TWI751388B - Disc brake rotor - Google Patents

Abstract

A disc brake rotor is provided that is rotatable about a rotational axis. The disc brake rotor includes a first portion and a second portion. The first portion is made of a first material and the second portion is made of a second material different from the first material. The second portion is connected to the first portion in a connecting direction non-parallel to the rotational axis.

Description

Disc Brake Rotor

In recent years, some high-performance small vehicles (specifically, bicycles) have been equipped with disc brake systems to improve braking performance. These disc brake systems use hydraulically actuated or cable-actuated pistons to apply friction to rotors attached to the vehicle's hub.

In order for disc brakes to be effective on vehicles (and in particular small vehicles, such as bicycles), the rotor should be lightweight and dissipate frictional heat efficiently. It is also desirable to manufacture rotors easily and economically. The exemplary embodiments of the disc brake rotors of the present invention described herein address one or more of these needs. For example, the exemplary embodiment provides a disc brake rotor made of two materials to improve cooling efficiency and/or to facilitate easy and economical manufacture.

According to a first aspect of the present invention, there is provided a disc brake rotor which is rotatable about a rotation axis. The disc brake rotor includes a first part and a second part. The first portion is made of a first material and the second portion is made of a second material different from the first material. The second portion is connected to the first portion in a connecting direction that is not parallel to the axis of rotation.

In the case of the disc brake rotor according to the first aspect, by using two different materials, it is possible to balance the strength and weight of one material with the cooling efficiency of the other material To achieve the desired balance of strength, weight and cooling effectiveness. Furthermore, because the second part is connected to the first part in a connection direction that is not parallel to the axis of rotation, the disc brake rotor can be easily and/or economically made from two materials without overlapping the two materials.

According to a second aspect of the present invention, the disc brake rotor according to the first aspect is configured such that the connection direction is perpendicular to the rotational axis.

In the case of the disc brake rotor according to the second aspect, since the connection direction is perpendicular to the axis of rotation, the disc brake rotor can be easily and/or economically made of two materials without overlapping the two materials.

According to a third aspect of the present invention, the disc brake rotor according to the first aspect or the second aspect is configured such that the disc brake rotor further includes an outer portion and an inner portion. The outer portion has at least one friction surface. The inner portion is located radially inward of the outer portion for attachment to a hub of the wheel.

In the case of the disc brake rotor according to the third aspect, it is possible for the friction surface to be provided in close proximity to the pad of the piston of the brake device, and in the state where the disc brake rotor is connected by the inner part to the hub, the friction surface effectively Dissipate frictional heat.

According to a fourth aspect of the present invention, the disc brake rotor according to the third aspect is configured such that the disc brake rotor further includes a connecting portion disposed between the first portion and the first portion in the connecting direction between the second parts so as to connect the first part to the second part.

In the case of the disc brake rotor according to the fourth aspect, since the connecting portion connects the second portion to the first portion in the connecting direction, the disc brake rotor can be easily and/or economically made of two materials It is not necessary to overlap the two materials.

According to the fifth aspect of the present invention, the disc brake rotor according to the fourth aspect is The configuration is such that the first portion, the second portion and the connecting portion are provided at least partially as part of the friction surface.

In the case of the disc brake rotor according to the fifth aspect, the cooling, strength, light weight and non-overlapping aspects of the first part, the second part and the connecting part may benefit the friction surface of the disc brake rotor.

According to the sixth aspect of the present invention, the disc brake rotor according to the fourth aspect or the fifth aspect is configured such that the first portion, the second portion and the connecting portion are configured to be at least on the friction surface have the same height as viewed from a direction perpendicular to the axis of rotation.

In the case of the disc brake rotor according to the sixth aspect, the disc brake rotor can be easily and/or economically made from two materials without having to overlap the two materials, and provides a smooth surface for contact attachment to Pads for pistons of brake equipment.

