Abstract: A disc brake is provided with a modified outer brake pad to brake flange contact area. The modified contact area leaves a substantial portion of the outer brake pad unsupported leading to reduced outer diameter/inner diameter radial taper wear of the brake pad.

Abstract: A disc brake is provided with a modified outer brake pad to brake flange contact area. The modified contact area leaves a substantial portion of the outer brake pad unsupported leading to reduced outer diameter/inner diameter radial taper wear of the brake pad.

Abstract: A massive, stiff disc brake rotor is provided which is modified by providing cuts through part or all of the rotor section having the friction braking surfaces. In a preferred embodiment, the cut has an interlocking conformation so that there is less potential for radial distortion of the disc under heavy centrifugal loads. The cut allows the rotor to vibrate axially while interrupting the propagation and amplification of circumferential waves, letting the rotor act more like a diametral spring instead of a bell. Depending on rotor inertia and braking forces to be applied, the cut can extend axially through parts of the rotors, or only partially through one or more rotor parts.

Abstract: The disc brake caliper housing is fully mounted on, supported and retained by the brake shoes of the brake pad assemblies. All brake torque forces are transmitted from the shoes to the fixed mounting bracket. The caliper housing is subjected only to axially clamping forces. In one embodiment no bolts or pins are required to support the caliper assembly, including the brake pad assemblies, on the mounting bracket. In another embodiment an uncomplicated roll pin arrangement supports and retains the shoes and the caliper housing on the mounting bracket.

Abstract: One-piece mounting pins are threaded into a caliper housing flange and guided in mounting bracket receiving holes having relatively large clearances between the hole diameters and the pin diameters. Rubber bushings formed as parts of protective boots, are installed at the hole entrances minimize free movement of the caliper housing subassembly on the mounting bracket. One pin may be removed and the caliper housing rotated on the other pin to provide access for removing shoe and lining assemblies.

Abstract: A short master cylinder uses solenoids to control the master cylinder compensating and bypass functions. The pressurizing pistons each use only one seal. There is a unitary primary piston and booster output push rod. The booster power piston return spring returns the primary piston and, through a lost motion interconnection, the secondary piston, omitting the secondary piston spring. Brake pedal travel and pressure sensors control the solenoid valves, reducing lost brake pedal travel.

Abstract: A short master cylinder assembly having a transversely disposed compensation and bypass port controlled by a check valve. The check valve is cammed to the open position by a pressurizing piston, and is closed by spring action upon movement of the pressurizing piston in the pressure actuating direction.

Abstract: The brake pedal force is amplified by an electric motor acting through a gear set which converts rotary motion and torque from the motor into linear motion and force to energize the master cylinder piston. The push rod forces are sensed, amplified, reduced and modulated by electronic means. The electric motor disengages from the gear set at rest or if there is an electrical failure, so that there is a manual mode of operation available when necessary.

Abstract: The mechanism provides a disc brake assembly with zero drag when released. It controls the retractive movements of the caliper housing and the actuating piston, relying on predetermined dimensional and mechanical properties for functional repeatability. It uses friction rings and spring washers.

Abstract: A semi-metallic lining is attached to one side of a disc brake shoe. A ceramic heat barrier is attached to the other side of the shoe. A rubber compound is attached to the heat barrier on the side opposite the shoe and a second shoe is attached to the rubber compound. An additional rubber compound is on the opposite side of the second shoe. The caliper piston rests on the additional rubber compound. The rubber compounds have high energy absorbing, vibration damping characteristics. They are heat resistant, ozone resistant, brake fluid resistant, oil resistant, must have low displacement and must be firm. Shoe mounting pins fit loosely through holes in the first shoe and heat barrier and tightly through holes in the second shoe. The loose fit through the first shoe eliminates a possible noise path from the lining through the first shoe and the pins into the caliper. The pins retain the entire shoe and lining assembly within the caliper.

Abstract: A disc brake caliper having a piston housing, preferably made of aluminum, cast on a U-shaped stamped steel bridge. The bridge is formed from an H-shaped flat blank with the legs being bent to obtain the desired U-shaped cross section. The piston housing encompasses one pair of legs on one side of the bridge.