Rotor assembly for a disc brake system

Patent metadata

Field	Value
Publication number	US-10920840-B2
Application number	US-201916288260-A
Country	US
Kind code	B2
Filing date	Feb 28, 2019
Priority date	Feb 28, 2019
Publication date	Feb 16, 2021
Grant date	Feb 16, 2021

Abstract

A rotor assembly for a disc brake system is provided with a central mounting section having a hub, a flange connected to a radially outer edge of the hub, and a first set of connection elements formed in or on the flange. The rotor assembly also includes an outer friction ring section including a radially inner flange and a second set of connection elements formed in or on the radially inner flange. The hub of the central mounting section is configured for connection to a wheel/axle of a vehicle. The outer friction ring section includes surfaces configured for contact with one or more brake pads of a caliper. Also, the first and second sets of connection elements are configured to be press fit together to connect the central mounting section with the outer friction ring section. The outer friction ring section may be implemented as attachable ring members.

First claim

What is claimed is:

1. A rotor assembly for a disc brake system, the rotor assembly comprising:
a central mounting section including a hub adapted to be connected to a wheel or axle of a vehicle, a flange connected to a radial outer edge of the hub, and a first set of connection elements formed in or on the flange; and
an outer friction ring section having friction surfaces adapted to make contact with one or more brake pads of a disc brake caliper, and including a radial inner flange and a second set of connection elements formed in or on the radial inner flange, the first set of connection elements of the central mounting section and the second set of connection elements of the outer friction ring section being configured to be press fit together to connect the central mounting section with the outer friction ring section;
wherein the outer friction ring section includes a first ring member including a third set of connection elements disposed radially outwards of the radial inner flange of the outer friction ring section and the first and second sets of connection elements and a second ring member including a fourth set of connection elements disposed radially outwards of the radial inner flange of the outer friction ring section and the first and second sets of connection elements, wherein the third and fourth sets of connection elements are configured to be press fit together to connect the first ring member with the second ring member.

2. The rotor assembly of claim 1 , wherein the first ring member is arranged substantially parallel with the second ring member.

3. The rotor assembly of claim 1 , wherein the first set of connection elements of the central mounting section include one or more openings, and wherein the second set of connection elements of the outer friction ring section includes one or more protruding inserts on one or more of the first and second ring members.

4. The rotor assembly of claim 3 , wherein, for connecting the outer friction ring section with the central mounting section, each of the one or more protruding inserts on the first ring member is press fit into a respective opening of the central mounting section from a first direction and each of the one or more protruding inserts on the second ring member is press fit into the respective opening of the central mounting section from a second direction opposite the first direction.

5. The rotor assembly of claim 3 , wherein each of the first and second ring members includes between 3 and 12 protruding inserts and the central mounting section includes between 3 and 12 openings.

6. The rotor assembly of claim 1 , wherein the third set of connection elements includes a plurality of projections and the fourth set of connection elements includes a plurality of stub receptacles, and wherein the projections are press fit into the stub receptacles to connect the first ring member with the second ring member.

7. The rotor assembly of claim 6 , wherein the projections extend from an axially inward surface of the first ring member facing the second ring member and the stub receptacles extend from an axially inward surface of the second ring member facing the first ring member.

8. The rotor assembly of claim 7 , wherein the length of the projections and stub receptacles define a separation distance between the axially inward surfaces of the first and second ring members to create a ventilation space between the first and second ring members.

9. The rotor assembly of claim 1 , wherein the central mounting section is press fit with one of the first and second ring members in a first connection operation and the central mounting section and the one of the first and second ring members are press fit with the other of the first and second ring members in a second connection operation.

10. The rotor assembly of claim 1 , wherein a material used to manufacture the outer friction ring section is different from a material used to manufacture the central mounting section.

11. The rotor assembly of claim 10 , wherein the outer friction ring section comprises one of grey iron, steel and a ceramic material and the central mounting section comprises a metal alloy.

12. The rotor assembly of claim 1 , wherein the flange of the central mounting section includes a non-circular outer edge and the radial inner flange of the outer friction ring section includes a non-circular inner edge corresponding to the non-circular outer edge of the flange of the central mounting section.

13. The rotor assembly of claim 1 , wherein the third and fourth sets of connection elements are arranged in multiple rows extending radially outwards from the radial inner flange of the outer friction ring section.

14. The rotor assembly of claim 1 , wherein the third and fourth sets of connection elements are arranged in multiple concentric rings extending radially outwards from the radial inner flange of the outer friction ring section.

15. A disc brake system of a vehicle, the disc brake system comprising:
a caliper assembly having a pair of deployable brake pads; and
a rotor assembly having friction surfaces adapted to engage the brake pads of the caliper assembly when deployed, the rotor assembly comprising:
a central mounting section including a hub adapted to be connected to a wheel or axle of the vehicle, a flange connected to a radial outer edge of the hub, and a plurality of openings formed in the flange;
a first ring member having a radial inner flange and a plurality of protruding inserts formed on the radial inner flange; and
a second ring member arranged substantially parallel with the first ring member, the second ring member having a radial inner flange and a plurality of protruding inserts formed on the radial inner flange;
wherein the protruding inserts of the first and second ring members are configured to be press fit into or disposed through the openings of the central mounting section to connect the central mounting section with the first and second ring members; and
wherein the first and second ring members include a plurality of projections and a plurality of stub receptacles, respectively, disposed radially outwards of the radial inner flanges of the first and second ring members and the associated protruding inserts, and wherein the projections are configured to be press fit into the stub receptacles to connect the first ring member with the second ring member.

16. The disc brake system of claim 15 , wherein, for connecting the first and second ring members with the central mounting section, the protruding inserts on the first ring member are press fit into the openings of the central mounting section from a first direction and the protruding inserts on the second ring member are press fit into the openings of the central mounting section from a second direction opposite of the first direction.

17. The disc brake system of claim 15 , wherein the projections extend from an axially inward surface of the first ring member facing the second ring member and the stub receptacles extend from an axially inward surface of the second ring member facing the first ring member.

18. The disc brake system of claim 17 , wherein the length of the projections and stub receptacles define a separation distance between the axially inward surfaces of the first and second ring members to create a ventilation space between the first and second ring members.

19. The disc brake system of claim 15 , wherein the central mounting section is press fit with the second ring member in a first connection operation and the central m

Assignees

• Volvo Car Corp

Inventors

• Jalkler Quintus

Classifications

• F16D65/123 Primary

  comprising an annular disc secured to a hub member; Discs characterised by means for mounting · CPC title

• F16D2065/1392

  Connection elements · CPC title

• F16D2065/1356

  interlocking · CPC title

• F16D55/22

  by clamping an axially-located rotating disc between movable braking members, e.g. movable brake discs or brake pads · CPC title

• F16D2065/132

  layered · CPC title