CA2046031A1 - Brake disks - Google Patents
Brake disksInfo
- Publication number
- CA2046031A1 CA2046031A1 CA 2046031 CA2046031A CA2046031A1 CA 2046031 A1 CA2046031 A1 CA 2046031A1 CA 2046031 CA2046031 CA 2046031 CA 2046031 A CA2046031 A CA 2046031A CA 2046031 A1 CA2046031 A1 CA 2046031A1
- Authority
- CA
- Canada
- Prior art keywords
- pads
- core
- brake disk
- friction
- holes
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Landscapes
- Braking Arrangements (AREA)
Abstract
ABSTRACT
A brake disk is disclosed, which comprises an annular core made of cast metal, preferably aluminum, and a plurality of friction pads set in the core on its opposing radial faces.
The pads have coplanar radial friction surfaces clear of cast metal. However, the latter circumscribes the friction pads and fills, at least partially, holes through the pads to secure them firmly to the core.
A brake disk is disclosed, which comprises an annular core made of cast metal, preferably aluminum, and a plurality of friction pads set in the core on its opposing radial faces.
The pads have coplanar radial friction surfaces clear of cast metal. However, the latter circumscribes the friction pads and fills, at least partially, holes through the pads to secure them firmly to the core.
Description
3 '~ ~
TITL~ OF THE INVENTION
Brake disks BACKGROUND OF THE INVENTION
Fiela of the invention The present invention generally concerns brake disks and more particularly, such disks having an annular core and friction pads mounted on opposing radial faces of the core.
The invention also concerns a method of producing a brake disk of this type.
Description of the prior art It is known to provide brake disks wherein friction pads are fastened on opposing faces of a disk core by various mechanical means such as snap fasteners, rivets, force-fit fasteners or by welding.
A prior art search made by the Applicant has revealed, in this respect, U.S. patent no. 4,276,969 to CHIN et al. who ; propose providing a brake disk comprising a disk-like core and friction pads disposed two-by-two on opposing surfaces of the core. The pads are fixed to the core by means of cylindrical bushings extending across the core and projection welded to the pads to hold the assembly fast with the core.
The search has also disclosed U.S. patent no. 4,613,021 to LACOMBE et al., wherein the core is a spoked hub and the friction pads are sector-shaped members mounted between the spokes of the hub and held in position by hook joints at an 2~4~
outer end and spring-like hub rings at an inner end pressing the hook joint components in the hook joints.
A further document found, U.S. patent no. 3,759,354 to DOWELL et al., discloses a brake disk of the same general type, in which the pads are sector-shaped and held together in succession by mechanical joints.
In constructions of the type described above and under the extreme temperatures to which the friction pads are subjected during braking, it has been found that they are prone to loosen on the core.
The structures disclosed in the above patents also have in common that they are of complex design and therefore difficult to assemble and costly to produce.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a brake disk in which the friction pads are held safely on the core against loosening in an extremely simplified manner, thereby resulting in a low-cost article of manufacture.
According to the invention, the friction pads are embedded in the core during casting of the latter except of course for the friction surfaces of the pads which are preferably flush with the core.
, 30 Thus, the invention provides a brake disk comprising an annular core made of cast metal and a plurality of friction pads set in the core on its opposing radial faces, the pads having coplanar radial friction surfaces, wherein the cast metal circumscribes the friction pads and fills, at least partially, holes made through the pads to secure them firmly to the core. In a preferred form, the core cast metal falls flush with the friction surfaces of the pads.
Another object of the invention lies in providing a method of producing a brake disk of the above type. This method essentially comprises providing a mold including a pair of mold shells, each shell having a bottom wall with a flat peripheral portion, and a plurality of pairs of holding plugs disposed at regular intervals along this peripheral portion, the plugs jutting out from the bottom wall;
providing pad-retaining means in the bottom walls of the shells for each of the friction pads; hanging flat friction pads, each formed with a pair of through holes, from the holding plugs over the pad-retaining means so that they be pressed against the flat peripheral portion by said retaining means; placing disk molding core means in the shell between the bottom walls; closing the mold and pouring casting metal into the mold around the core means, around the friction pads and into the through holes to produce the brake disk.