According to a seventh aspect of the present invention, the disc brake rotor according to any one of the fourth to sixth aspects is configured such that the connecting portion is formed by welding the first portion and the second portion to the each other to form a weld.

In the case of the disc brake rotor according to the seventh aspect, the first part and the second part can be connected reliably, and the disc brake rotor can be easily and/or economically made of two materials without overlapping the two materials.

According to an eighth aspect of the present invention, the disc brake rotor according to the seventh aspect is configured such that the welding is one of laser welding or friction stir welding.

In the case of the disc brake rotor according to the eighth aspect, no additional filler material is required for the welding process. Thus, the need to remove excess welding material from the friction surface after welding may be reduced or eliminated.

According to the ninth aspect of the present invention, the disc brake rotor according to the seventh or eighth aspect is configured such that at least the connecting portion, a portion of the first portion, and a portion of the second portion are after the welding ground.

In the case of the disc brake rotor according to the ninth aspect, any unevenness caused by welding can be eliminated to provide a smooth and flat friction surface.

According to a tenth aspect of the present invention, the disc brake rotor according to any one of the third to ninth aspects is configured such that the outer portion includes a radially inner edge of the outer portion and the outer portion A cooling fin on at least one of the radially outer edges of a portion.

In the case of the disc brake rotor according to the tenth aspect, the cooling effectiveness of the disc brake rotor can be increased.

According to an eleventh aspect of the present invention, the disc brake rotor according to the tenth aspect is configured such that the outer portion includes the cooling fins on the radially inner edge.

In the case of the disc brake rotor according to the eleventh aspect, the cooling effectiveness of the disc brake rotor can be increased.

According to a twelfth aspect of the present invention, the disc brake rotor according to any one of the third to eleventh aspects is configured such that the outer portion is connected to the inner portion by at least one rivet.

In the case of the disc brake rotor according to the twelfth aspect, the outer portion can be reliably connected to the inner portion.

According to a thirteenth aspect of the present invention, the disc brake rotor according to the twelfth aspect is configured such that the inner portion includes an attachment portion configured to attach to the wheel. At least one arm portion extends radially outward from the attachment portion. Each of the at least one rivet is located at a radially outer end of each of the at least one arm, respectively.

In the case of the disc brake rotor according to the thirteenth aspect, the outer part can be reliably connected to the inner part while keeping the overall weight of the disc brake rotor low.

According to a fourteenth aspect of the present invention, the disc brake rotor according to any one of the first to thirteenth aspects is configured such that the second portion includes an opening.

In the case of the disc brake rotor according to the fourteenth aspect, by providing the opening, the disc brake rotor can reduce the total weight of the second part.

According to a fifteenth aspect of the present invention, the disc brake rotor according to any one of the first to fourteenth aspects is configured such that the first portion is made of only one of the first materials in cross-section A single layer is formed, and the second portion is formed in cross-section of only a single layer of one of the second materials.

In the case of the disc brake rotor according to the fifteenth aspect, the disc brake rotor can be easily and/or economically made of two materials without overlapping the two materials.

According to the sixteenth aspect of the present invention, the disc brake rotor according to any one of the first to fifteenth aspects is configured such that the second material is aluminum or an aluminum alloy.

In the case of the disc brake rotor according to the sixteenth aspect, the second material can effectively dissipate frictional heat.

According to the seventeenth aspect of the present invention, the disc brake rotor according to any one of the first to sixteenth aspects is configured such that the first material is iron or steel.

In the case of the disc brake rotor according to the seventeenth aspect, the first material has a high strength for physical impact.

According to the eighteenth aspect of the present invention, the disc brake rotor according to any one of the first to seventeenth aspects is configured such that the second portion is configured in a polygonal shape, as in the Viewed in the axial direction of one of the axes of rotation.

In the case of the disc brake rotor according to the eighteenth aspect, the circumference of the second part is long enough to achieve a strong connection to the first part.

According to the nineteenth aspect of the present invention, the disc brake rotor according to the eighteenth aspect is configured such that the second portion has at least five sides, as viewed in the axial direction.

