Vehicle drum-in-hat disc brake assembly and method for producing same

Abstract

A vehicle drum-in-hat disc brake assembly comprises: a shield adapted to be secured to an axle flange; a drum brake portion carried by the shield; an abutment tower operatively disposed with the drum brake portion; and a caliper bracket assembly formed separate from the abutment tower and adapted to be secured to the axle flange; wherein at least one first fastener is provided for securing the abutment tower to the caliper bracket assembly and a plurality of second fasteners are provided for securing the caliper bracket assembly and the shield to the axle flange.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a portion of a first embodiment of a vehicle drum-in-hat disc brake assembly.

FIG. 2 is an exploded perspective view of selected components of the first embodiment of the vehicle drum-in-hat disc brake assembly illustrated in FIG. 1.

FIG. 3 is a view of selected components of the first embodiment of the vehicle drum-in-hat disc brake assembly illustrated in FIGS. 1 and 2 partially assembled.

FIG. 4 is a view of partially selected components of the first embodiment of the vehicle drum-in-hat disc brake assembly illustrated in FIGS. 1 and 2 partially assembled.

FIG. 5 is another view of the partially assembled components illustrated in FIG. 4.

FIG. 6 is a view in the direction of arrow 6-6 of a portion of the first embodiment of a vehicle drum-in-hat disc brake assembly illustrated in FIG. 1.

FIG. 7 illustrates an embodiment of a sequence of installation steps for producing the first embodiment of the vehicle drum-in-hat disc brake assembly illustrated in the above drawing figures.

FIG. 8A is an exploded perspective view of selected components of a second embodiment of a vehicle drum-in-hat disc brake assembly.

FIG. 8B is a perspective view of selected components of a third embodiment of a vehicle drum-in-hat disc brake assembly.

FIG. 9 is a perspective view of a portion of a fourth embodiment of a vehicle drum-in-hat disc brake assembly.

FIG. 10 is a perspective view of a selected component of the fourth embodiment of a vehicle drum-in-hat disc brake assembly illustrated in FIG. 9.

FIG. 11 is a perspective view of other selected components of the fourth embodiment of a vehicle drum-in-hat disc brake assembly illustrated in FIG. 9.

FIG. 12 is a view of selected components of the fourth embodiment of the vehicle drum-in-hat disc brake assembly illustrated in FIG. 9 partially assembled.

FIG. 13 is another view of selected components of the fourth embodiment of the vehicle drum-in-hat disc brake assembly illustrated in FIG. 9 partially assembled.

FIG. 14 is a perspective view of selected components for use in a fifth embodiment of a vehicle drum-in-hat disc brake assembly.

Claims

1. A vehicle drum-in-hat disc brake assembly comprising: a shield adapted to be secured to an axle flange;a drum brake portion carried by the shield;an abutment tower operatively disposed with the drum brake portion; anda caliper bracket assembly formed separate from the abutment tower and adapted to be secured to the axle flange;wherein at least one first fastener is provided for securing the abutment tower to the caliper bracket assembly and a plurality of second fasteners are provided for securing the caliper bracket assembly and the shield to the axle flange.

2. The vehicle drum-in-hat disc brake assembly of claim 1 wherein the abutment tower includes at least one threaded hole for receiving the at least one first fastener for securing the abutment tower to the caliper bracket assembly.

3. The vehicle drum-in-hat disc brake assembly of claim 1 wherein the abutment tower includes a pair of threaded holes and two first fasteners are provided for securing the abutment tower to the caliper bracket assembly.

4. The vehicle drum-in-hat disc brake assembly of claim 1 wherein the plurality of second fasteners extend through openings provided in the axle flange, openings provided in the caliper bracket, and openings provided in the shield and are received in nuts for securing the caliper bracket assembly and the shield to the axle flange.

5. The vehicle drum-in-hat disc brake assembly of claim 1 wherein the plurality of second fasteners include a first plurality of second fasteners which extend through openings provided in the caliper bracket, through openings provided in the axle flange, and are received in threaded openings provided in the abutment tower to secure the caliper bracket and the abutment tower to the axle flange, and a second plurality of second fasteners which extend through openings provided in the shield and are received in threaded openings provided in the axle flange to secure the shield to the axle flange.

