Hayes Lemmerz International, Inc.

Anwar R Daudi

Weston E Dickerson

John E Saum

Rob Walkowiak

Chris Milosavlevski

The invention relates to a brake rotor having improved damping characteristics and a method for producing the same. A surface of the brake rotor is EDG machined, also known as EDM machined, for improving the damping characteristics of the rotor. The decay rate of the brake rotor is increased and the Q factor of the brake rotor is reduced. The portion of the brake rotor which is EDG machined is formed of an electrically conductive material, preferably a ferrous material, more preferably a cast iron material, a gray iron material or a damped iron material. The brake rotor may include a solid friction section or a ventilated friction section. The brake rotor is preferably cast from a single material, although alternatively, it may be a composite rotor formed of more than one material.

Damped disc brake rotor

A vented disc brake rotor having an airflow director for funneling air into the braking plate vents thereby improving the cooling effectiveness of the rotor. The vented disc brake rotor includes first and second braking plates connected together in a mutually parallel, spaced apart relationship. Braking plate fins are disposed between the inwardly facing surfaces of the braking plates forming a plurality of braking plate vents between the braking plates. The rotor includes an airflow director having an annular flange extending generally radially inwards from the radially inner end of one of the braking plates. The flange includes an inner surface forming an angle with respect to the inner surface of the other braking plate such that the distance between these inner surfaces increases as the flange extends radially inwards. A plurality of director fins are disposed between the flange and the inner surface of one of the braking plates. The cross sectional area of the director vent inlets are larger than the cross sectional area of the braking plate vent inlets. The larger director vent inlets and the angled inner flange surface create a funnel which directs more air into the braking plate vents thereby improving the cooling effectiveness of the rotor.

Brake rotor with airflow director

The present invention is a drum brake shoe assembly having an improved support structure which limits the lateral travel of the leading brake shoe, to thereby reduce or eliminate audible impacts between the brake shoe and the backing plate of the drum brake assembly. In accordance with the invention, two or more spaced apart hold down devices are provided on the leading brake shoe while a single hold down device is used on the trailing brake shoe. Each of the hold down device includes a hold down pin connected at a first end to the backing plate of the drum brake assembly. The second end of each hold down pin extends through an opening in the web of the brake shoe. Springs such as coil springs or the like are disposed between the second ends of the hold down pins and the brake shoe web for urging the brake shoe against the backing plate.

Reduced noise brake shoe assembly

A modular brake rotor includes a core having a central wall and a plurality of support ribs extending radially outwards therefrom. A pair of friction rings are secured to the support ribs. A viscoelastic vibration reducing element is disposed between the support ribs and the friction rings for creating a vibration reducing interface therebetween. The viscoelastic vibration reducing element is preferably a viscoelastic adhesive. In an alternate embodiment, the viscoelastic vibration reducing element is viscoelastic laminate including one or more layers of viscoelastic adhesive bonded to one or more intermediate materials.

Rotor with viscoelastic vibration reducing element and method of making the same

The present invention discloses a vented brake rotor having tubular ducts. The rotor includes universal rotor blank having a hat section and a peripheral section radially extending therefrom. The hat section includes a mounting face and hat wall extending from the periphery of the mounting face. The peripheral section includes a first and a second braking plate joined together in a parallel, spaced apart relationship by a plurality of spacers. A plurality of duct tubes are fastened to the inner surfaces of the braking plates. Each one of the duct tubes has an inlet and an outlet allowing air to flow through the duct tube to provide an airflow path between the braking plates for cooling the rotor. In an alternate embodiment, the present invention may include a plurality of fins fastened to the inner surfaces of the braking plates. The fins extend between the braking plates forming a passages between them. A plurality of duct tubes are fastened in the passages between the fins.

Rotor with tubular vent ducts

The invention is directed to a vehicle braking system having a plurality of two-state actuators disposed at each vehicle wheel and method braking same. The vehicle braking system further includes a brake rotor or brake drum secured to each vehicle wheel for rotation therewith. The brake rotors or drums each include a plurality of friction surfaces. A plurality of brake pads are disposed adjacent the friction surfaces such that a different brake pad corresponds to each friction surface. A different two-state actuator corresponding to each brake pad is disposed adjacent the corresponding brake pad. Each two-state actuator is either unactuated or actuated to provide a maximum translational force against the corresponding brake pad to achieve the desired braking force requirements at each vehicle wheel.

Vehicle braking system and braking method using a plurality of two-state actuators

The invention relates to an air flow test apparatus for determining the amount of air moving through vents in a turning ventilated rotor. The air flow test apparatus includes an elongated cylindrical shaft journalled for rotation in spaced apart bearing blocks mounted in a frame. A conventional belt drive couples the shaft to a variable speed motor for rotation. An adapter is mounted to the shaft and a work piece is mounted to the adapter end for rotation with the shaft. The work piece includes a hub secured to the adapter for receiving a plurality of different sized rotors, and a ventilated rotor mounted to the hub. The work piece may also include other vehicle components such as the caliper, a wheel, even an entire corner portion of a vehicle for simulation purposes. A pressure gauge is disposed adjacent the rotor, near the vents, to measure the air pressure near the turning rotor. The cooling effectiveness of the ventilated rotor can be determined by the amount of air moved through the vents which is proportional to the change in pressure of the moving air.

Air flow test machine for rotors

The present invention relates to a modular brake rotor having friction rings secured to a core. The core includes a hat section having a hat wall, and a plurality of circumferentially spaced apart support ribs. A pair of friction rings having inner surfaces are secured to the support rib inboard and outboard mounting surfaces. The support ribs extend into recesses formed in the inner surfaces of the friction rings to secure the friction rings to the support ribs. The ribs may include protrusions formed using dowels which extend through the support ribs and project out of the inboard and outboard mounting surfaces and into the recesses. Alternatively, the protrusions may be formed integrally with the support ribs.

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Ann Arbor, MI, United States of America

Anwar R Daudi