Pot-shaped composite brake rotor for motor vehicles

Patent metadata

Field	Value
Publication number	US-11885384-B2
Application number	US-202017421849-A
Country	US
Kind code	B2
Filing date	Jan 9, 2020
Priority date	Jan 11, 2019
Publication date	Jan 30, 2024
Grant date	Jan 30, 2024

Abstract

A pot-shaped composite brake rotor for motor vehicles, which combines at least one securing component as a hub interface with at least one friction ring component (as a friction partner for at least one friction lining. Distinction is made between a torque transmission function a fixing function between the paired components by the provision of a heat-conductive joint interface between the components on one side. The components are assembled coaxially with one another and joined rotationally fixedly in the axial direction so that the securing component serves as a heat sink for the friction ring component. At least one fixing element between the components is provided separately, and this fixing element substantially exclusively (nominal load) performs a fixing function by mutual form fit by a radially directed engagement behind at least one undercut. A press-fit connection s present for torque transmission between the securing component and the friction ring component.

First claim

The invention claimed is:

1. A manufacturing method for a pot-shaped composite brake rotor comprising:
forming at least one fixing element on a securing component;
defining a deformation zone on one of the at least one fixing element and a friction ring component;
defining a cavity on the other of the at least one fixing element and the friction ring component;
engaging a press-fit connection between the securing component and the friction ring component by axially moving at least one of the securing component and the friction ring component, wherein the press-fit connection rotationally fixes the securing component and the friction ring component to one another;
joining the securing component and the friction ring component with the at least one fixing element by forming the at least one fixing element in the deformation zone subsequent to engaging the press-fit connection;
one of: a pressing and a rolling process by one of: forcing a tool in a working chamber in a direction of a rotationally driven workpiece and forcing the workpiece in the direction of the tool; and
in the working chamber:
rotating the workpiece about a centrally arranged rotational axis parallel to the axial direction of the friction component and securing component for rotational movement;
mounting the tool in the working chamber to be movably guided in all directions; and
arranging the tool with defined spatial angle relative to the workpiece and physically orientable relative to the rotational axis.

2. The manufacturing method for a pot-shaped composite brake rotor as claimed in claim 1 , controlling the working chamber, tool and workpiece movements electronically with microprocessor, such that the working chamber, tool and workpiece movements are regulated with at least one of a given cycle time and cycle frequency.

3. The manufacturing method for a pot-shaped composite brake rotor as claimed in claim 2 , controlling the working chamber, tool and workpiece movements are matched to one another.

4. The manufacturing method for a pot-shaped composite brake rotor as claimed in claim 3 , controlling the working chamber, tool and workpiece movements further comprises regulating mutual synchrony by at least one of a given cycle time and cycle frequency.

5. The manufacturing method for a pot-shaped composite brake rotor as claimed in claim 1 , wherein engaging the press-fit connection further comprises pressing at least one of the securing component and the friction ring component axially relative to one another to achieve a mutual axial overlap; and wherein joining the securing component and the friction ring component further comprises directing a deformation of the at least one fixing element in the deformation zone transversely to the axial direction to form a form-fit connection between the at least one fixing element and a joined undercut.

6. The manufacturing method for a pot-shaped composite brake rotor as claimed in claim 1 , wherein defining the at least one deformation zone further comprises defining a plurality of deformation zones which one of: run a periphery of the at least one fixing element, run a periphery of the friction ring, run a periphery of the at least one fixing element and are offset relative to one another, run a periphery of the friction ring and are offset relative to one another.

7. The manufacturing method for a pot-shaped composite brake rotor as claimed in claim 1 , wherein the forming is a cold-forming process.

8. The manufacturing method for a pot-shaped composite brake rotor as claimed in claim 1 , wherein the tool is one of: a punch, a pressing tool, and a rolling tool.

9. The manufacturing method for a pot-shaped composite brake rotor as claimed in claim 1 , wherein the forming further comprises the tool acting on at least one of the friction ring component and the securing components with a defined oriented working movement and a defined forming force.

10. The manufacturing method for a pot-shaped composite brake rotor as claimed in claim 1 , wherein during the forming the tool is mounted fixedly in the working chamber and wherein the workpiece is guided in an advance movement with a defined force in coordination of the workpiece.

11. The manufacturing method for a pot-shaped composite brake rotor as claimed in claim 1 , further comprising forming in the deformation zone in the radial direction is at least one of: from radially inward to radially outward on the composite brake rotor; and from radially outward to radially inward on the composite brake rotor.

12. A brake rotor comprising:
a hub interface comprising:
an axially directed retaining collar formed at a periphery of the hub interface; and
a circumferential ring protrusion formed in axial extension at the periphery of the hub interface on an end face of the hub interface; and

a friction ring, the friction ring comprising:
a joint configured to form a press-fit connection with the end face of the hub interface;
a stop arranged at an interior end of the joint, the stop configured to provide a form-fit stop against the axially directed retaining collar; and
a groove arranged at an exterior end of the joint, the groove configured to receive the circumferential ring protrusion fixed within the groove.

Assignees

• Continental Teves Ag & Co Ohg

Inventors

• Bach Uwe
• Metzen Hans-Peter
• Sefo Ahmed
• Hoffmann Jens
• Rüffer Manfred

Classifications

• F16D65/10 Primary

  Drums for externally- or internally-engaging brakes · CPC title

• F16D65/827

  with open cooling system, e.g. cooled by air · CPC title

• F16D2065/136

  with relative movement radially · CPC title

• F16D2065/1316

  radially segmented · CPC title

• F16D2065/1328

  internal cavities, e.g. cooling channels · CPC title