6. The vehicle drum-in-hat disc brake assembly of claim 5 wherein the abutment tower includes a pair of arms, each arm having an extension having a reduced outer diameter and a threaded opening formed therethrough, the axle flange includes a pair of countersunk holes, and wherein the reduced outer diameter extensions are disposed in the countersunk holes.

7. The vehicle drum-in-hat disc brake assembly of claim 1 wherein the abutment tower includes a portion for attaching a wheel speed sensor.

8. The vehicle drum-in-hat disc brake assembly of claim 1 wherein the shield includes a protrusion for locating the abutment tower.

9. The vehicle drum-in-hat disc brake assembly of claim 1 wherein the shield includes a protrusion for locating the axle flange.

10. The vehicle drum-in-hat disc brake assembly of claim 1 wherein the caliper bracket assembly includes a slot and the abutment tower includes a key which is adapted to be guided in the slot to assist in the mating of the abutment tower to the caliper bracket assembly during assembly.

11. The vehicle drum-in-hat disc brake assembly of claim 1 wherein the shield includes a protrusion adapted to engage an outboard surface of the axle flange to provide a predetermined clearance therebetween for subsequent installation of the caliper bracket assembly.

12. The vehicle drum-in-hat disc brake assembly of claim 1 wherein the caliper bracket assembly includes a caliper bracket and a piston caliper assembly.

13. The vehicle drum-in-hat disc brake assembly of claim 12 wherein the caliper bracket is disposed on an inboard side of the axle flange.

14. The vehicle drum-in-hat disc brake assembly of claim 12 wherein the caliper bracket is disposed on an outboard side of the axle flange.

15. A method for producing a vehicle drum-in-hat disc brake assembly comprising the steps of: (a) providing an assembled drum brake assembly including a shield adapted to be secured to an axle flange of an axle, a drum brake portion carried by the shield, and an abutment tower operatively disposed with the drum brake portion;(b) providing a caliper bracket assembly formed separate from the abutment tower of the assembled drum brake assembly provided in step (a);(c) installing the assembled drum brake assembly on the axle;(d) installing a brake rotor on the axle;(e) installing the caliper bracket assembly on the axle;(f) providing at least one first fastener for securing the abutment tower to the caliper bracket assembly; and(g) providing a plurality of second fasteners for securing the caliper bracket assembly and the shield to the axle flange.

16. The method of claim 15 wherein the abutment tower includes at least one threaded hole for receiving the at least one first fastener for securing the abutment tower to the caliper bracket assembly.

17. The method of claim 15 wherein the abutment tower includes a pair of threaded holes and two first fasteners are provided for securing the abutment tower to the caliper bracket assembly.

18. The method of claim 15 wherein the plurality of second fasteners extend through openings provided in the axle flange, openings provided in the caliper bracket, and openings provided in the shield and are received in nuts for securing the caliper bracket assembly and the shield to the axle flange.

19. The method of claim 15 wherein the plurality of second fasteners include a first plurality of second fasteners which extend through openings provided in the caliper bracket, through openings provided in the axle flange, and are received in threaded openings provided in the abutment tower to secure the caliper bracket and the abutment tower to the axle flange, and a second plurality of second fasteners which extend through openings provided in the shield and are received in threaded openings provided in the axle flange to secure the shield to the axle flange.

20. The method of claim 15 wherein the abutment tower includes a pair of arms, each arm having an extension having a reduced outer diameter and a threaded opening formed therethrough, the axle flange includes a pair of countersunk holes, and wherein the reduced outer diameter extensions are disposed in the countersunk holes.

21. The method of claim 15 wherein the shield includes at least one protrusion for locating at least one of the abutment tower and the axle flange.

22. The method of claim 15 wherein the caliper bracket assembly includes a slot and the abutment tower includes a key which is adapted to be guided in the slot to assist in the mating of the abutment tower to the caliper bracket assembly during assembly.