U.S. patent application number 15/972682 was filed with the patent office on 2018-09-06 for vehicle brake rotor and method of making same.
The applicant listed for this patent is GRI Engineering & Development, LLC. Invention is credited to Edgar CALAGO, Mingxu ZHOU.
Application Number | 20180252282 15/972682 |
Document ID | / |
Family ID | 57937695 |
Filed Date | 2018-09-06 |
United States Patent
Application |
20180252282 |
Kind Code |
A1 |
ZHOU; Mingxu ; et
al. |
September 6, 2018 |
VEHICLE BRAKE ROTOR AND METHOD OF MAKING SAME
Abstract
A vehicle brake rotor is provided, including manufacturing a
friction ring with an opening, an annular flange projecting axially
relative to a face of the friction ring, and a plurality of spaced
lugs projecting radially from the flange. A hub is manufactured
with a plurality of recesses integrally upon the friction ring.
Next, the hub is manufactured or machined so that outermost ends of
the lugs are visible from an exterior of the hub.
Inventors: |
ZHOU; Mingxu; (Buffalo
Grove, IL) ; CALAGO; Edgar; (Lake Villa, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GRI Engineering & Development, LLC |
Long Grove |
IL |
US |
|
|
Family ID: |
57937695 |
Appl. No.: |
15/972682 |
Filed: |
May 7, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14817833 |
Aug 4, 2015 |
9982732 |
|
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15972682 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F16D 2065/1312 20130101;
F16D 2065/1328 20130101; B22D 19/04 20130101; F16D 2065/1348
20130101; B22D 19/16 20130101; F16D 2200/0013 20130101; F16D 65/123
20130101; F16D 2200/0026 20130101 |
International
Class: |
F16D 65/12 20060101
F16D065/12; B22D 19/04 20060101 B22D019/04; B22D 19/16 20060101
B22D019/16 |
Claims
1. A vehicle brake rotor, comprising: a friction ring with an
opening, an annular flange projecting axially relative to a face of
the friction ring that defines the opening, and a plurality of
spaced lugs projecting radially from the flange; and, a hub with a
plurality of recesses matingly engaging said lugs and an endcap
covering said opening integrally joined to said friction ring,
wherein one of said annular flange and said hub includes an annular
groove radially spaced from the lugs and surrounded by the other of
said annular flange and said hub and the annular groove matingly
engaging an annular tongue in the other of said annular flange and
said hub, wherein outermost ends of said lugs are visible from an
exterior of said hub, and, wherein the outermost ends of said lugs
do not extend radially beyond the hub.
2. The vehicle brake rotor of claim 1, wherein the friction ring is
made of gray iron.
3. The vehicle brake rotor of claim 1, wherein the hub is made of
aluminum.
4. The vehicle brake rotor of claim 1, wherein said hub is
integrally joined to said friction ring by embed casting.
5. The vehicle brake rotor of claim 4, wherein said hub is provided
with an endcap covering said opening.
6. The vehicle brake rotor of claim 5, wherein the hub is made of
aluminum
7. The vehicle brake rotor of claim 1, wherein the outermost ends
of the lugs are visible from an exterior of said hub after
manufacturing said hub is made by machining said hub, and said ends
are circular.
8. The vehicle brake rotor of claim 1, wherein said hub is
manufactured on said friction ring so that said outermost ends of
the lugs are not visible from an exterior of said hub friction
ring, and then said hub is manufactured on said friction ring so
that said outermost ends of the lugs are visible from an exterior
of said hub.
9. The vehicle brake rotor of claim 1, wherein the lugs of the
friction ring are concentric with the recesses on the hub and are
spaced equidistantly.
10. A vehicle brake rotor obtained by a process comprising:
manufacturing a friction ring with an opening, an annular flange
projecting axially relative to a face of the friction ring, and a
plurality of spaced lugs projecting radially from the flange;
manufacturing a hub with a plurality of recesses upon said friction
ring, joining said hub integrally to said friction ring so that
outermost ends of said lugs are not visible from an exterior of
said hub; and manufacturing said hub on said friction ring so that
outermost ends of said lugs are visible from an exterior of said
hub to form the vehicle brake rotor, wherein said vehicle brake
rotor comprises: one of said annular flange and said hub including
an annular groove radially spaced from the lugs and surrounded by
the other of said annular flange and said hub and the annular
groove matingly engaging an annular tongue in the other of said
annular flange and said hub and, wherein the outermost ends of said
lugs do not extend radially beyond the hub.
