Commercial vehicle brake disc

Abstract

In one aspect of the disclosure, a commercial vehicle brake disc is provided that includes a unitary annular body having a central axis of rotation. The annular body includes a vent and a braking portion having an inner braking surface and an outer braking surface. The annular body includes a central mounting flange having through openings to receive studs of a wheel hub. At least a portion of each through opening extends axially intermediate the inner and outer braking surfaces of the annular body. The annular body further includes an inner intake port and an outer intake port in communication with the vent.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 020,209, filed May 5, 2020, which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure relates to brake discs for commercial vehicles, and more specifically, to ventilated brake discs for commercial vehicles. Background Technology

[0004] Brake discs used in commercial vehicles are subjected to high torque loads and high temperatures during braking operations. Commercial vehicles are typically vehicles with a gross vehicle weight classification (GWT) between 5 and 8 and equipped with air or hydraulic braking systems. To compensate for the high torque loads, brake discs for commercial vehicles often have a geometry and materials that allow for greater rigidity than those used in passenger cars. Brake discs for commercial vehicles may also be ventilated to provide airflow through the rotating brake disc and to cool it after braking operations. Due to the brake disc clearance space required to form ventilation holes, the rigidity of ventilated commercial vehicle brake discs may be lower than that of similarly sized brake discs without ventilation holes. The improvement in heat transfer provided by ventilation holes in commercial vehicle brake discs for specific applications may therefore be limited by the corresponding reduction in brake disc rigidity. Furthermore, the geometry of ventilated brake discs can lead to two types of high-temperature-related failures.

[0005] The first type of high-temperature-related failure is thermal shock failure, in which the brake disc temperature suddenly and significantly increases, such as when the brake caliper locks onto the brake disc and the vehicle continues to move. The temperature at the brake disc surface may surge above normal operating temperature. Due to the suddenness of the thermal shock event, the brake disc mounting flange may be at ambient temperature, while the brake surface is at extremely high temperatures. The temperature difference between the brake surface and the mounting flange can cause the brake disc to bend. Bending of the brake disc can create cracks that propagate outward from the bolt holes near the bolt holes of the brake disc mounting flange.

[0006] Another high-temperature-related failure of commercial vehicle brake discs is thermal cycling failure, where the brake disc repeatedly heats up during braking operations and cools down afterward. Some existing ventilated brake discs have geometries that cause the inner and outer sides of the disc to expand and contract at different rates in response to thermal cycling. This difference in expansion and contraction rates causes the brake disc to bend and promotes the propagation of surface cracks, ultimately leading to brake disc failure. The required strength of commercial vehicle brake discs and the encapsulation considerations of their positioning on the wheel ends of commercial vehicles can make addressing both types of high-temperature-related failures that commercial vehicle brake discs may be susceptible to challenging. Summary of the Invention

[0007] In one aspect of this disclosure, a commercial vehicle brake disc is provided, comprising a unified, one-piece annular body having a central axis of rotation. The annular body includes vents and brake portions having inner and outer brake surfaces. The annular body includes a central mounting flange having through openings to receive studs from a wheel hub. At least a portion of each through opening extends axially between the inner and outer brake surfaces of the annular body. The annular body also includes inner and outer air inlets communicating with the vents. The brake disc can provide improved airflow within a compact enclosure on the wheel hub via the inner and outer air inlets.

[0008] This disclosure also provides a commercial vehicle brake disc including an annular body having a central mounting portion, a brake portion radially external to the central mounting portion, and a vent for the brake portion. The annular body includes an outer air intake that opens toward the central mounting portion and communicates with the vent. The mounting portion of the annular body includes an inner boss, such as an ABS voice coil mounting boss. The annular body also includes an inner air intake that alternates with the inner boss around the annular body. The inner air intake opens toward the central mounting portion and communicates with the vent. In one embodiment, the inner boss provides rigidity to the inner side of the annular body and helps limit radial expansion of the annular body during braking operation.

