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: Some embodiments are directed to a duct assembly for cooling a brake assembly of a vehicle. The duct assembly can include a hollow inlet section that is disposed at the vehicle sub-frame and configured to capture air from beneath the vehicle sub-frame; and a hollow intermediate section that communicates with the inlet section so as to form a contiguous channel therewith. The intermediate section can be disposed entirely within the vehicle sub-frame. A hollow outlet section can communicate with the intermediate section so as to form a contiguous channel between the inlet, intermediate and outlet sections. The outlet section can be disposed and configured to direct the air captured by the inlet section to the front end of the brake assembly to thereby cool at least a portion of the brake assembly.

Abstract: Some embodiments are directed to a duct assembly for cooling a brake assembly of a vehicle. The duct assembly can include a hollow inlet section that is disposed at the vehicle sub-frame and configured to capture air from beneath the vehicle sub-frame; and a hollow intermediate section that communicates with the inlet section so as to form a contiguous channel therewith. The intermediate section can be disposed entirely within the vehicle sub-frame. A hollow outlet section can communicate with the intermediate section so as to form a contiguous channel between the inlet, intermediate and outlet sections. The outlet section can be disposed and configured to direct the air captured by the inlet section to the front end of the brake assembly to thereby cool at least a portion of the brake assembly.

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 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 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 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.