In the case of the disc brake rotor according to the nineteenth aspect, the perimeter of the second part is long enough to achieve a strong connection to the first part while avoiding possible complication of the connection between the first part and the second part or Any small angled corners that reduce the strength of the connection.

These and other objects, features, aspects, and advantages will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the accompanying drawings, discloses the details of certain exemplary embodiments.

4: Line/Area

10: Disc brake rotor

12: Part One

14: Part II

16: Connection part

20: External Section

20a: First friction surface

20b: Second friction surface

21a: Radial inner edge

21b: Radial outer edge

22: Internal Section

24: Cooling fins

26: Attachment part

27: Rivets

28: Arm Section

30: Opening

31: Opening

A: Rotation axis

C: Disc brake caliper

F: Front fork

H: height

HB: Hub

P: radial plane

W: wheel

Exemplary embodiments are described below with reference to the following figures: Figure 1 depicts an exemplary embodiment of a disc brake rotor mounted to the hub of the front wheel of a bicycle; Figure 2 depicts the disc brake in an unmounted state viewed along the axis of rotation Illustrative embodiment of a rotor; FIG. 3 depicts an exemplary embodiment of a disc brake rotor in an unmounted state viewed in a direction perpendicular to the axis of rotation; FIG. 4 is an enlarged view of area 4 in FIG. 2; and FIG. 5 is a cross-sectional view of an exemplary embodiment of a disc brake rotor taken along line 5 in FIG. 2 and viewed in a direction perpendicular to the axis of rotation of the disc brake rotor.

Those skilled in the field of small vehicles (and in detail the field of bicycles) will It will be apparent from the present invention that the following description of exemplary embodiments is provided by way of example only, and is not intended to limit the broad inventive concept described herein or included within the scope of the appended claims.

1-5 depict an exemplary embodiment of a disc brake rotor 10 . In use, the disc brake rotor 10 is typically attached to the hub of a small vehicle. By way of example, in Figure 1, a disc brake rotor 10 is shown attached to a hub HB of a front wheel W provided on a bicycle. The disc brake rotor 10 is thus a bicycle disc brake rotor in this exemplary embodiment. When the braking force is to be applied, the pad of the disc brake caliper C mounted on the front fork F of the bicycle contacts the disc brake rotor 10 . As shown in FIGS. 2 and 4 , the disc brake rotor 10 includes a first portion 12 and a second portion 14 . The first portion 12 is made of a first material. In this exemplary embodiment, the first material is iron or steel. More specifically, in this exemplary embodiment, the first material is stainless steel. However, any other material effective in resisting thermal or mechanical deformation may be used as the first material if necessary and/or desired. The second portion 14 is made of a second material different from the first material. In this exemplary embodiment, the second material is aluminum or an aluminum alloy. More specifically, the second material is an aluminum alloy with relatively high stability to frictional heat. But any other material effective in dissipating frictional heat can be used as the second material. The second portion 14 is connected to the first portion 12 in a connecting direction that is not parallel to the axis of rotation A. Thus, as shown in FIGS. 2 and 4 , the disc brake rotor 10 includes a connecting portion 16 that is disposed between the first portion 12 and the second portion 14 in the connecting direction so as to connect the first portion 12 to the second portion 16 . Section 14. As shown in FIGS. 2 and 3 , the rotation axis A corresponds to the central axis of the disc brake rotor 10 , and in the mounted state of the disc brake rotor 10 to the bicycle wheel W, the rotation axis A is also the central axis of the hub HB .

According to this exemplary embodiment, the connection direction is any direction in the radial plane P that is perpendicular to the axis of rotation A (see FIG. 3 ). In other words, the connection direction is perpendicular to the axis of rotation A. However, the connection direction can also be other directions that are not parallel to the rotation axis A.

