Thermally compensating cast-in-place torsion joint with improved axial stiffness

Patent metadata

Field	Value
Publication number	US-9316276-B2
Application number	US-201314107432-A
Country	US
Kind code	B2
Filing date	Dec 16, 2013
Priority date	Dec 16, 2013
Publication date	Apr 19, 2016
Grant date	Apr 19, 2016

Abstract

A number of variations may include a brake disc may include a hub portion and a cheek portion. The hub portion may include a receiving flange for mechanically engaging the cheek portion. The cheek portion may include an upper cheek and a lower cheek connected and separated by a web, and an inner flange extending radially inward from the upper cheek to mechanically engage and communicate with the receiving flange of the hub portion such that the hub portion and the cheek portion form a single brake disc. The inner flange may include a at least one spline tooth circumferentially arranged around the inner flange and constructed and arranged to facilitate the mechanical engagement of the receiving flange and the inner flange.

First claim

What is claimed is:

1. A product comprising:
a hub portion and a cheek portion;
the hub portion comprising a receiving flange;
the cheek portion comprising an upper cheek and a lower cheek connected and separated by a web;
the cheek portion comprising an inner flange extending radially inward from the upper cheek and being constructed and arranged to mechanically engage and communicate with the receiving flange of the hub portion such that the hub portion and the cheek portion are be a single part; and
the inner flange comprising at least one spline tooth constructed and arranged to facilitate the mechanical engagement of the receiving flange and the inner flange and wherein the at least one spline tooth and the inner flange gradually converge in thickness as the inner flange and the at least one spline tooth extend radially inward from the cheek portion and wherein a portion of the inner flange located between adjacent spline teeth are radially shorter in length than the adjacent spline teeth.

2. A product as set forth in claim 1 :
wherein the upper cheek portion comprises a first working surface and the lower cheek portion comprises a second working surface, the second working surface facing the opposite direction of the first working surface.

3. A product as set forth in claim 1 :
wherein one or more spline teeth are arranged symmetrically around the circumference of the inner flange and wherein a portion of the inner flange is adjacent to each individual spline tooth.

4. A product as set forth in claim 1 :
wherein the thickest portion of the at least one spline tooth is thicker than the thickness of the upper cheek portion such that a portion of each individual spline tooth extends a distance above the working surface of the upper cheek portion.

5. A product as set forth in claim 1 :
wherein the hub portion comprises a receiving flange which comprises an upper flange and a lower flange and wherein the receiving flange is constructed and arranged to engage the inner flange of the cheek portion.

6. A product as set forth in claim 1 :
wherein the receiving flange defines a gap between the receiving flange and the inner flange of the cheek portion at an inner circumference of the inner flange and the at least one spline tooth.

7. A method comprising:
providing a cheek portion;
the cheek portion comprising an upper cheek, a lower cheek, and a webbing;
the upper cheek comprising an inner flange extending radially inward from the upper cheek;
placing the cheek portion within a mold;
casting a hub portion around the cheek portion;
forming an upper flange and a lower flange as a part of the hub portion;
forming a gap located at the interface of the inner flange of the cheek portion and the receiving flange of the brake hub;
the inner flange being constructed and arranged to engage the receiving flange of hub portion wherein the upper flange engages an upper surface of the inner flange and the lower flange engages a lower surface of the inner flange such that the brake hub and the cheek portion are connected.

8. A method as set forth in claim 7 :
wherein the hub portion comprises a at least one of integral columns disposed between the upper flange and lower flange and wherein the upper flange, lower flange, and integral columns define at least one void.

9. A method as set forth in claim 7 :
wherein the inner flange of the cheek portion comprises at least one spline tooth arranged symmetrically around the circumference of the inner flange and wherein adjacent to each individual spline tooth is a portion of the inner flange.

10. A method as set forth in claim 7 :
wherein a portion of the inner flange located between individual spline teeth is radially shorter in length than the adjacent spline teeth.

11. A method as set forth in claim 7 :
wherein the thickest portion of the at least one spline tooth is thicker than the thickness of the upper cheek portion such that a portion of each individual spline tooth extends a distance above the upper cheek portion.

12. A method as set forth in claim 7 further including:
post-processing the inner flange such that the at least one spline tooth extends radially inward farther than the inner flange.

13. A method as set forth in claim 7 further including:
prior to casting a hub portion, coating the at least one spline tooth with a ceramic or non-wetting coating or similar material to prevent intermetallic bonding between the cheek portion and a second molten material subsequently added to the cavity.

14. A product comprising:
a cheek portion comprising an upper cheek, a lower cheek, and webbing;
the webbing being disposed between the upper cheek and the lower cheek;
the upper cheek comprising an upper working surface, and the lower cheek comprising a lower working surface;
the cheek portion also comprising an inner flange extending radially inward from an inner circumference of the upper cheek and ending at an inner flange inner circumference;
the inner flange comprising one or more spline teeth arranged circumferentially around the inner flange, extending from the inner flange inner circumference to the inner circumference of the upper cheek and wherein the one or more spline teeth extend radially inward farther than the inner flange;
the one or more spline teeth being thicker than the thickness of the inner flange and being constructed and arranged to be a raised ridge on the inner flange;
the thickness of both the inner flange and the one or more spline teeth gradually converging as the inner flange and the one or more spline teeth extend inward from the inner circumference of the upper cheek;
a hub portion connected to the inner flange and one or more spline teeth;
the hub portion comprising a receiving flange comprising an upper flange and a lower flange;
the receiving flange being constructed and arranged to both overly and underlie the inner flange and one or more spline teeth such that a gap exists between the inner flange and the receiving flange at the interface of the hub portion and the cheek portion.

15. A product as set forth in claim 14 :
wherein the one or more spline teeth comprise a ceramic coating or similar material to prevent intermetallic bonding between the cheek portion and the hub portion.

Assignees

• Gm Global Tech Operations Inc

Inventors

• Kleber Richard M
• Warzecha Tomasz
• Pepescu Silviu A
• Riefe Mark T

Classifications

• F16D2065/1388

  to shaft or axle · CPC title

• F16D2065/1376

  inner circumference · CPC title

• F16D65/123 Primary

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

• B22D19/0081

  pretreatment of the insert, e.g. for enhancing the bonding between insert and surrounding cast metal · CPC title

• F16D2065/1328

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