A non-limitative description now follows of a preferred ; embodiment of the invention, made with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRA~INGS
Figure 1 is a perspective view of a disk brake construction using a brake disk made according to the invention;
'.
Figure 2 is a cross-section, along line II-II in Figure 3, of a portion of the brake disk taken in the brake lining area;
Figure 3 is a front view of part of the brake disk, partially broken away to show its inner structure;
Figure 4 is a cross-section along line IV-IV in Figure 3;
Figure 5 is a front view of a portion of one of the mold shells used in molding a brake disk made according to the invention; and Figures 6 and 7 are cross-sections along lines VI-VI and VII-VII of Figure 5, respectively.
DESCRIPTION OF THE PREFE~RED EMBODIMENT
The illustrated brake disk 1 is for use on a conventional brake construction 3 having a hub 5 on which the disk l is mounted and an outer caliper housing 7 containing brake linings 9 -(Figure 2).
The brake disk or rotor 1 comprises an annular core 11, cast in light metal, such as aluminum, over the opposing faces 13, 13' (Figure 2), of which are set a plurality of friction pads 15 having coplanar radial friction surfaces 17 that are of course clear of core cast metal. As shown, the cast metal circumscribes the friction pads 15 and preferably falls flush with the pads friction surfaces 17 to hold the pads firmly in the core 11.
The friction pads 15 consist of small plates that are preferably sector-shaped and have radially oriented side edges 19, l9' (Figure 3), outer arcuate edges 21 and inner arcuate edges 23. They are formed with peripherally outward holes 25, partially filled with cast metal as further explained hereinafter, and inward holes 27, completely filled with cast metal, again to hold the pads 15 firmly in the core.
All holes 25, 27, have the same configuration so that only one will be described with reference to Figure 4, particularly.
As shown, each hole defines a tapering bore 29 that converges from the pad friction surface 17. Within the core 11 itself, the bore 29 is defined by an annular bead 31 that projects inwardly from the inner surface 33 of the pad 15.
It will be noted that the bead 31 also forms an annular retaining shoulder 35 preferably perpendicular to the inner A 15 surface 33 and located radially outwardly of the bore 29.
To provide still a better embedding of the pads 15, the latter have their peripheral edges 19, 19', 21, 23, taper radially outwardly from the friction surfaces 17.
Preferably, the peripheral edges 19, 19', 21, 23, taper at an angle of about 15, while the bores 29 taper at an angle of about 20, both to the vertical.
It will be noted form Figure 2 that the outward holes 25 are only partially filled with cast metal 11 while the inward holes 27 are, as shown in Figure 2, completely filled, as said above.
The cast metalll is preferably a heat conductive, light metal alloy such as an aluminum alloy, that may be reinforced with suitable fillers if necessary. It may also be a nickel-based refractory alloy or molybdenum or beryllium. As to the friction pads 15, they may advantageously be made of gritted material such as carbon-silicon-carbide material, or gritted metal that is heat conductive and very resistant to abrasion. Indeed, the purpose of these pads is to "reinforce" the core of light metal alloy where this core is subject to intensive friction.
To improve heat dissipation, the annular cast metal core 11 is preferably formed with appropriate ventilating louvers 37 between the opposing faces 13, 13', of the rotor disk 1. It is also formed, on one side, with radial brackets 39 (Figure 3) for connection to the hub 5.
As said above, the invention also concerns a method of - 15 producing a brake disk of the type described above.