As shown in FIG. 2 , the disc brake rotor 10 includes an outer portion 20 and an inner portion 22 . The pads of the disc brake caliper C will contact at least a portion of the outer portion 20 . The portion of the surface of the outer portion 20 that the pad will contact is considered the friction surface. Thus, the outer part 20 has at least one friction surface. In this exemplary embodiment, the disc brake caliper C is configured to clamp the disc brake rotor 10 by means of two pads. Thus, the outer part 20 has a first friction surface 20a and a second friction surface 20b facing in the opposite direction along the axis of rotation A with respect to the first friction surface 20a. The first portion 12, the second portion 14 and the connecting portion 16 are provided at least partially as portions of friction surfaces (in this exemplary embodiment, the first friction surface 20a and the second friction surface 20b). The inner part 22 is radially inward of the outer part 20 for attachment to the hub HB of the wheel W.

The connecting portion 16 may be a weld formed by welding the first portion 12 and the second portion 14 to each other, such as by laser welding or friction stir welding. By using one of these welding techniques, the second portion 14 can be placed adjacent to and connected to the first portion 12 without either the first portion 12 or the second portion 14 having to be connected as the other Technical requirements generally overlap with each other. Furthermore, the surface of the second portion 14 may be relatively smooth as a result of such welding, depending on the type of welding and/or welding technique used. In this exemplary embodiment, the connecting portion 16 is formed by stir welding. Furthermore, in this exemplary embodiment, at least the connecting portion 16, a portion of the first portion 12, and a portion of the second portion 14 are grounded after soldering to remove any unevenness that may have been caused by soldering. Preferably, the first friction surface 20a and the second friction surface 20b are completely grounded. Alternatively, the connection portion 16 may be formed by other connection techniques such as gluing, diffusion bonding, and the like.

As shown in FIGS. 2 and 5 , the inner portion 22 is provided as a separate component from the outer portion 20 . The outer part 20 is connected to the inner part 22 by means of rivets 27 . In this exemplary embodiment, five rivets 27 are used to connect outer portion 20 to inner portion 22 . Of course However, the number of rivets 27 may vary depending on the particular configuration of inner portion 22 and outer portion 20 . As shown in FIG. 2 , the inner portion 22 includes an attachment portion 26 configured to attach to the hub HB of the wheel W. As shown in FIG. At least one arm portion 28 extends radially outward from the attachment portion 26 and a rivet 27 is located at the end of each arm portion 28 . In this exemplary embodiment, five arm portions 28 extend from attachment portion 26 . However, the number of arm portions 28 may vary depending on the particular configuration of the inner portion 22 and outer portion 20 .

As shown in FIGS. 2 and 3 , the outer portion 20 includes cooling fins 24 on at least one of the radially inner edge 21 a of the outer portion 20 and the rivets 27 of the outer portion 20 . In this exemplary embodiment, outer portion 20 includes cooling fins 24 on a radially inner edge 21a of outer portion 20 . The cooling fin 24 may be one of a plurality of cooling fins 24 . In this exemplary embodiment, five cooling fins 24 are provided on the radially inner edge 21a. The number of cooling fins 24 corresponds to or is related to the number of arm portions 28 of the inner portion 22 . However, such cooling fins 24 need not be present. Alternatively or additionally, cooling fins 24 may be provided on the radially outer edge 21b of the outer portion 20 .

As shown in Figures 2 and 4, the second portion 14 includes openings 30 to reduce weight. In this exemplary embodiment, ten second portions 14 are provided on outer portion 20 . In more detail, two second portions 14 are provided at the radially outer side of each arm portion 28 . In this exemplary embodiment, each second portion 14 has an opening 30 . However, opening 30 need not be part of second portion 14 . The first part includes openings 31 to reduce weight. In this exemplary embodiment, three openings 31 are located between the two second portions 14 . Therefore, all fifteen openings 31 are provided on the first portion 12 . In other words, a plurality of openings 31 are provided on the first part 12 and between the two second parts 14 . However, the opening 31 need not be part of the first portion 12 . Also, as shown in FIG. 2 , the second portion 14 is configured in the shape of a polygon, as viewed in the axial direction of the axis of rotation A. Preferably, at least one of the second portions 14 has at least five sides, such as at the axis of rotation A Viewed in the axial direction of . In this exemplary embodiment, the five second portions 14 have five sides, and the other five second portions 14 have four sides, as viewed in the axial direction of the axis of rotation A. However, in other embodiments, non-polygonal shaped openings may be used.