11. The vehicle brake rotor of claim 10, wherein the friction ring
is made of gray iron.
12. The vehicle brake rotor of claim 10, wherein the hub is made of
aluminum.
13. The vehicle brake rotor of claim 10, wherein said hub is
integrally joined to said friction ring by embed casting.
14. The vehicle brake rotor of claim 10, wherein said hub is
provided with an endcap covering said opening.
15. The vehicle brake rotor of claim 10, wherein manufacturing said
hub until said outermost ends of said lugs are visible from an
exterior of said hub occurs by machining said hub.
16. The vehicle brake rotor of claim 15, wherein the hub is made of
aluminum
17. The vehicle brake rotor of claim 10, wherein the outermost ends
of the lugs are visible from an exterior of said hub after
manufacturing said hub is made by machining said hub, and said ends
are circular.
18. The vehicle brake rotor of claim 10, wherein the lugs of the
friction ring are concentric with the recesses on the hub, and are
spaced equidistantly.
19. The vehicle brake rotor of claim 10, wherein the hub is made of
aluminum and wherein said hub is integrally joined to said friction
ring by embed casting.
20. The vehicle brake rotor of claim 19, wherein manufacturing said
hub until said outermost ends of said lugs are visible from an
exterior of said hub occurs by machining said hub.
Description
RELATED APPLICATIONS
[0001] This application is a continuation of and claims priority to
U.S. patent application Ser. No. 14/817,833 filed on Aug. 4, 2015,
the entirety of which is incorporated herein by reference.
BACKGROUND
[0002] The invention generally relates to vehicle brakes, and more
specifically to an improved vehicle brake rotor, and a process for
making same.
[0003] Vehicle brake rotors are known and typically include a
friction ring or disc to which is fastened a hub used to connect
the ring to a vehicle wheel. As is well known, friction rings have
opposing friction surfaces for engagement by brake pads mounted in
vehicle calipers such that each of two pads engage a corresponding
surface of the friction ring under driver control to stop the
vehicle. The friction ring of the vehicle brake rotor rotates about
a central axis, coincident with the rotational axis of the wheel to
which it is attached.
[0004] To reduce vehicle brake rotor weight, and improve the
vehicle brake rotor's heat dissipation efficiency, brake rotors
made of two materials have become both more popular and common,
particularly among high-end vehicles. Friction rings are typically
cast from a ferrous material, such as cast or grey iron. The
friction rings are then machined in multiple operations to shape
the rotor and form an inner mounting section and the friction
surfaces. The friction surfaces of the rotor are also machined to a
predetermined tolerance range.
[0005] The hub of a vehicle brake rotor is typically cast from
metallic materials such as aluminum. A conventional hub further
includes a centrally located bore, and a plurality of equally
spaced fastener mounting holes formed circumferentially in a
mounting surface around the bore. Hubs are connected to the disc
body, usually with a plurality of fasteners such as rivets, or
threaded fasteners, such as screws. By connecting the hub to the
friction ring, fasteners keep the hub and friction ring together.
As a result, fasteners aid in movement of the vehicle brake
rotor.
[0006] To accurately assemble the brake rotors made of two
materials, complicated equipment is needed. Due to the high level
of skill needed to operate such complicated equipment, the costs of
manufacturing the two material vehicle brake rotor with fasteners
are high.
[0007] Another drawback of conventional bi-metallic brake rotors is
that a hub made of lighter materials has a higher expansion rate
than the friction ring made of cast iron. When the vehicle brake
rotor undergoes high temperature conditions, expansion of the hub
and the friction ring will occur. Such expansion will further occur
when the vehicle brake rotor and friction rings engage. There is a
concern that multi-component brake rotors will be subject to
shorter operational life due to the different expansion and
contraction properties of the materials used in production. Thus,
there is a need for an improved technique for manufacturing vehicle
brake rotors.
SUMMARY
[0008] The above-listed needs and drawbacks are addressed by an
improved vehicle brake rotor designed to be constructed so that the
friction ring and the hub are connected to each other without
fasteners. Vehicle brake rotors made according to the present
process are simpler and less expensive to manufacture. Further,
vehicle brake rotors without fasteners are more reliable, and have
a longer lifespan, because the possibilities of the fasteners
touching the friction ring are reduced. A method for making the
brake rotor without fasteners, and a brake rotor made by such a
process are thus disclosed as a solution to the problems described
above.