[0009] On the other hand, a commercial vehicle wheel-end assembly is provided, comprising a wheel hub and a brake disc rotatable with the wheel hub. The brake disc includes an inner brake surface, an outer brake surface, and a central mounting portion having multiple through openings for receiving studs from the wheel hub. At least a portion of each through opening extends axially between the inner and outer brake surfaces of the brake disc. The brake disc also includes vents, an inner air inlet communicating with the vents, and an outer air inlet communicating with the vents. Because at least a portion of each through opening of the mounting portion is axially located between the inner and outer brake surfaces of the brake disc, the central mounting portion of the brake disc can transmit torque to the wheel hub during braking operations via clamping between a nut and the wheel hub. The clamping occurs within or adjacent to a plane defined between the inner and outer brake surfaces of the brake disc. This increases the robustness of the brake disc. Furthermore, the inner air inlet, outer air inlet, and vents of the brake disc contribute to the cooling of the brake disc. Attached Figure Description

[0010] Figure 1 It is a three-dimensional view of the wheel end assembly, including the brake disc and wheel hub;

[0011] Figure 2 yes Figure 1An exploded view of the wheel end assembly shows the brake disc with a central mounting flange having a through opening that receives studs from the wheel hub.

[0012] Figure 3 yes Figure 2 A plan view of the inner side of the brake disc, showing the through opening of the brake disc and the ABS voice coil mounting boss of the brake disc alternating around the brake disc;

[0013] Figure 4 It is roughly along Figure 3 A perspective view of a portion of the brake disc, taken by line 4-4, showing the inner air intake of the brake disc communicating with the internal ventilation holes of the brake disc;

[0014] Figure 5 yes Figure 2 A plan view of the outer side of the brake disc;

[0015] Figure 6 It is roughly along Figure 5 A perspective view of a portion of the brake disc, taken by line 6-6, showing the outer air intake communicating with the ventilation holes of the brake disc and the chamfer near the outer air intake that allows air to flow into the outer air intake;

[0016] Figure 7A It is along Figure 3 The cross-sectional view taken by line 7A-7A shows the outer connection portion of the brake disc, which connects the mounting flange to the outer brake portion of the brake disc.

[0017] Figure 7B yes Figure 7A An enlarged view of the area indicated by the dashed circle;

[0018] Figure 8A It is along Figure 3 The cross-sectional view taken by line 8A-8A shows the inner connection portion of the brake disc, which connects the mounting flange to the inner braking portion of the brake disc.

[0019] Figure 8B yes Figure 8B An enlarged view of the area indicated by the dashed circle;

[0020] Figure 8C It is along Figure 3 The cross-sectional view taken from line 8C-8C shows the radial connection portion that connects the mounting flange to the inner and outer braking parts;

[0021] Figure 9 yes Figure 2 A side view of the brake disc, showing the inner and outer braking portions of the brake disc separated by the blades of the brake disc;

[0022] Figure 10 It is along Figure 9 The cross-sectional view taken at centerline 10-10 shows the airflow path extending radially outward from one of the outer air intakes through the ventilation holes of the brake disc;

[0023] Figure 11 It is along Figure 9 The cross-sectional view taken at centerline 11-11 shows the alternating arrangement of the radial portions surrounding the outer and inner connecting parts of the brake disc;

[0024] Figure 12 It is along Figure 9 The cross-sectional view taken by line 12-12 in the figure shows the airflow path extending radially outward from one of the inner air intakes through the ventilation holes of the brake disc;

[0025] Figure 13 This is a cross-sectional view of another brake disc, showing a recess on the inner side of the brake disc opposite to the outer air intake of the brake disc;

[0026] Figure 14 This is a plan view of the inner side of another brake disc, showing that the nut seat of the brake disc's mounting flange has an alternating arrangement with the ABS voice coil mounting boss of the mounting flange; and

[0027] Figure 15 yes Figure 14 A cross-sectional view of the brake disc, showing the internal blades of the brake disc.