Reference is made, in this respect, to Figures 5, 6 and 7, showing a portion of one of the two shells 41 of a mold suitable for making the disk; the inner molding core having been omitted. The shell 41 is cup-shaped and has a circular bottom wall with a peripheral flat portion 43 from which project a plurality of pairs of short plate-holding plugs 45 (Figures 5 and 6) equally distributed around its periphery;
each pair corresponding to one friction pad 15. Also, corresponding to each pad 15 are holes 47 (Figure 7) through the mold 41; these holes being operatively connected to an air suction source 49 which acts as pad-retaining means as will be explained hereinafter. Instead of such air suction, it could be made of small magnets embedded into the mold surface to retain the friction pads.
In use, the plate-shaped friction pads are hooked by their outward holes 25 on the said plugs 45, provided on the flat peripheral portion of the mold bottom wall 43, and the holes 47 connected to the suction source 49 to draw their friction surfaces 17 tight against the shell bottom walls 43 and thus retain them. An appropriate disk molding core is then inserted in the shells 41 which are brought together to close the mold. The casting metal is poured into the mold around the molding core, around the periphery of the pads 15 and into the through holes 25, 27. Because of the particular design of the pads 15 (bevelled edges 19, 19', 21, 23;
tapered holes 25, 27, and annular beads 31), it will be appreciated that the pads 15 are solidly embedded in the cast metal core 11. It will be seen also that the mold and pad construction are extremely simplified while the mold preparation is limited to a small number of operations.
The brake disk disclosed hereinabove has numerous advantages. First of all, it is very light as compared to the existing one-piece brake disk, since its core is made of light material such as aluminum or magnesium which have been rejected so far because of their lack of resistance. It is also very efficient to dissipate heat, thereby making its braking efficiency steady. Furthermore, it can be used very efficiently as part of an ABS brake control system. In such system, it is necessary to measure the rotational speed of each wheel to adjust and balance the braking force applied to each wheel. With the brake disk according to the invention, this measurement can be made in a very easy, simple and reliable manner, by fixing a Hall-effect sensor 10 onto the caliper 7 so that it extends at a few millimeters from one side of the disk. The sensor 10 may i count the number of pads 15 that pass in front of it because they are made of a material different from the core, and thus allows calculation of the speed of the disk.
TITL~ OF THE INVENTION
Brake disks BACKGROUND OF THE INVENTION
Fiela of the invention The present invention generally concerns brake disks and more particularly, such disks having an annular core and friction pads mounted on opposing radial faces of the core.
The invention also concerns a method of producing a brake disk of this type.
Description of the prior art It is known to provide brake disks wherein friction pads are fastened on opposing faces of a disk core by various mechanical means such as snap fasteners, rivets, force-fit fasteners or by welding.
A prior art search made by the Applicant has revealed, in this respect, U.S. patent no. 4,276,969 to CHIN et al. who ; propose providing a brake disk comprising a disk-like core and friction pads disposed two-by-two on opposing surfaces of the core. The pads are fixed to the core by means of cylindrical bushings extending across the core and projection welded to the pads to hold the assembly fast with the core.
The search has also disclosed U.S. patent no. 4,613,021 to LACOMBE et al., wherein the core is a spoked hub and the friction pads are sector-shaped members mounted between the spokes of the hub and held in position by hook joints at an 2~4~
outer end and spring-like hub rings at an inner end pressing the hook joint components in the hook joints.
A further document found, U.S. patent no. 3,759,354 to DOWELL et al., discloses a brake disk of the same general type, in which the pads are sector-shaped and held together in succession by mechanical joints.
In constructions of the type described above and under the extreme temperatures to which the friction pads are subjected during braking, it has been found that they are prone to loosen on the core.
The structures disclosed in the above patents also have in common that they are of complex design and therefore difficult to assemble and costly to produce.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a brake disk in which the friction pads are held safely on the core against loosening in an extremely simplified manner, thereby resulting in a low-cost article of manufacture.
According to the invention, the friction pads are embedded in the core during casting of the latter except of course for the friction surfaces of the pads which are preferably flush with the core.
