Brake disc assembly and method of construction

• US 20070284200A1
• Filed: 06/09/2006
• Published: 12/13/2007
• Est. Priority Date: 06/09/2006
• Status: Abandoned Application

• Current Assignee: Federal-Mogul Worldwide Incorporated (Apollo Global Management, Inc.)
• Original Assignee: Federal-Mogul Worldwide Incorporated (Apollo Global Management, Inc.)
• Inventors: Hampton, Keith
• Application Number:
  US11/450,728
• Publication Number:
  US 20070284200A1
• Time in Patent Office: Days
• US Class Current: 188/218.XL
• CPC Class Codes: F16D 2065/1328 internal cavities, e.g. cooling channels
• CPC Class Codes: F16D 2065/1348 resilient
• CPC Class Codes: F16D 2065/1368 with relative movement both radially and axially
• CPC Class Codes: F16D 65/123 comprising an annular disc secured to a hub member; Discs characterised by means for mounting

Abstract

A brake disc assembly comprises a rotor and a hat assembly. The hat assembly is comprised of two hat portions, each having a plurality of curved projections. The curved projections interact with radial recesses formed in the rotor to ensure a secure connection between the hat assembly and the rotor over a wide range of operating conditions.

Claims

1. A brake disc assembly, comprising:

a rotor, said rotor comprising an opening, said opening comprising a plurality of radial recesses, wherein each of said plurality of radial recesses comprises a first and second side portion, and

a hat assembly operably connected to said rotor, said hat assembly comprising a first hat portion and a second hat portion, each of said first and second hat portions comprising a bowl-shaped body portion, a hat opening, and a plurality of curved projections, each of said plurality of curved projections extending outwardly from said bowl-shaped body portion, wherein;

said first hat portion is arranged such that each of said curved projections of said first hat portion contact one of said first side portions,

said second hat portion is arranged such that each of said curved projections of said second hat portion contact one of said second side portions, and

said first hat portion is nested within said second hat portion.

2. The brake disc assembly of claim 1, wherein each of said plurality of curved projections of said first hat portion and said first side portions have the shape of an involute.

3. The brake disc assembly of claim 2, wherein said bowl-shaped body portion of said second hat portion comprises a top portion, said top portion being capable of restraining differential movement between said rotor and said hat assembly in an axial direction.

4. The brake disc assembly of claim 3, wherein each of said plurality of curved projections comprises a curled tab, said curled tabs being capable of restraining differential movement between said rotor and said hat assembly in an axial direction.

5. The brake disc assembly of claim 4, wherein said rotor is formed of a material selected from the group consisting of cast iron, steel, carbon-carbon, metal matrix composite, carbon fiber reinforced ceramic, carbon fiber reinforced silicon carbide, titanium and titanium alloys.

6. The brake disc assembly of claim 2, wherein each of said plurality of curved projections comprises a curled tab, said curled tabs being capable of restraining differential movement of said rotor and said hat assembly in an axial direction.

7. The brake disc assembly of claim 6, wherein said rotor is formed of a material selected from the group consisting of cast iron, steel, carbon-carbon, metal matrix composite, carbon fiber reinforced ceramic, carbon fiber reinforced silicon carbide, titanium and titanium alloys.

8. The brake disc assembly of claim 2, wherein said rotor is formed of a material selected from the group consisting of cast iron, steel, carbon-carbon, metal matrix composite, carbon fiber reinforced ceramic, carbon fiber reinforced silicon carbide, titanium and titanium alloys.

9. The brake disc assembly of claim 1, wherein said bowl-shaped body portion of said second hat portion comprises a top portion, said top portion being capable of restraining differential movement between said rotor and said hat assembly in an axial direction.

10. The brake disc assembly of claim 9, wherein said rotor is formed of a material selected from the group consisting of cast iron, steel, carbon-carbon, metal matrix composite, carbon fiber reinforced ceramic, carbon fiber reinforced silicon carbide, titanium and titanium alloys.

11. The brake disc assembly of claim 1, wherein each of said plurality of curved projections comprises a curled tab, said curled tabs being capable of restraining differential movement of said rotor and said hat assembly in an axial direction.

12. The brake disc assembly of claim 1, wherein said rotor is formed of a material selected from the group consisting of cast iron, steel, carbon-carbon, metal matrix composite, carbon fiber reinforced ceramic, carbon fiber reinforced silicon carbide, titanium and titanium alloys.

13. A method of assembling a brake disc assembly, said brake disc assembly comprising a rotor, said rotor comprising an opening, said opening comprising a plurality of radial recesses, wherein each of said plurality of radial recesses comprises a first and second side portion, comprising the steps of:

inserting a first hat portion through said opening of said rotor,

inserting a second hat portion through said opening of said rotor such that said first hat portion and said second hat portion are nested,

rotating said first hat portion within said opening such that each of a plurality of first curved projections formed on said first hat portion contact one of said first side portions,

rotating said second hat portion within said opening such that each of a plurality of second curved projections formed on said second hat portion contact one of said second side portions, and

securing said first and second hat portions together to form a hat assembly.

14. The method of claim 13, wherein the step of rotating said first hat portion within said opening comprises preloading said plurality of first curved projections with a force sufficient to maintain contact between said plurality of first curved projections and said first side portions over varied operating conditions.

15. The method of claim 14, wherein each of said plurality of first curved projections comprises a curled tab, said curled tabs being capable of restraining differential movement of said rotor and said hat assembly in an axial direction.

16. The method of claim 15, wherein said bowl-shaped body portion of said second hat portion comprises a top portion, said top portion being capable of restraining differential movement between said rotor and said hat assembly in an axial direction.

17. The method of claim 16, wherein said rotor is formed of a material selected from the group consisting of cast iron, steel, carbon-carbon, metal matrix composite, carbon fiber reinforced ceramic, carbon fiber reinforced silicon carbide, titanium and titanium alloys.

18. The method of claim 13, wherein each of said plurality of first curved projections comprises a curled tab, said curled tabs being capable of restraining differential movement of said rotor and said hat assembly in an axial direction.

19. The method of claim 18, wherein said bowl-shaped body portion of said second hat portion comprises a top portion, said top portion being capable of restraining differential movement between said rotor and said hat assembly in an axial direction.

20. The method of claim 19, wherein said rotor is formed of a material selected from the group consisting of cast iron, steel, carbon-carbon, metal matrix composite, carbon fiber reinforced ceramic, carbon fiber reinforced silicon carbide, titanium and titanium alloys.