Delphi Technologies, Inc.

Federal-mogul Technology Limited

Bwi Company Limited S.a.

Delphi Technology, Inc.

Kenneth James Bunker

John David Holme

Hans Fischer

Peter Gareth Denton

Stephen Roy Orton

Alan Jeffory Phillips

Method and apparatus for controlling the front and rear wheel braking system of a road-going mass-produced motor car or automobile enables provision of brake-by-wire facilities utilizing an electrically-powered servo motor to generate brake-operating thrust which is applied to the interleaved friction elements and twin discs of a disc brake having axially slideable discs and a fixed caliper and disc and friction element-attitude control structure. The brake is of spot-type disc brake construction and the servo motor applies less brake-actuating thrust than is required for a comparable fixed disc and floating caliper construction.

Method and apparatus for controlling a braking system

A hub support () by which a wheel-supporting hub () may be supported for rotation relative to an axis (). The hub support () comprises a one-piece metal casting, the casting comprising mounting means () by which the hub support () may be mounted on a vehicle, and support means for a hub (). The support () also forms part of or a mounting for operating means () by which friction material pads () of a disc brake () are brought into force-applying engagement with one or more discs () mounted on the hub (). Said one-piece metal casting also comprises a guide () on which at least one of said friction material pads () may be mounted for movement relative to the axis ().

Hub support

A spot-type automotive disc brake ( ) provides parking brake and primary brake functions based on the same pair of friction elements ( ) and without resorting to supplemental drums or supplemental friction elements. The mechanism is simple and can be made at a size applicable to small mass produced vehicles. A sliding disc ( ) has fixed ( ) and actuated ( ) friction elements at its opposite sides. A piston ( ) and an external bifurcated lever mechanism ( ) act completely independently yet symmetrically on the actuated friction element ( ) without any common thrust-transmitting parts, whereby the asymmetry and complexity and consequential unreliability and high cost and duplication of mechanisms of prior proposals is avoided.

Spot type disc brake with parking brake function

A disc brake system ( ) comprises a disc ( ), and a hub ( ) which is arranged to rotate about an axis ( ) thereof. The system ( ) also comprises a mounting arrangement ( ) by which the disc ( ) is mounted on the hub ( ) so that the hub and the disc rotate as a unit about the axis ( ) and the disc can perform axial sliding movement on said hub. The mounting arrangement comprises a plurality of axially-extending grooves ( ) formed in the hub ( ) and teeth ( ) projecting from the disc ( ) into the grooves. The system ( ) also comprises springs ( ) located in at least some of the grooves ( ) and engaging the teeth ( ) acting to apply radial force between the disc ( ) and the hub ( ).

Multiple disc brake system

An axially, slidable brake disc system employs leaf springs between a hub of a suspension casting or knuckle to float the brake discs for axial sliding movement, while holding the discs against wobbling, and employs brake pads which are biased by springs to float on a stationary bridge so that the contact between the brake pads and discs is a light random contact thereby resulting in reduced residual torque drag and disc thickness variation. The rotating brake discs will shift axially, slightly from the braking position to the off-brake position with the brake pads urged by their spring forces to keep their pad faces parallel to and slightly spaced from adjacent brake disc surfaces to prevent corner engagement and localized rubbing contact thereby reducing pad wear, residual drag torque and disc thickness variation. The brake force applicator may be mounted at a 12:00 position and in an integral bore in the suspension knuckle to reduce the size, weight, and space envelope of the braking system. Less braking pressure is needed with two brake discs and four brake pads and the system will pass the AMS fade test.

Slidable brake disc system

A disc brake system comprising a disc, and a hub which is arranged to rotate about an axis thereof. The system also comprises a mounting arrangement by which the disc is mounted on the hub so that the hub and the disc rotate as a unit about the axis and the disc can perform axial sliding movement on the hub. The system also comprises a plurality of leaf springs mounted on the hub and engaging the disc so that the springs apply radially-directed forces between the disc and the hub. Each of the springs comprises at least three abutments which project transversely of the spring and engage the disc so that the abutments apply forces to the disc.

A disc brake ( ) comprises a disc ( ), friction material pads ( ) arranged on opposite sides of the disc, and an operating mechanism ( ) operable to bring the pads into contact with the disc so that the pads apply a braking force to the disc. The brake ( ) also comprises a slideway ( ) on which at least one of the pads ( ) is suported for sliding movement towards or away from the disc ( ). The slideway ( ) is formed by a guidance member ( ) which defines at least two parallel grooves ( ) in a surface ( ) of the guidance member. The grooves ( ) extend parallel to the direction of the slideway ( ). The guidance member ( ) is supported by parallel rods ( ) which are received in the grooves ( ).