[0028] Figure 16 This is a cross-sectional view of another brake disc showing the narrowed internal blades of the brake disc;

[0029] Figure 17 This is a cross-sectional view of another brake disc showing the internal pin blades of the brake disc;

[0030] Figure 18 This is a perspective view of another brake disc, showing the bosses of the mounting flanges that alternate with the through openings around the brake disc;

[0031] Figure 19 It is along Figure 18 The cross-sectional view taken by line 19-19 shows the inner connection portion of the brake disc where the mounting flange is connected to the inner brake surface of the brake disc. Detailed Implementation

[0032] In one aspect of this disclosure, a commercial vehicle brake disc is provided, comprising a unified, one-piece annular body including ventilation holes. The annular body includes a center mounting portion, an inner braking portion, and an outer braking portion. The annular body includes a plurality of outer connecting portions connecting the outer braking portion and the center mounting portion, the outer connecting portions extending outward from the center mounting portion to the outer braking portion. The annular body has an inner air intake between the outer connecting portions and the inner braking portion. The inner air intake communicates with the ventilation holes to allow air to flow from the inside of the annular body into the ventilation holes. The annular body also includes a plurality of inner connecting portions connecting the inner braking portion and the center mounting portion, the inner connecting portions extending inward from the center mounting portion to the inner braking portion. The annular body also has an outer air intake between the inner connecting portions and the outer braking portion. The outer air intake communicates with the ventilation holes to allow air to flow from the outside of the annular body into the ventilation holes. The outer and inner connecting portions provide symmetry in the thermal expansion and contraction of the annular body, such that the annular body is constrained to expand and contract radially rather than bend. In this way, the outer and inner connecting portions improve the robustness of the commercial vehicle brake disc by limiting the propagation of surface cracks along the annular body, thereby restricting the bending of the annular body caused by temperature.

[0033] In one embodiment, the outer connecting portion and the inner connecting portion alternately surround the annular body. The alternating outer and inner connecting portions contribute to the rigidity of the annular body. Furthermore, the alternating outer and inner connecting portions facilitate symmetrical thermal expansion and contraction of the annular body about its centerline.

[0034] about Figure 1 The system provides a wheel end assembly 10 including a brake disc 12 connected to a wheel hub 14. The wheel end assembly 10 has an opening 21 for receiving a vehicle spindle, and is configured to rotate about the vehicle spindle. The wheel hub 14 may include various components for rotatably securing the wheel end assembly 10 to the vehicle spindle, such as bearings, spacers, and spindle lock nuts, which are not shown for clarity. The brake disc 12 has a body 16 with a braking portion 17 including an inner braking portion 18 and an outer braking portion 20. The inner braking portion has an inner braking surface 22, and the outer braking portion 20 has an outer braking surface 24. The inner and outer braking surfaces 22, 24 are frictionally engaged by a pad of a commercial vehicle brake caliper to slow the rotation of the wheel end assembly 10. The brake disc 12 also includes blades 30 extending between the inner and outer braking portions 18, 20, which cooperate with the inner and outer braking portions 18, 20 to form a vent 32. Ventilation hole 32 allows airflow between the inner and outer brake portions 18, 20 to cool brake disc 12 during and after braking operation.

[0035] about Figure 2 The body 16 of the brake disc 12 includes a central mounting portion, such as a mounting flange 40, and a transition portion 42 connecting the mounting flange 40 to inner and outer brake portions 18, 20. The mounting flange 40 includes a through opening 46 for receiving a stud 52 of the wheel hub 14, a central opening 48, and an annular inner surface 50. The wheel hub 14 includes a body 54 supporting the stud 52 and a tubular portion 60. The wheel hub body 54 may also include an opening 63 that receives fasteners such as bolts to connect the wheel rim and tire assembly.

[0036] In some embodiments, the wheel end assembly 10 includes an insulator 62 that resists heat transfer between the brake disc 12 and the wheel hub 14. The insulator 62 has an opening 64 that receives a stud 52 of the wheel hub 14 and is clamped between the wheel hub body 54 and the brake disc mounting flange 40. The wheel end assembly 10 may also include a nut 68 that is threadedly engaged with a distal portion of the stud 52 to secure the brake disc 12 to the wheel hub 14.

[0037] about Figure 3 The body 16 has an annular configuration extending around a central axis 29. The mounting flange 40 includes bosses, such as ABS voice coil mounting portions. In one embodiment, the ABS voice coil mounting portion includes an ABS voice coil mounting boss 70, which alternates with a through opening 46 around the mounting flange 40. The ABS voice coil mounting boss 70 includes one or more portions for attachment to the ABS voice coil, such as a recess 71 for receiving a portion of the voice coil and a recess 73 for receiving a retaining ring. The retaining ring can engage with the recess 73 and hold the ABS voice coil secured to the ABS voice coil mounting boss 70.