[0009] The process works by first manufacturing a friction ring
conventionally made of gray iron, or other heavy metal. In a
preferred embodiment, there are two of the manufactured friction
rings, each having an edge and a face, and being connected by
conventional materials used to join two friction rings. One of the
faces of the friction rings has an annular flange projecting
axially relative to the face of the friction ring. On an exterior
surface of the annular flange, a preferably equally distributed
plurality of spaced lugs project radially from the annular flange.
An interior surface of the annular flange has an interior groove or
flat surface.
[0010] The present brake rotor features the hub being integrally
joined to the friction ring. The friction ring is placed into a
cavity corresponding of an embed casting mold. Once this is
accomplished, a molten material conventional in embed casting, such
as aluminum, is poured into the cavity, and covers the lugs and the
flange of the friction ring. As the molten aluminum cools, the hub
is formed and is integrally joined to the friction ring. Once this
is accomplished, the positive and negative chambers of the embed
casting mold are removed, and the combined friction ring and hub
are withdrawn from the mold. Next, an exterior peripheral edge of
the hub is manufactured or machined, such that outermost ends of
lugs on the annular flange are visible.
[0011] More specifically, a method of making a vehicle brake rotor
is provided, including, manufacturing a friction ring with an
opening, an annular flange projecting axially relative to a face of
the friction ring, and a plurality of spaced lugs projecting
radially from the flange. A hub is manufactured with a plurality of
recesses integrally upon the friction ring. Next, the hub is
manufactured or machined so that outermost ends of the lugs are
visible from an exterior of the hub.
[0012] In another embodiment, a vehicle brake rotor is provided,
including a friction ring with an opening, an annular flange
projecting axially relative to a face of the friction ring that
defines the opening and a plurality of spaced lugs projecting
radially from the flange. A hub is provided with a plurality of
recesses matingly engaging the lugs, an endcap covering the opening
of the hub, and the hub is integrally joined to the friction ring.
After machining or manufacturing the hub, outermost ends of the
lugs of the brake rotor are visible from an exterior of the
hub.
[0013] In yet another embodiment, a vehicle brake rotor
manufactured by a process is provided, including the steps of
manufacturing a friction ring with an opening, an annular flange
projecting axially relative to a face of the friction ring, and a
plurality of spaced lugs projecting radially from the flange.
Manufacturing a hub with a plurality of recesses upon the friction
ring, each recess engaging a corresponding lug, and joining the hub
integrally to the friction ring. The hub is then machined or
manufactured so that outermost ends of the lugs are visible.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a front perspective view of an assembled friction
ring, and a hub forming the present vehicle brake rotor;
[0015] FIG. 2 is a vertical cross-section taken along the line 2-2
of FIG. 1 and in the direction generally indicated;
[0016] FIG. 3 is an exploded front perspective view of the present
friction ring and the hub before the friction ring and hub are
integrally joined;
[0017] FIG. 4 is a front perspective of the present vehicle brake
rotor with the hub integrally formed upon the friction ring,
preferably via embed casting;
[0018] FIG. 5 is a vertical cross-section taken along the line 5-5
of FIG. 4 and in the direction generally designated;
[0019] FIG. 6 is a vertical cross-section of an embed casting mold
used to make the present vehicle brake rotor;
[0020] FIG. 7 is a vertical cross-section of another embodiment of
the present vehicle brake rotor; and
[0021] FIG. 8 is a vertical cross-section of still another
embodiment of the present vehicle brake rotor.
DETAILED DESCRIPTION
[0022] Referring now to FIGS. 1-3, the present vehicle brake rotor,
generally designated 10, is configured to be mounted to a vehicle
wheel, not shown. As is known in the art, the rotational axis of
the vehicle brake rotor 10 is coincident with the rotational axis
of the wheel to which it is attached.
[0023] The present vehicle brake rotor 10 has a friction ring 12.