, 30 Thus, the invention provides a brake disk comprising an annular core made of cast metal and a plurality of friction pads set in the core on its opposing radial faces, the pads having coplanar radial friction surfaces, wherein the cast metal circumscribes the friction pads and fills, at least partially, holes made through the pads to secure them firmly to the core. In a preferred form, the core cast metal falls flush with the friction surfaces of the pads.
Another object of the invention lies in providing a method of producing a brake disk of the above type. This method essentially comprises providing a mold including a pair of mold shells, each shell having a bottom wall with a flat peripheral portion, and a plurality of pairs of holding plugs disposed at regular intervals along this peripheral portion, the plugs jutting out from the bottom wall;
providing pad-retaining means in the bottom walls of the shells for each of the friction pads; hanging flat friction pads, each formed with a pair of through holes, from the holding plugs over the pad-retaining means so that they be pressed against the flat peripheral portion by said retaining means; placing disk molding core means in the shell between the bottom walls; closing the mold and pouring casting metal into the mold around the core means, around the friction pads and into the through holes to produce the brake disk.
A non-limitative description now follows of a preferred ; embodiment of the invention, made with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRA~INGS
Figure 1 is a perspective view of a disk brake construction using a brake disk made according to the invention;
'.
Figure 2 is a cross-section, along line II-II in Figure 3, of a portion of the brake disk taken in the brake lining area;
Figure 3 is a front view of part of the brake disk, partially broken away to show its inner structure;
Figure 4 is a cross-section along line IV-IV in Figure 3;
Figure 5 is a front view of a portion of one of the mold shells used in molding a brake disk made according to the invention; and Figures 6 and 7 are cross-sections along lines VI-VI and VII-VII of Figure 5, respectively.
DESCRIPTION OF THE PREFE~RED EMBODIMENT
The illustrated brake disk 1 is for use on a conventional brake construction 3 having a hub 5 on which the disk l is mounted and an outer caliper housing 7 containing brake linings 9 -(Figure 2).
The brake disk or rotor 1 comprises an annular core 11, cast in light metal, such as aluminum, over the opposing faces 13, 13' (Figure 2), of which are set a plurality of friction pads 15 having coplanar radial friction surfaces 17 that are of course clear of core cast metal. As shown, the cast metal circumscribes the friction pads 15 and preferably falls flush with the pads friction surfaces 17 to hold the pads firmly in the core 11.
The friction pads 15 consist of small plates that are preferably sector-shaped and have radially oriented side edges 19, l9' (Figure 3), outer arcuate edges 21 and inner arcuate edges 23. They are formed with peripherally outward holes 25, partially filled with cast metal as further explained hereinafter, and inward holes 27, completely filled with cast metal, again to hold the pads 15 firmly in the core.
All holes 25, 27, have the same configuration so that only one will be described with reference to Figure 4, particularly.
As shown, each hole defines a tapering bore 29 that converges from the pad friction surface 17. Within the core 11 itself, the bore 29 is defined by an annular bead 31 that projects inwardly from the inner surface 33 of the pad 15.
It will be noted that the bead 31 also forms an annular retaining shoulder 35 preferably perpendicular to the inner A 15 surface 33 and located radially outwardly of the bore 29.
To provide still a better embedding of the pads 15, the latter have their peripheral edges 19, 19', 21, 23, taper radially outwardly from the friction surfaces 17.
Preferably, the peripheral edges 19, 19', 21, 23, taper at an angle of about 15, while the bores 29 taper at an angle of about 20, both to the vertical.
It will be noted form Figure 2 that the outward holes 25 are only partially filled with cast metal 11 while the inward holes 27 are, as shown in Figure 2, completely filled, as said above.
The cast metalll is preferably a heat conductive, light metal alloy such as an aluminum alloy, that may be reinforced with suitable fillers if necessary. It may also be a nickel-based refractory alloy or molybdenum or beryllium. As to the friction pads 15, they may advantageously be made of gritted material such as carbon-silicon-carbide material, or gritted metal that is heat conductive and very resistant to abrasion. Indeed, the purpose of these pads is to "reinforce" the core of light metal alloy where this core is subject to intensive friction.