[0038] The brake disc 12 includes an inner air inlet 72 that allows airflow from the inner side 74 of the brake disc 12 into the vent 32. The inner air inlet 72 is located outside or recessed from the inner brake surface 22. In one embodiment, the inner air inlet 72 is radially aligned with a through opening 46 of the mounting flange 40. As used herein, the term radial alignment is intended to cover components that have at least partial overlap along a radius (e.g., radius 76) derived from the central axis 29. Similarly, the term axial alignment is intended to cover components that have at least partial overlap along the central axis 29.

[0039] about Figure 4 and Figure 12 The brake disc 12 includes an internal annular channel 90 between the inner air intake 72 and the vent 32. The annular channel 90 serves as a manifold to connect the inner air intake 72 and the outer air intake 120 (see...) of the brake disc 12. Figure 5 The air is distributed to the ventilation opening 32. (e.g.) Figure 12As shown, during the rotation of the brake disc 12, air can enter the inner air inlet 72A, enter the passage 90, enter the ventilation holes 32A and 32B, and pass through the ventilation outlets 121 and 123 along paths 125 and 127. As the airflow travels along paths 125 and 127, it cools the inner and outer braking portions 18 and 20 of the brake disc 12. The brake disc 12 can be mounted to rotate in either direction and generate a similar airflow through the brake disc 12.

[0040] about Figure 4 Air can generally enter the inner air intake 72 along direction 92 and enter the passage 90. The inner air intake 72 includes an opening 94 and may include a recess 96 leading to the opening 94. The mounting flange 40 includes a nut seat 97, which may include, for example, a flat annular surface, on which the outer surface of one of the nuts 68 may rest. The inner air intake 72 may also include a chamfer 100 around the opening 94, which smooths the transition between the sidewall portion 102 of the inner brake portion 18 and the opening 94. The recess 96 and the chamfer 100 provide geometry for guiding air into the opening 94 while minimizing stress rise in the vicinity of the inner air intake 72 in the brake disc 12.

[0041] about Figure 3 and Figure 4 The groove 96 removes material radially outside the nut seat 96 and forms a step 108 that transitions from the nut seat 97 to the bottom surface 110 of the groove 96. The step 108 reduces the thickness of the body 16 radially outside the nut seat 96. This reduced thickness creates a low-stress portion 112 radially outside the through opening 46. In the event of surface cracks forming at the surface portion 114, the low-stress portion 112 inhibits the radial outward propagation of stress fracture. In this way, the inner air intake 72 and its associated geometry contribute to improved robustness of the brake disc 12.

[0042] about Figure 4 The brake disc 12 may have a radius 103A on the opposite side of each inner air inlet 72. Each radius 103A connects the inner surface portion 103B to the sidewall portion 102. There may be a radius 103A on either side of each ABS voice coil mounting boss 70, which contributes to the rigidity of the inner brake portion 18 relative to the mounting flange 40.

[0043] about Figure 5 and Figure 6An outer air intake 120 is shown on the outer side 75 of the brake disc 12. The outer air intake 120 is located inside or recessed from the outer brake surface 24. The outer air intake 120 includes an opening 140 and a tapered surface 142 that transitions from a sidewall portion 144 of the brake disc 12 into the opening 140. The mounting flange 40 includes an outer surface 122 with a chamfer 124 that allows airflow to travel around the end of the tubular portion 60 of the wheel hub body 54 and into the gap of the outer air intake 120. The outer air intake 120 may also include a bottom surface 146 that guides the airflow traveling along the chamfer 124 into the opening 140.

[0044] about Figure 10 During the rotation of the brake disc 12, air can flow into the outer air intake 120A, into the channel 90, into the vents 32C and 32D, and outwards through the vents 129 and 131 along paths 130 and 132. As the airflow travels along paths 130 and 132, it cools the inner and outer brake portions 18 and 20. The airflow entering the inner and outer air intakes 72 and 120 can mix in the channel 90 and the vents 32, providing a more uniform airflow temperature within the brake disc 12. During braking operation, this more uniform airflow temperature within the brake disc 12 can limit localized high-temperature areas within the brake disc 12.

