# US 9,038,271 B2 · High thermal conductivity disk brakes

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- Number: US 9,038,271 B2
- Document ID: US9038271B2
- Status: Granted
- Kind: B2
- Application number: 13/565,481
- Filed: 2012-08-02
- Published: 2013-10-24
- Granted: 2015-05-26
- Earliest claimed: 2012-04-18
- Applicants: Xiaodi Huang; Nannon R. Huang; Xiaobin Song
- Inventors: Xiaodi Huang; Nannon R. Huang; Xiaobin Song
- Web page: https://patentgrep.com/patent/US9038271B2

## CPC

- B22D 19/0081: {pretreatment of the insert, e.g. for enhancing the bonding between insert and surrounding cast metal}
- B22D 19/16: for making compound objects cast of two or more different metals, e.g. for making rolls for rolling mills (casting compound ingots B22D7/02)
- B32B 15/01: all layers being exclusively metallic {(making layered metal workpieces by pressure cladding B23K20/22; making coatings with a metallic material characterised by its composition C23C30/00)}
- F16D 65/125: {characterised by the material used for the disc body}
- F16D 65/127: {characterised by properties of the disc surface; Discs lined with friction material}
- F16D 2069/0491: {Tools, machines, processes}
- F16D 2200/0013: Cast iron
- F16D 2200/003: Light metals, e.g. aluminium
- F16D 2250/0015: around inserts
- Y10T 29/49496: Disc type wheel
- B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- F16D: COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

An automotive disk brake assembly installed in an automobile having a wheel. The assembly includes a floating caliper supporting inner and outer brake pads and a brake rotor having a disk, a hat, wherein the hat is bolted to the wheel. A hydraulic cylinder pushes the inner brake pads into the disk surface, thereby causing the floating caliper to move so as to bring the outer brake pad into contact with the disk surfaces. Finally, the rotor is made of a material having a thickness and a coefficient of thermal expansion and conductivity, such that a complete 100 kilometer per hour, 0.9 gross vehicle weight braking causes the disk to expand in thickness by at least 0.10 mm and to cool to shrink in thickness, from its expanded thickness, by at least 0.05 mm within 60 seconds of cessation of braking, in an ambient temperature of less than 30° C.

## Claims

### Claim 1

A method of fabricating a disk for a disk brake system, comprising:
(a) forming a cladding workpiece having a first major external surface defining engagement features, which include beads arranged with groups of beads in mutual contact, to increase rigidity of said cladding workpiece;
(b) coating said first major external surface with a second metal;
(c) providing a mold, defining an interior shape of a rotor;
(d) inserting said cladding workpiece into said mold;
(e) providing a molten third metal; and
(f) pouring said molten third metal into said mold so that it engages to said engagement features and reacts with said second metal and permitting said molten third metal to cool, thereby forming a disk made in part of said third metal, which is metallurgically bonded and mechanically interlocked to said cladding workpiece, together forming a complete disk.

### Claim 2 (depends on 1)

The method of claim 1, wherein said step of inserting said cladding workpiece into said mold, further includes inserting additional cladding workpieces into said mold.

### Claim 3 (depends on 1)

The method of claim 1, wherein said cladding workpiece defines radial slots, adapted to ameliorate the effects of thermal expansion of said cladding workpiece.

### Claim 4 (depends on 3)

The method of claim 3, wherein said engagement features include beads affixed onto said cladding workpiece, said beads arranged medially between said radial slots.

### Claim 5 (depends on 1)

The method of claim 1, wherein said engagement features include beads affixed onto said cladding workpiece.

### Claim 6 (depends on 1)

The method of claim 1, wherein said engagement features include step cuts formed into said cladding workpiece.

### Claim 7 (depends on 1)

The method of claim 1, further comprising heating said complete disk to release residual stress caused by fabrication and reduce potential thermal stress induced in service.

### Claim 8 (depends on 1)

The method of claim 1, further comprising machining said complete disk to a specified shape and dimensions.

### Claim 9 (depends on 1)

The method of claim 1, further comprising machining said complete disk to a specified shape and dimensions having a steel and aluminum hybrid surface characteristic.

### Claim 10 (depends on 1)

The method of claim 1, further comprising painting said completed disk partially with a high temperature paint.

### Claim 11 (depends on 1)

The method of claim 1, wherein said cladding workpiece is in the shape of an arc, thereby defining an inner rim, and has a second major external surface, opposed to said first major external surface and further comprising machining said cladding workpiece at said second major external surface, selectively removing material from a machined area, to enhance said inner rim with an increased-thickness relative to said machined area, to maintain the rigidity of said cladding workpiece.

### Claim 12 (depends on 11)

The method of claim 11, wherein said machining takes place as a last step in fabrication of said disk.