To improve heat dissipation, the annular cast metal core 11 is preferably formed with appropriate ventilating louvers 37 between the opposing faces 13, 13', of the rotor disk 1. It is also formed, on one side, with radial brackets 39 (Figure 3) for connection to the hub 5.
As said above, the invention also concerns a method of - 15 producing a brake disk of the type described above.
Reference is made, in this respect, to Figures 5, 6 and 7, showing a portion of one of the two shells 41 of a mold suitable for making the disk; the inner molding core having been omitted. The shell 41 is cup-shaped and has a circular bottom wall with a peripheral flat portion 43 from which project a plurality of pairs of short plate-holding plugs 45 (Figures 5 and 6) equally distributed around its periphery;
each pair corresponding to one friction pad 15. Also, corresponding to each pad 15 are holes 47 (Figure 7) through the mold 41; these holes being operatively connected to an air suction source 49 which acts as pad-retaining means as will be explained hereinafter. Instead of such air suction, it could be made of small magnets embedded into the mold surface to retain the friction pads.
In use, the plate-shaped friction pads are hooked by their outward holes 25 on the said plugs 45, provided on the flat peripheral portion of the mold bottom wall 43, and the holes 47 connected to the suction source 49 to draw their friction surfaces 17 tight against the shell bottom walls 43 and thus retain them. An appropriate disk molding core is then inserted in the shells 41 which are brought together to close the mold. The casting metal is poured into the mold around the molding core, around the periphery of the pads 15 and into the through holes 25, 27. Because of the particular design of the pads 15 (bevelled edges 19, 19', 21, 23;
tapered holes 25, 27, and annular beads 31), it will be appreciated that the pads 15 are solidly embedded in the cast metal core 11. It will be seen also that the mold and pad construction are extremely simplified while the mold preparation is limited to a small number of operations.
The brake disk disclosed hereinabove has numerous advantages. First of all, it is very light as compared to the existing one-piece brake disk, since its core is made of light material such as aluminum or magnesium which have been rejected so far because of their lack of resistance. It is also very efficient to dissipate heat, thereby making its braking efficiency steady. Furthermore, it can be used very efficiently as part of an ABS brake control system. In such system, it is necessary to measure the rotational speed of each wheel to adjust and balance the braking force applied to each wheel. With the brake disk according to the invention, this measurement can be made in a very easy, simple and reliable manner, by fixing a Hall-effect sensor 10 onto the caliper 7 so that it extends at a few millimeters from one side of the disk. The sensor 10 may i count the number of pads 15 that pass in front of it because they are made of a material different from the core, and thus allows calculation of the speed of the disk.
Claims (20)
1. A brake disk comprising:
- an annular core made of cast metal; and - a plurality of friction pads set in said core on opposing radial faces thereof, said pads having coplanar radial friction surfaces clear of said core cast metal;
- wherein said core cast metal circumscribes said friction pads and fills, at least partially, holes made through said pads, whereby to secure said pads firmly in said core.
- an annular core made of cast metal; and - a plurality of friction pads set in said core on opposing radial faces thereof, said pads having coplanar radial friction surfaces clear of said core cast metal;
- wherein said core cast metal circumscribes said friction pads and fills, at least partially, holes made through said pads, whereby to secure said pads firmly in said core.
2. A brake disk as claimed in claim 1, wherein said circumscribing core cast metal falls flush with said pads friction surfaces.
3. A brake disk as claimed in claim 2, wherein said holes define tapering bores that converge from said pads friction surfaces.
4. A brake disk as claimed in claim 3, wherein each of said friction pads has an inner surface within said core and each of said tapering bores is extended, within said core, by an annular bead projecting from said inner surface, said beads forming retaining shoulders located radially outwardly of said bores.
