Antilock brake rotor assembly with corrosion resistant tone ring
AssigneeCommercial Vehicle Components, LLC
InventorsDavid G. Gonska, Anthony Guerriero
Life of this patent
Estimating the term…
Abstract
A brake rotor assembly is provided. The brake rotor assembly includes a brake rotor portion formed from a first material. A tone ring formed from a second material is coupled to the brake rotor portion. The tone ring is formed by an additive manufacturing process, a subtractive manufacturing process, or a combination thereof. The brake rotor portion may be cast from an iron or iron alloy. The tone ring is formed by an additive manufacturing, or 3D printing, process machine from a second material that is corrosion resistive, such as, for example, stainless steel.
Claims18
A method for producing a brake rotor assembly having a brake rotor portion and a tone ring, the method comprising:
- obtaining a brake rotor portion of a brake rotor assembly made from a first material, the brake rotor portion comprising a rotor disc and an inner circumferential portion formed with the rotor disc wherein a top edge of the inner circumferential portion forms a deposition surface, the inner circumferential portion including an inwardly extending mounting flange;
- placing the brake rotor portion into a work station of an additive manufacturing process machine;
- building up a cylindrical member on the deposition surface of the brake rotor using the additive manufacturing process machine from a second material dissimilar to the first material;
- and
- removing material from the cylindrical member to form a plurality of channels and a corresponding plurality of protrusions to form an integrated brake rotor with an integral tone ring.
A brake rotor assembly comprising:
- a brake rotor portion formed from a first material, the brake rotor portion comprising:
- a rotor disc;
- and
- an inner circumferential portion integrally formed with the rotor disc, the inner circumferential portion comprising at least one sidewall having an inner surface and a top edge forming a deposition surface and an inwardly extending mounting flange forming a surface;
- and
- a tone ring formed from a second material different than the first material, the tone ring comprising:
- an engagement surface to be deposited on and coupled to the deposition surface of the brake rotor portion;
- and
- a sensor surface opposite the engagement surface, wherein the sensor surface is formed by machining the tone ring to remove material and form a plurality of teeth, and
- wherein the second material is magnetic.
A vehicle comprising:
- at least one wheel with an anti-lock braking system;
- the wheel comprising a brake rotor assembly where the brake rotor assembly comprises:
- a brake rotor portion formed from a first material, the brake rotor portion comprising:
- a rotor disc;
- and
- an inner circumferential portion integrally formed with the rotor disc, the inner circumferential portion comprising at least one sidewall having an inner surface and an inwardly extending mounting flange forming a deposition surface and a mounting surface;
- and
- a tone ring formed from a second material different than the first material, the tone ring comprising:
- an engagement surface to be deposited on and coupled to the deposition surface of the inwardly extending mounting flange;
- and
- a sensor surface opposite the engagement surface such that the sensor surface is formed by removing material from the tone ring to form a plurality of protrusions, and
- wherein the second material is magnetic.
Dependencies are inferred from the claim text.