Brake rotor and method for making same

A brake rotor assembly comprising:

• first and second spaced apart annular cast iron plates, each said plate including an inner surface and an outer braking surface;
• a plurality of radially disposed ribs protruding from said inner surface of said first plate having machined distal surfaces and a plurality of corresponding radially disposed ribs protruding from said inner surface of said second plate having machined distal surfaces, wherein said ribs protruding from said first plate are adapted for mating with said ribs protruding from said second plate for maintaining space between said inner surfaces of said plates when said plates are assembled;
• and
• a plurality of aluminum heat sinks, a portion of which are attached to said inner surface of said first plate between said ribs protruding therefrom and a portion of which are attached to said inner surface of said second plate between said ribs protruding therefrom, wherein said heat sinks each include a plurality of fins for dissipating heat from the assembly.

A method of manufacturing a brake rotor, wherein said brake rotor comprises two annular disks and at least one heat sink therebetween, said method comprising the steps of:

• forming a first annular plate having generally flat first and second surfaces and a first set of radially disposed ribs protruding from said first surface;
• forming a second annular plate having generally flat first and second surfaces;
• forming a heat sink having fins defining passages therebetween;
• attaching said heat sink to the first surface of at least one of said first and second plates;
• and
• assembling said first and second plates such that said ribs and said heat sink are located between said plates.