Abstract: A disc brake for a vehicle axle includes a brake rotor, a brake caliper that straddles the brake rotor, a wheel hub, and a plurality of brake rotor mounting elements that couple the brake rotor to the wheel hub. The brake rotor includes a friction ring portion and a rotor mounting portion radially inward of the friction ring portion. The rotor mounting portion is formed on a radially inner circumference of the brake rotor, and includes a plurality of splines extending radially inward toward an axis of rotation of the brake rotor and a radially inward extending axial motion limiting feature disposed between each adjacent pair of the plurality of splines.

Abstract: An arrangement for mounting a brake disc to an axle hub of a vehicle is provided. The arrangement includes mounting rings and may include bushing blocks interposed between an axle hub and a brake disc in a manner that permits transfer of braking forces from the brake disc to the axle hub while minimizing heat transfer from the disc to the hub.

Abstract: A disc brake for a vehicle axle includes a brake rotor, a brake caliper that straddles the brake rotor, a wheel hub, and a plurality of brake rotor mounting elements that couple the brake rotor to the wheel hub. The brake rotor includes a friction ring portion and a rotor mounting portion radially inward of the friction ring portion. The rotor mounting portion is formed on a radially inner circumference of the brake rotor, and includes a plurality of splines extending radially inward toward an axis of rotation of the brake rotor and a radially inward extending axial motion limiting feature disposed between each adjacent pair of the plurality of splines.

Abstract: A system and method are provided for mounting, removing and retaining brake pads in disc brakes, such as air-operated disc brakes utilized on commercial vehicles, in a manner which does not require the use of separate brake pad retaining devices while providing positive retention of the brake pad. A preferred embodiment includes a brake caliper mount having brake pad abutment surfaces having radially-oriented and lateral grooves which permit a brake pad with corresponding projections on is lateral sides to be inserted through an opening of the brake caliper into the radially-oriented grooves until the backing plate projections are aligned with the lateral groove, and advancing the brake actuator behind the brake pad to place the brake pad in an operating position in which the actuator prevents the brake pad from realigning with the radially-oriented grooves until the actuator is retracted to permit brake pad extraction.

Abstract: A brake assembly includes a brake, an actuator, and an automatic slack adjuster for adjusting the clearance between the brake shoes and the brake drum. The actuator includes a housing, a piston moveably disposed in the housing, a yoke disposed outside of the housing, and a pushrod extending through the housing. The pushrod is connected to the piston, and an end portion of the pushrod forms a rivet that attaches the yoke to the end portion of the pushrod.

Abstract: A power spring arrangement of a spring-type brake actuator for a vehicle brake, in which the actuator's power spring is located between the service brake actuator and parking brake release actuator, and the power spring comprises a plurality of concentric springs. The power spring is captured between the actuator's intermediate flange and a spring retainer. The use of two or more concentric springs allows higher parking brake actuator force to be generated than with a standard single power spring, without the need to enlarge the actuator housing or to use more costly spring materials or spring configurations.

Abstract: A slack adjuster for a vehicle drum brake includes a pinion that rotates about a worm axis whenever the slack adjuster pivots. Excess clearance is taken up upon commencement of the apply stroke, at an accelerated rate. This enables a larger amount of initial clearance to be built into the brake.

Abstract: A pressure-energized seal for a spring-type brake actuator for a vehicle brake, in which the actuator's power spring is located between the service brake actuator and parking brake release actuator. The power spring is captured between the actuator's intermediate flange and a spring retainer. In order to prevent pressure leakage past the spring retainer into a power spring cavity, a pressure-energized seal is located between the plate and the housing. The seal member, which is carried by the spring plate or the housing, has a pressure-receiving section with resilient outer portions, which are deflected by pressure in the service chamber into firm contact with the spring plate and the actuator housing interior wall, increasing the sealing force between the seal and both the plate and the housing. The pressure-energized seal provides improved seal performance with a seal which is easy to inspect and/or replace, highly reliable, and relatively inexpensive.

Abstract: An improved seal/bearing arrangement employs an O-ring type seal which has segmented fingers. The seal ring has a recess which is sized to mate with a corresponding projecting lug of a bore use, for example, in brake actuator mechanisms. The seal ring can be made from synthetics such as polyamides and polyethylenes. The fingers are so arranged that locking of the seal rings in the bore occurs with insertion of a sliding, oscillating and/or rotating shaft or the like through the rings.