As shown in FIG. 5 , the first portion 12 consists in cross-section of only a single layer of the first material. That is, the first portion 12 includes only a single layer of the first material, as viewed in a cross-section that appears to be perpendicular to the axis of rotation A (eg, FIG. 5 ). In other words, in cross-section, within the first portion 12, no other material is present above or below the first material. Similarly, the second portion 14 in cross-section consists of only a single layer of the second material. That is, the second portion 14 includes only a single layer of the second material, as viewed in a cross-section that appears to be perpendicular to the axis of rotation A (eg, FIG. 5 ) - in cross-section, within the first portion 12, the first No other material is present above or below the second material. Furthermore, as shown in FIG. 5 , the first portion 12 , the second portion 14 and the connecting portion 16 have the same height H at least on the friction surface, viewed from a direction perpendicular to the axis of rotation A. In other words, at least one surface of the second portion 14 is flush with a surface of the first portion 12, so that the first portion 12 and the second portion 14 together form at least one friction surface.

In the above description and the scope of the appended claims, the term "comprising" and its derivatives are intended to specify the presence of recited features, elements, components, groups, integers and/or steps but not to exclude other unrecited features, elements, components An open-ended term for the existence of , groups, integers, and/or steps. This concept also applies to words of similar meaning, such as the terms "having", "including" and their derivatives. Terms of any degree such as "substantially" or "substantially" are intended to confer a reasonable amount of deviation, within the limit that the end result or expected effect is not significantly changed. Furthermore, as used herein, directional terms such as "front" and its derivatives refer to the direction as viewed from a small vehicle rider seated on the vehicle's seat or in a driving position facing the handlebars direction. The terms "internal", "external", "axial" and "radial" refer to directions relative to the axis A of rotation. As used herein, the term "small vehicle" refers to electric and non-electric vehicles regardless of the number of wheels purposes, but does not include a four-wheeled vehicle (eg, a car or truck) that has an internal combustion engine as a power source to drive the wheels, or a four-wheeled vehicle that requires a driver's license to operate on public roads.

While illustrative embodiments have been described in order to explain the principles of the invention, it will be apparent to those skilled in the art that various changes and modifications can be made herein without departing from the broader principles of the invention. For example, the size, shape, location or orientation of the various components can be changed as needed and/or desired. Components shown directly connected or in contact with each other may have intermediate structures disposed therebetween. The functions of one element can be performed by two elements, and vice versa. All advantages described herein need not be achieved by a particular embodiment at the same time. Accordingly, the foregoing description of exemplary embodiments is not intended to limit the scope of the appended claims unless expressly recited therein.

12: Part One

14: Part II

16: Connection part

20: External Section

20a: First friction surface

20b: Second friction surface

24: Cooling fins

27: Rivets

28: Arm Section

30: Opening

A: Rotation axis

H: height

Claims (19)