In the preferred embodiment, the friction ring 12 is made of gray
iron, or other suitable metals, alloys or other materials used in
conventional friction rings. The friction ring 12 is also made up
of a pair of generally parallel plates 12a and 12b, each having an
edge 14, and a face 16. Joining the friction rings 12a and 12b is a
plurality of connectors 18. On the face 16 of the friction ring 12a
are an axially projecting annular flange 20, and an opening 22 of
the friction ring defined by the annular flange 20. Projecting
radially from the axially projecting annular flange 20 is a
plurality of lugs 24. The annular flange 20 also includes an
interior wall 26. A hub 28 is integrally joined to the flange 20,
preferably by embed casting. In the preferred embodiment, the hub
is composed of aluminum or other metals. On top of the hub 28 is an
endcap 30.
[0024] Casting the hub 28 upon the friction ring 12 produces a
plurality of recesses 32, which matingly engage the lugs 24
projecting radially from the annular flange 20. The hub 28 also
engages the annular flange 20 via an interior groove 34. The lugs
24 are concentric with the recesses 32 on hub 28, and are
preferably spaced equidistantly. While in the preferred embodiment
the lugs 24 are generally cylindrical in shape, other shapes are
contemplated, including various polygonal shapes (when viewed in
transverse cross-section). As seen in FIG. 3, after the hub 28 is
cast, the lugs 24 are completely covered by the hub.
[0025] The rotor 10 is mounted to the vehicle wheel using mounting
holes 36 in the endcap 30, and a central opening 38 engages an axle
shaft (not shown). The vehicle brake rotor 10 is mounted to a wheel
of, for example, an automotive vehicle on the inboard side of the
wheel, with respect to the assembled vehicle, for stopping the
rotation of the wheel in operation of the vehicle. Conventionally,
four such vehicle brake rotors 10 are used on a vehicle, one with
each of the four wheels. However, some older vehicles are equipped
with only two front disk brakes, the rear brakes being
drum-type.
[0026] Referring now to FIGS. 4 and 5, the vehicle brake rotor 10
is shown integrally joined to the friction ring 12 before the hub
28 is manufactured or machined. In this application, "manufactured"
will be understood to refer to any of a variety of fabricating
steps commonly known to skilled practitioners, including casting,
grinding, fastening, or the like. As the hub 28 is joined
integrally to the friction ring 12 the endcap 30 on the hub
partially covers the opening 22. As seen in FIG. 3, the lugs 24 are
completely covered by the hub 28.
[0027] Referring now to FIG. 6, in the preferred embodiment of the
present vehicle brake rotor 10, the friction ring 12 and the hub 28
are integrally joined by embed casting, using a mold generally
designated 40, including two mating portions 40a, 40b as is well
known in the art. Once the friction ring 12 is cast and suitably
machined, it is placed into a corresponding cavity 42 of the mold
40. A molten material 44, typically aluminum, or another suitable
alloy, is then poured into a chamber 46 of the embed casting mold
40. As the molten material 44 flows down the chamber 46, it forms
the hub 28, The high temperatures of the molten material 44 cause
the friction ring 12 to expand, and interior groove 34 of the hub
matingly engages the flange 20. Also, the lugs 24 matingly engage
the recesses 32, located in a skirt 48 of the hub 28.
[0028] After the molten material 44 cools, the friction ring 12 and
the hub 28 are integrally joined to each other, and the lugs 24 are
matingly received in the recesses 32. After cooling, the joined hub
28 and friction ring is then machined so that outermost ends 50 of
the lugs 24 are visible from an exterior of the rotor 10 (FIGS. 1
and 2). While in the preferred embodiment, the ends 50 are
circular, other shapes are contemplated, depending on the
cross-sectional geometry of the lugs 24 as discussed above.
[0029] Referring now to FIG. 7, an alternate embodiment of the
present vehicle brake rotor 10 is generally designated 60.
Components shared with the rotor 10 are designated with identical
reference numbers. A major difference between the rotor 60 and the
rotor 10 is that the flange 20 is provided with an annular groove
62 which matingly engages a corresponding annular tongue 64 in the
hub 28.
[0030] Referring now to FIG. 8, another alternate embodiment of the
present vehicle brake rotor 10 is generally designated 70.
Components shared with the rotors 10 and 60 are designated with
identical reference numbers. A main feature of the rotor 70 is that
the annular flange 20 is provided with an outermost flat surface 72
that engages a corresponding flat surface 74 on the hub 28.
[0031] While a particular embodiment of the vehicle brake rotor and
method of making same has been described herein, it will be
appreciated by those skilled in the art that changes, and
modifications may be made thereto without departing from the
invention in its broader aspects and as set forth in the following
claims.
* * * * *