5. A brake disk as claimed in claim 2, wherein said pads have tapering peripheral edges.
6. A brake disk as claimed in claim 3, wherein said pads have tapering peripheral edges.
7. A brake disk as claimed in claim 4, wherein said pads have peripheral edges that taper radially outwardly from said friction surfaces of said pads.
8. A brake disk as claimed in claim 3, wherein said holes of said friction pads include a pair of circumferentially spaced outward holes partially filled with said core cast metal and one inward hole located circumferentially between said outward holes and completely filled with cast metal of said core.
9. A brake disk as claimed in claim 8, wherein each of said friction pads has an inner surface within said core and each of said tapering bores is extended, within said core, by an annular bead projecting from said inner surface.
10. A brake disk as claimed in claim 9, wherein said bores taper at an angle of about 20 from the vertical.
11. A brake disk as claimed in claim 7, wherein said peripheral edges taper at an angle of about 15 from the vertical.
12. A brake disk as claimed in claim 4, wherein said cast metal is made of an aluminum alloy and said friction pads are made of gritted metal.
13. A brake disk as claimed in claim 6, wherein said cast metal is made of an aluminum alloy and said friction pads are made of gritted metal.
14. A brake disk as claimed in claim 9, including ventilation louvers formed through said core between said friction pads.
15. A brake disk as claimed in claim 14, wherein said friction pads are in the form of sector plates.
16. A brake disk as claimed in claim 15, wherein said cast metal is made of an aluminum alloy and said friction pads are made of gritted metal.
17. A method of producing a brake disk, comprising:
- providing a mold including a pair of mold shells, each shell having a bottom wall with a flat peripheral portion and a plurality of pairs of holding plugs disposed at regular intervals along said peripheral portion, said plugs jutting out from said bottom wall;
- providing pad-retaining means in said bottom walls proximity to said holding plugs;
- providing flat friction pads each formed with a pair of through holes disposed for hanging on one of said pairs of holding plugs;
- hanging said pads from said holding plugs over said pad-retaining means so that said pads be pressed against said flat peripheral portion;
- placing disk molding core means in said shells between said bottom walls;
- closing said mold; and - pouring casting metal into said mold around said core means, around said friction pads and into said through holes to produce said brake disk.
- providing a mold including a pair of mold shells, each shell having a bottom wall with a flat peripheral portion and a plurality of pairs of holding plugs disposed at regular intervals along said peripheral portion, said plugs jutting out from said bottom wall;
- providing pad-retaining means in said bottom walls proximity to said holding plugs;
- providing flat friction pads each formed with a pair of through holes disposed for hanging on one of said pairs of holding plugs;
- hanging said pads from said holding plugs over said pad-retaining means so that said pads be pressed against said flat peripheral portion;
- placing disk molding core means in said shells between said bottom walls;
- closing said mold; and - pouring casting metal into said mold around said core means, around said friction pads and into said through holes to produce said brake disk.
18. A method as claimed in claim 17, wherein said pad-retaining means consist of suction apertures connected to an air suction source.
19. A method as claimed in claim 17, wherein said pad-retaining means are magnets.
20. A method as claimed in claim 17, wherein said holding plugs have a height smaller than the depth of said through holes.
R O B I C .
R O B I C .
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2046031 CA2046031A1 (en) | 1991-07-02 | 1991-07-02 | Brake disks |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2046031 CA2046031A1 (en) | 1991-07-02 | 1991-07-02 | Brake disks |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2046031A1 true CA2046031A1 (en) | 1993-01-03 |
Family
ID=4147937
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2046031 Abandoned CA2046031A1 (en) | 1991-07-02 | 1991-07-02 | Brake disks |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2046031A1 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2018117811A1 (en) * | 2016-12-22 | 2018-06-28 | Ng Yong Thye | Brake disc |
-
1991
- 1991-07-02 CA CA 2046031 patent/CA2046031A1/en not_active Abandoned
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2018117811A1 (en) * | 2016-12-22 | 2018-06-28 | Ng Yong Thye | Brake disc |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |