Anchor bracket for use in a disc brake assembly, disc brake assembly including such an anchor bracket and method for producing such an anchor bracket

1. A method for producing an anchor bracket for use in a disc brake assembly, the method comprising the steps of:

providing an anchor bracket in an as-cast condition, the anchor bracket in the as-cast condition having:

first and second arms;

a first window through the first arm;

a first notch in the first arm;

a second window through the second arm;

a second notch in the second arm;

material connecting the first window to the first notch and connecting the second window to the second notch; and

at least one tie rod connecting the first and second arms; and

machining a first rotor channel in the first arm by removing the material connecting the first window to the first notch; and

machining a second rotor channel in the second arm by removing the material connecting the second window to the second notch.

2. The method of claim 1 further comprising:

machining first and second guide rails in the first arm and third and fourth guide rails in the second arm, wherein the machining of the first, second, third, and fourth guide rails is localized by the first and second windows.

3. The method of claim 2 wherein the first rotor channel is machined to divide the first and second guide rails and the second rotor channel is machined to divide the third and fourth guide rails.

4. The method of claim 2 wherein the first arm has first and second shoulder portions and the first and second guide rails are machined between the first and second shoulders and the second arm has third and fourth shoulder portions and the third and fourth guide rails are machined between the third and fourth shoulders.

5. The method of claim 4 wherein the first shoulder portion is stepped back from the second shoulder portion and the third shoulder portion is stepped back from the fourth shoulder portion.

6. The method of claim 4 wherein the first rotor channel is machined through the first and second shoulder portions and the second rotor channel is machined through the third and fourth shoulder portions.

7. The method of claim 2 wherein the first, second, third, and fourth guide rails are c-shaped recesses.

8. The method of claim 2 further comprising:

mounting a first brake shoe on the first and third guide rails;

mounting a second brake shoe on the second and fourth guide rails;

securing guide pins to a brake caliper;

machining mounting holes in the anchor bracket;

machining guide pin holes in the anchor bracket; and

inserting the guide pins in the guide pin holes.

9. The method of claim 8 further comprising:

mounting an actuator on the brake caliper.

10. The method of claim 1 further comprising:

a first perimeter around the first window, wherein the first perimeter is fully bordered by the first arm before machining of the first window; and

a second perimeter around the second window, wherein the second perimeter is fully bordered by the second arm before machining of the second window.

11. The method of claim 1 wherein the first and second guide rails are coaxial and the third and fourth guide rails are coaxial.

12. The method of claim 1 further comprising:

machining a first guide pin hole and a first mounting hole in the first arm;

machining a second guide pin hole and a second mounting hole in the second arm.

13. The method of claim 1 further comprising:

machining first and second guide rails in the first arm and third and fourth guide rails in the second arm, wherein the machining of the first, second, third, and fourth guide rails is localized by the first and second windows.

14. The method of claim 13 wherein the first rotor channel is machined to divide the first and second guide rails and the second rotor channel is machined to divide the third and fourth guide rails.

15. The method of claim 13 wherein the first arm has first and second shoulder portions and the first and second guide rails are machined between the first and second shoulders and the second arm has third and fourth shoulder portions and the third and fourth guide rails are machined between the third and fourth shoulders.

16. A method for producing an anchor bracket for use in a disc brake assembly, the method comprising the steps of:

providing an anchor bracket in an as-cast condition, the anchor bracket in the as-cast condition having:

first and second arms;

a first window through the first arm;

a second window through the second arm;

material connecting the first window to an opened lower end of the first arm and connecting the second window to an opened lower end of the second arm;

at least one tie rod connecting the first and second arms; and

machining a first rotor channel in the first arm by removing the material connecting the first window to the opened lower end of the first arm; and

machining a second rotor channel in the second arm by removing the material connecting the second window to the opened lower end of the second arm.