A disc brake rotor rotatable about an axis of rotation, the disc brake rotor comprising: a first part made of a first material; and a second part made of a second material different from the first material so that the second part is connected to the first part in a connecting direction that is not parallel to the axis of rotation, wherein at least one surface of the second part is flush with a surface of the first part such that the first part and the first part are The two parts together form at least one friction surface. The disc brake rotor of claim 1, wherein: the connection direction is perpendicular to the rotation axis. The disc brake rotor of claim 1 or 2, further comprising: an outer portion having at least one friction surface; and an inner portion radially inward of the outer portion for attachment to a hub of the wheel. The disc brake rotor of claim 3, further comprising: a connecting portion disposed between the first portion and the second portion in the connecting direction so as to connect the first portion to the second portion. The disc brake rotor of claim 4, wherein: the connecting portion is formed by welding the first portion and the second portion to each other A weldment, and the weld is one of laser welding or friction stir welding. The disc brake rotor of claim 4, wherein: the connecting portion is a weld formed by welding the first portion and the second portion to each other, and at least the connecting portion, a portion of the first portion and the A portion of the second portion is grounded after the soldering. The disc brake rotor of claim 3, wherein: the outer portion includes a cooling fin on at least one of a radially inner edge of the outer portion and a radially outer edge of the outer portion. The disc brake rotor of claim 7, wherein: the outer portion includes the cooling fins on the radially inner edge. The disc brake rotor of claim 3, wherein: the outer portion is connected to the inner portion by at least one rivet. The disc brake rotor of claim 9, wherein: the inner portion includes an attachment portion configured to attach to the wheel; at least one arm portion extends radially outward from the attachment portion; and the at least one Each of the rivets is located at a radially outer end of each of the at least one arm, respectively. 2. The disc brake rotor of claim 1 or 2, wherein: the first portion is composed of only a single layer of the first material in cross-section, and the second portion is composed of only one of the second materials in cross-section Single layer construction. The disc brake rotor of claim 1 or 2, wherein: the second portion is configured in the shape of a polygon, as viewed in an axial direction of the axis of rotation. The disc brake rotor of claim 12, wherein: the second portion has at least five sides, as viewed in the axial direction. A disc brake rotor rotatable about an axis of rotation, the disc brake rotor comprising: a first part made of a first material; and a second part made of a second material different from the first material the second part is connected to the first part in a connecting direction not parallel to the axis of rotation; an outer part having at least one friction surface; and an inner part radially inward of the outer part in order to Attached to a hub of a wheel; a connecting portion disposed between the first portion and the second portion in the connecting direction so as to connect the first portion to the second portion; wherein the first portion, the second portion The part and the connecting part are provided at least in part as part of the friction surface. A disc brake rotor rotatable about an axis of rotation, the disc brake rotor comprising: a first part made of a first material; and a second part made of a second material different from the first material the second part is connected to the first part in a connecting direction not parallel to the axis of rotation; an outer part having at least one friction surface; and an inner part radially inward of the outer part in order to Attached to a hub of a wheel; a connecting portion disposed between the first portion and the second portion in the connecting direction so as to connect the first portion to the second portion; wherein the first portion, the second portion The portion and the connecting portion are configured to have the same height at least on the friction surface, as viewed from a direction perpendicular to the axis of rotation. A disc brake rotor rotatable about an axis of rotation, the disc brake rotor comprising: a first part made of a first material; and a second part made of a second material different from the first material the second part is connected to the first part in a connecting direction not parallel to the axis of rotation; an outer part having at least one friction surface; and an inner part radially inward of the outer part in order to Attached to a hub of a wheel, a connecting portion disposed between the first portion and the second portion in the connecting direction so as to connect the first portion to the second portion; wherein the connecting portion is provided by the The first portion and the second portion are welded to each other to form a weld. A disc brake rotor rotatable about an axis of rotation, the disc brake rotor comprising: a first part made of a first material; and a second part made of a second material different from the first material In this way, the second portion is connected to the first portion in a connecting direction that is not parallel to the axis of rotation; wherein the second portion includes an opening. A disc brake rotor rotatable about an axis of rotation, the disc brake rotor comprising: a first part made of a first material; and a second part made of a second material different from the first material The second part is connected to the first part in a connecting direction which is not parallel to the rotation axis; wherein the second material is aluminum or an aluminum alloy. A disc brake rotor rotatable about an axis of rotation, the disc brake rotor comprising: a first part made of a first material; and a second part made of a second material different from the first material The second part is connected to the first part in a connecting direction that is not parallel to the axis of rotation; wherein the first material is iron or steel.

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