Abstract: A pneumatically- or electrically-actuated disk brake, in particular a pneumatic disk brake for commercial vehicles, in which a mounting frame which supports the brake caliper, and a torque plate which secures the mounting plate to the a vehicle axle, are arranged such that the fasteners securing the mounting frame to the torque plate are oriented in at least one plane that is essentially perpendicular to a longitudinal axis of the axle. Compared to previous disk brakes with longitudinally-oriented fasteners, this arrangement results in a lighter, stronger, simpler, less expensive, and more easily serviced disk brake by eliminating excess material, eliminating offset of the mounting hole portion of the torque plate to clear an axle flange, minimizing or eliminating a need to rotate the brake assembly away from an optimal position about the axle in order to clear adjacent vehicle components, and places the fastener heads in more readily accessible locations.

Abstract: A spring-type brake actuator for a pneumatically-operated vehicle brake is provided, with a brake actuator spring located on a front side of the actuator's intermediate flange, between a service brake actuator and a parking brake release actuator. The spring is captured between the intermediate flange and a retaining plate which is connected to the parking brake release actuator via a shaft through the intermediate flange. Because the retaining plate and parking brake release actuator are connected to one another on opposite sides of the intermediate flange, spring expansion is checked, thereby increasing safety during actuator production and servicing by virtually eliminating the potential for uncontrolled spring energy release. The actuator configuration also reduces structural loads on the rear portion of the housing and shifts spring and housing weight closer to the vehicle brake, permitting simpler designs and use of alternative materials, such as plastic or aluminum to lower costs.

Abstract: When a disc brake is mounted on an axle, particularly an air disc brake on the axle of a commercial vehicle, there is a possibility that an incompatible wheel may be installed. When such a wheel then rotates, interference between wheel and disc brake components may occur, such as a wheel valve stem striking the brake caliper. Equipment damage and tire deflation may result. In order to preclude such brake-wheel interference, a disc brake shield device is interposed between the disc brake and the wheel. When an incompatible wheel is installed over the shield device, the valve stem is deflected away from the brake components. The shield device may further be provided with vanes to circulate cooling air, and may include recesses to minimize valve stem deflection and cut-away portions to enhance brake inspection and maintenance, as long as contact with brake components continues to be precluded.

Abstract: For an air-operated disc brake there is provided an internal brake actuator stroke indicator which provides an indication, readily ascertained from outside the brake caliper, of the amount of actuator stroke remaining in a disc brake apparatus before a remaining available actuator stroke limit is reached. In one embodiment, the stroke indicator is a mechanical device, readable through a sight glass in a caliper port, coupled to the brake actuator in a manner which results in rotary motion of the indicator when the brake actuator is displaced through its stroke. Alternatively, the indicator may be a rotary sensor such as an electrical potentiometer coupled to the actuator, where the potentiometer sends an electrical signal indicative of the actuator stroke to an external display, such as a remote actuator stroke display at a vehicle operator's position.

Abstract: A disc brake for a vehicle such as a commercial vehicle, wherein the brake rotor extends from a hub end of an axle inboard a sufficient distance to place the friction surface of the rotor and the brake caliper outside the envelope of a wheel mounted at the end of the axle. The placement of the rotor friction surface and the caliper outside the envelope of the wheel enhances brake cooling, makes the brake more readily accessible for inspection and maintenance without significant vehicle disassembly, and permits the rotor outer diameter to be extended beyond the diameter of the wheel rim, thereby lowering brake components stresses and permitting use of lighter, lower cost brake components.

Abstract: A brake disc for a vehicle which, when the brake disc is located on a hub end of a vehicle axle, places the friction portion of the brake disc closer to the center of the axle than a rim of a vehicle wheel mounted on the axle hub, such that the friction portion of the brake disc is outside of the wheel envelope. The friction surface of the brake disc located in this manner may have a greater radius than the inner wheel radius, thereby permitting increased braking torque to be generated, and is exposed to the cooling environment outside the wheel rim envelope. Heat transfer from the friction portion to the hub end of the vehicle axle may be inhibited by ring-shaped reduced-thickness sections, which may also serve as flexible hinges that permit the brake disc to flex to accommodate asymmetric loading by a brake caliper.