Brakes – Wheel – Axially movable brake element or housing therefor
Reexamination Certificate
1998-09-11
2001-06-05
Oberleitner, Robert J. (Department: 3613)
Brakes
Wheel
Axially movable brake element or housing therefor
C188S268000, C188S2180XL
Reexamination Certificate
active
06241055
ABSTRACT:
BACKGROUND OF INVENTION
The present invention relates to a vehicle brake rotor and more specifically to a brake rotor having viscoelastic vibration dampening interfaces disposed between the friction rings and ribs.
Wheeled vehicles are typically slowed and stopped with a braking system that generates frictional forces. One known braking system is the disc braking system which includes a rotor attached to one or more of the vehicle wheels for rotation therewith. The rotor has an annular peripheral section comprised of a pair of annular friction rings joined together by spacers or ribs in a mutually parallel, spaced apart relationship to form spaces or vents therebetween. Friction surfaces are disposed on the opposite, outwardly facing annular surfaces of the friction rings.
The disc brake system also includes a caliper assembly secured to a non-rotating component of the vehicle, such as the vehicle frame. The caliper assembly includes a pair of brake pads, each having a backing plate and brake lining material attached thereto. A pad is disposed adjacent each friction ring such that the braking lining material is adjacent the friction surface. The caliper assembly includes at least one moveable piston operatively connected to the backing plate of the brake pads. When the driver brakes the vehicle, hydraulic or pneumatic forces move the piston which clamps the brake lining material of the pads against the friction surfaces of the rotating rotor. As the pads press against the moving rotor friction surfaces, frictional forces are created which oppose the rotation of the wheels and slow the vehicle.
While the conventional rotors function in an effective manner, unwanted noise and vibrations are often generated during braking. A significant portion of the unwanted noise and vibration is generated at the interface of the brake pads and rotor friction surfaces. Vibrations generated at these interfaces excite the rotors creating noise which is transmitted to the occupants of the vehicle. This problem is compounded by the increased use of metallic and semi-metallic brake lining materials which produce more noise and vibration than previously used lining materials.
It is known to apply damping material to the brake backing plate to reduce transmission of the noise and vibration through the backing plate thereby quieting the braking noise. However, the dampened backing plate does not adequately quiet the disc braking system, because it does not adequately reduce the noise and vibration at the friction rings. It is desirable to reduce the noise and vibration created at the friction rings and thus further quiet the disc braking system.
SUMMARY OF INVENTION
The invention relates to an improved modular brake rotor and method for producing the same. The modular brake rotor includes a core having a central hat wall and a plurality of support ribs extending radially outwards therefrom. A pair of friction rings are secured to the support ribs. A viscoelastic vibration reducing element is disposed between the support ribs and the friction rings for creating a vibration reducing interface therebetween. The viscoelastic vibration reducing element includes both viscous and elastic properties and has a greater tendency for reducing the transmission of vibrations therethrough relative to the material forming the friction rings. The viscoelastic vibration reducing element is preferably a viscoelastic adhesive. In an alternate embodiment, the viscoelastic vibration reducing element is a viscoelastic laminate including one or more layers of viscoelastic adhesive bonded to one or more intermediate materials. The viscoelastic adhesive may be a silicone adhesive, an enamel, or any other suitable adhesive with both viscous and elastic properties having a greater tendency for reducing the transmission of vibrations therethrough relative to the material forming the friction rings.
The method for producing the modular disc brake rotor comprises the steps of forming a rotor core including a hat section and ribs extending from the hat section, forming annular friction rings, and securing the friction rings to the rotor core with a viscoelastic vibration reducing element to create a vibration reducing interface therebetween. The viscoelastic vibration reducing element is a preferably a viscoelastic adhesive, or a viscoelastic laminate having a viscoelastic adhesive bonded to an intermediate material.
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Enamels for Engine Structure Damping,W.D. Brentnall, A.R. Stetson, and A.D.Nashif, Oct. 1983.; Air Force Wright Aeronautical Laboratories Materials Laboratory (AFWAL/MLLN) Wright Patterson Air Force Base, Ohio 45433.
Hayes Lemmerz International Inc.
Marshall & Melhorn LLC
Oberleitner Robert J.
Torres Melanie
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