Performance Friction Corporation

Wenqi Qian

Donald L Burgoon

Jason Oakley

Grafton Robertson

Sean E Killeen

Scott Andrew Paul

Craig A Van Harken

Darrick Dong

Seen E Killeen

A brake assembly for use on vehicles includes a rotor having connection tabs and a hub having bobbins, integrally formed or separate, with the rotor connection tabs being positioned between the hub bobbins and clamped together with a top plate. An ABS tone ring is fastened to the hub and is circumscribed by the rotor. Alternatively, an ABS tone ring can be formed as part of the top plate. A spring clip can be used with the top plate to accommodate thermal expansion of the rotor and eliminate rotor rattling. Torque is transferred from the brake rotor to the hub in a common plane to prevent twisting in the fastener connection.

Brake rotor and abs tone ring attachment assembly that promotes in plane uniform torque transfer distribution

A wheel bearing hub and disc brake rotor assembly for use on vehicles includes a rotor () and a wheel mount (), formed as a package bearing, fastened to the rotor with a connection assembly that promotes in plane torque transfer. The rotor has a flange form as a series of spaced tabs (), and the wheel bearing hub () has a shoulder with complementary spaced tabs (). The rotor is connected to the bearing hub by clamping a bridge () that spans the shoulder tabs over the rotor tabs. A spring clip () can be use with the bridge to accommodate thermal expansion of the rotor and eliminate rattling. Torque is transferred from the brake rotor to the bearing hub in a common plane to prevent twisting. In one embodiment, the bearing hub shoulder tabs may be formed by milling or machining slots. In another embodiment, the bearing hub shoulder tabs may be formed by fine-blanking or stamping slots.

Direct drive braking system including an integrated package bearing

A brake caliper has a removable bridge that acts as a rigid mount for a pair of brake pad holders. The removable bridge is retained on the caliper body by spring loaded push button that allows quick removal for replacement of the brake pads, which is especially suited for automotive racing situations. The bridge is snapped in place and rigidly retained on caliper body when in use.

Quick release removable bridge caliper

A brake assembly for use on vehicles includes a rotor and a wheel mount, formed as a hat portion, fastened to the rotor with a bobbin assembly. The rotor has a flange formed as a series of spaced tabs, and the bobbin assembly is bolted to the hat portion with the rotor flange clamped therebetween. A spring clip can be used with the bobbin to accommodate thermal expansion of the rotor and eliminate rotor rattling. The bobbin has a binocular shape that receives a pair of bolts. A crush zone can be provided between the rotor and the bobbin yields to accommodate machining tolerances of the rotor and promote uniform torque transfer distribution to the hub. Torque is transferred from the brake rotor to the hat portion in a common plane to prevent twisting in the fastener connection.

Brake rotor attachment assembly that promotes in plane uniform torque transfer distribution

A brake assembly for use on vehicles includes a rotor and a wheel mount, formed as a hat portion, fastened to the rotor with a bobbin assembly. The rotor has a flange formed as a series of spaced tabs, and the bobbin assembly is bolted to the hat portion with the rotor flange clamped therebetween. A spring clip can be used with the bobbin to accommodate thermal expansion of the rotor and eliminate rotor rattling. The bobbin has a binocular shape that receives a pair of bolts. A crush zone between the rotor and the bobbin yields to accommodate machining tolerances of the rotor and promote uniform torque transfer distribution to the hub. Torque is transferred from the brake rotor to the hat portion in a common plane to prevent twisting in the fastener connection.

A brake caliper has a piston retained in a bore that abuts a brake pad for moving the brake pad into selective engagement with a rotor to effect braking. The piston has a composite cap that is formed of a cap piece made of strong material, such as steel, and an insulator, made of polyimide resin material, for example. The insulator is preferably in the form of a ring clamped between the cap piece and the piston to create a thermal break and minimize heat transfer from the brake pad to the piston and caliper assembly.

Piston having a cap and a brake caliper for use therewith

A hub rotor assembly includes a hub, a rotor supported by the hub and a plurality of fasteners that connect the rotor to the hub. The hub includes a wheel mounting flange and rotor mounting flange to which a flange of the rotor is attached. The rotor mounting flange has a larger diameter than the wheel mounting flange, or other hub elements outboard of the rotor mounting flange, so that the rotor can be easily removed from the hub. Features of the invention also include floatation elements associated with a fastener to fasten the rotor to the hub while allowing the rotor to move or float relative to the hub. A spring clip may be used with the floatation elements to prevent the rotor from rattling. The assembly is particularly suited for commercial highway vehicles and high performance vehicles.

Brake hub with floating rotor and mounting flange allowing simplified rotor removal and replacement

A rotor has an array of grooves formed on the brake pad contact surface. The array is preferably formed as a repeating pattern of regularly spaced grooves. The repeating pattern of grooves creates a plurality of radially and circumferentially offset rings of grooves. The rings can radially overlap. The rotor is preferably ventilated having two brake pad contact surfaces separated by a plurality of vanes. The grooves are preferably arranged on the brake pad contact surfaces between the vanes. The grooves can have various configurations and shapes. The array of grooves increases friction between a brake rotor and brake pads, and decreases the thermal gradient and thermal distortion on the brake pad contact surfaces.

Brake rotor having an array of grooves formed thereon

A hub rotor assembly includes a hub, a rotor supported by the hub and a plurality of fasteners that connect the rotor to the hub and allow relative movement between the rotor and the hub. The hub rotor assembly of the invention focuses on a brake hub and rotor assembly that uses a floatation element associated with a fastener to fasten the rotor to the hub while allowing the rotor to move or float relative to the hub. The rotor thus fastened is permitted to move or float in a limited manner with respect to the hub. This reduces the need for precise balancing due to float self-balancing. Such floatation reduces first and second order thermal distortion by allowing the rotor to thermally expand and also accommodates and significantly reduces the temperature variation and thermal distortion across the rotor surface during braking. The assembly is particularly suited for commercial highway vehicles.

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Fort Mill, SC, United States of America

Wenqi Qian