned in series with a part of the flow gap in a magnetic circuit generated by the magnet assembly and dimensioned/sized to permit fluid flowing the passage to experience a magnetorheological effect less than a magnetorheological effect experienced by fluid flowing through the flow gap but not through the groove. Preferably, the passage is formed in an inner annular surface of a flux ring positioned around a piston core.