Disc brake

A disc brake system ( ) comprises a disc ( ), and a hub ( ) which is arranged to rotate about an axis ( ) thereof. The hub ( ) comprises a mounting portion ( ) which is generally in the shape of a hollow cylinder. The system ( ) also comprises grooves ( ) and teeth ( ) by which the disc ( ) is mounted on the external surface of the mounting portion ( ) for rotation with the hub ( ) as a unit about the axis ( ) and the disc ( ) can perform axial sliding movement on the hub. The hub ( ) carries vanes ( ) arranged so that, during rotation of the hub ( ) about the axis ( ), the vanes act to force air into the interior of the mounting portion ( ). The mounting portion ( ) has openings ( ) therethrough arranged so that air forced into the interior of the mounting portion ( ) passes through the openings and flows over said disc ( ).

Disc brake system

A brake system ( ) comprises a disc brake ( ) and a drum brake ( ), and a hub ( ). The hub ( ) comprises a mounting portion ( ) generally having the shape of a hollow cylinder. The disc brake ( ) comprises a disc ( ) mounted on our outer surface of said portion ( ) of the hub for rotation with the hub, the disc ( ) also being mounted for axial sliding movement on the hub ( ). The drum brake ( ) comprises frictional material shoes ( ) which are moveable into engagement with an internal cylindrical surface ( ) of said mounting portion ( ) of the hub ( ) to act as a parking brake.

Multiple disk brake system with integrated parking brake

A disc brake ( ) comprising at least two discs ( ), and a hub ( ) which is arranged to rotate about an axis ( ) thereof. The system ( ) also comprises mounting arrangement ( ) by which the discs ( ) are mounted on the hub ( ) so that the hub and the discs rotate as a unit about the axis ( ) and the discs can perform axial sliding movement on the hub. The system ( ) also comprises a plurality of leaf springs ( ) mounted on the hub ( ) and engaging the discs ( ) so that the springs apply force between the discs and the hub. The leaf springs ( ) are arranged in groups, one spring in each group acting on each disc, at least one spring in each group being retained in position by a connection ( ) to another spring in the group.

Leaf spring for a disc brake

An ABS brake system employs two axially slidable brake discs and four brake pads that are biased to have floating light random contact therebetween in the off brake position. The ABS controller operates the brake pads with about one half of the usual brake pressure and about double the number of the usual braking and release cycles. The floating axially slidable brake discs and four brake pads have reduced residual torque drag during the brake release cycle and have reduced hystersis. The result is operation at a higher frequency and with less amplitude, than the usual sliding caliper and fixed brake system, and a resolution of a modulating scale for cycling that is usually associated with a much lower coefficient of friction surface than is actually present.

Disc brake system with ABS

A disc brake system comprises a hub and a disc. The hub is mounted for rotation about a central rotational axis and the disc is mounted on the hub to rotate therewith. The disc is slidable on the hub in a direction which is parallel to said central rotational axis. The system also comprises a plurality of leaf springs which are mounted between the hub and the disc, the leaf springs acting to apply radially-directed forces to the disc. The leaf springs are arranged so that they extend tangentially of the hub when the disc is not mounted on the hub but are deformed by the presence of the disc.

A disc brake comprises an operating mechanism operable to move friction material pads into contact with a disc. The operating mechanism comprises a support body located on one side of the disc, a cylinder defined by the support body, and a piston in the cylinder. The operating mechanism also comprises a guidance member for the pads. The guidance member projects from the support body past the disc and supports an abutment on which one of said pads is mounted. The guidance member is mounted on the support body by means of a plurality of bolts which extend through bores in the guidance member to said abutment. The bolts take the load during application of the brake.

A method of manufacturing a brake pad comprising casting a back plate in a mould. The plate is formed with at least one integral projection which overhangs an adjacent surface of the plate. The mould is formed from frangible material and has a recess in the shape of the projection. The mould is formed from particulate material compressed around a projection made of resilient material which deforms to the shape of the projection. The resilient material is withdrawn to form the recess. Metal is cast in the mould including the recess. After solidification of the metal, the mould is broken away from the projection. The method also comprises pressing a mixture containing friction material and curable material against the plate including pressing the mixture around the projection so that it extends beneath the overhang and curing the curable material to form a block of friction material adhered to the plate.

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Rearsby, United Kingdom

Kenneth James Bunker