Disc Brake Assembly With Non-Rotatable Vehicle Component and Method For Producing Same

A disc brake assembly comprising:

• an anchor bracket having a pair of arms interconnected by at least one tie bar, each of the arms including a first non-threaded opening formed in a first portion thereof and a second threaded opening formed in a second portion thereof;
• a caliper supported on the anchor bracket by first fasteners which are configured to be installed in the caliper and be disposed in the first non-threaded openings of the anchor bracket;
• and
• a non-rotatable vehicle component having a pair of lugs, each of the lugs provided with a third non-threaded opening formed therethrough, the third non-threaded openings configured to receive second threaded fasteners therein which are installed in the second threaded openings of the anchor bracket to secure the non-rotatable vehicle component to the anchor bracket;
• wherein the anchor bracket includes on at least one of the arms a first shoulder at a transition between the first and second portions thereof;
• wherein the non-rotatable vehicle component includes on at least one of the lugs a second shoulder having a shape which is generally complimentary to the shape of the first shoulder of the at least one arm of the anchor bracket such that when the non-rotatable vehicle component and anchor bracket are secured together by the second threaded fasteners selected surfaces of the first and second shoulders contact each other to substantially prevent movement of the anchor bracket relative to the non-rotatable vehicle component;
• wherein the second openings in the anchor bracket define a first axis and the third non-threaded openings in the non-rotatable vehicle component define a second axis which is offset relative to the first axis;
• wherein at least one of the second threaded fasteners includes a conical shaped surface, at least one of the third non-threaded openings of the non-rotatable vehicle component includes a conical shaped surface, wherein the conical shaped surface of the at least one of the third non-threaded openings of the non-rotatable vehicle component is configured to be at least partially contacted by the conical shaped surface of the at least one of the second threaded fasteners.

A method comprising the steps of:

• (a) providing an anchor bracket having a pair of arms, each of the arms including a first non-threaded opening formed in a first portion thereof and a second threaded opening formed in a second portion thereof;
• (b) supporting a caliper on the anchor bracket by first fasteners which are configured to be installed in the caliper and be disposed in the first non-threaded openings of the anchor bracket;
• and
• (c) securing the anchor bracket to a non-rotatable vehicle component having a pair of lugs by second fasteners, wherein each of the lugs is provided with a third non-threaded opening formed therethrough, the third non-threaded openings configured to receive second fasteners therein which are installed in the second threaded openings of the anchor bracket to secure the non-rotatable vehicle component to the anchor bracket, wherein the anchor bracket includes on at least one of the arms a first shoulder at a transition between the first and second portions thereof, and wherein the non-rotatable vehicle component includes on at least one of the lugs a second shoulder having a shape which is generally complimentary to the shape of the first shoulder of the at least one arm of the anchor bracket such that when the non-rotatable vehicle component and anchor bracket are secured together by the second fasteners selected surfaces of the first and second shoulders contact each other to substantially prevent movement of the anchor bracket relative to the non-rotatable vehicle component.