[0045] about Figure 7A and Figure 7B The transition portion 42 of the brake disc 12 includes an outer connecting portion 150 that connects the mounting flange 40 to the outer brake portion 20. The outer connecting portion 150 intersects with or is close to the centerline or center line 151 of the brake disc 12. In one embodiment, the outer connecting portion 150 has a first portion, such as a radial portion 152 extending radially along the center line 151. The outer connecting portion 150 also includes a second portion, such as a lateral portion 154 extending in an outward direction along the central axis 29. The outer connecting portion 150 includes an elbow portion 153 connecting the radial portion 152 and the lateral portion 154.

[0046] about Figure 8A and Figure 8B The transition portion 42 of the brake disc 12 also includes an inner connecting portion 160 that connects the mounting flange 40 to the inner brake portion 18. The inner connecting portion 160 intersects with or is close to the centerline 151. The inner connecting portion 160 has a first portion, such as a radial portion 162, which includes one of the ABS voice coil mounting bosses 70 and has a thickness 182. The inner connecting portion 160 may also include a second portion, such as a thinner radial portion 164 having thicknesses 183A, 183B.

[0047] The brake disc 12 has alternating outer connecting portions 150 and inner connecting portions 160 arranged around it. The alternating outer and inner connecting portions 150, 160 provide a rigid structure to connect the inner and outer brake portions 18, 20 to the mounting flange 40. The alternating inner and outer connecting portions 150, 160 help the brake disc 12 to handle the high loads experienced by brake discs in commercial vehicles.

[0048] Furthermore, the alternating outer and inner connecting portions 150, 160 expand and contract at substantially similar rates, causing the brake disc 12 to expand and contract radially along the centerline 151 as a whole, rather than bending of the inner and outer brake portions 18, 20. Moreover, the alternating outer and inner connecting portions 150, 160 allow the expansion and contraction of each outer connecting portion 150 to balance the expansion and contraction of the adjacent inner connecting portion 160, and vice versa. This balance of thermal expansion and contraction of the alternating outer and inner connecting portions 150, 160 further suppresses bending of the inner and outer brake portions 18, 20, which could propagate surface cracks. In this way, the brake disc 12 is more resistant to the propagation of surface cracks on the brake disc 12 including the mounting flange 40.

[0049] Furthermore, the uniform stiffness of the brake disc 12 between its inner and outer surfaces 22, 24 primarily provides radial deflection or expansion in response to heating of the brake disc 12 during braking operation. Radial expansion maintains uniform contact between the outer surfaces 22, 24 and the brake pads, which in turn maintains uniform heat input to the brake disc 12. This uniform heat input to the brake disc 12 contributes to radial expansion rather than axial deflection. In this way, the uniform stiffness of the brake disc 12 between its inner and outer surfaces 22, 24 provides a positive feedback loop with a high ratio of radial expansion to axial deflection.

[0050] As an example, due to the heat generated by the first caliper pad and the outer brake surface 24, the outer connector portion 150 and the outer brake portion 20 can expand radially outward at a first rate (e.g., one-thousandth of an inch / degree Fahrenheit). Due to the heat generated by the second caliper pad and the inner brake surface 22, the inner connector portion 160 and the inner brake portion 18 can expand radially outward at a second rate. The first and second rates can be substantially similar, such as differing from each other by ten percent or less, such as five percent or less. Once the first caliper pad is removed from the outer brake surface 24, the outer connector portion 150 and the outer brake portion 20 can retract radially inward at a third rate. Once the second caliper pad is removed from the inner brake surface 22, the inner connector portion 160 can retract radially inward at a fourth rate. The third and fourth rates can be substantially similar, such as differing from each other by ten percent or less, such as five percent or less.

[0051] about Figure 7A and Figure 7B The brake disc 12 includes at least one recess 170 opposite to the inner ventilation inlet 72 (see...). Figure 5 In one embodiment, the recess 170 is annular and extends around the circumference of the mounting flange 40. The inner ventilation inlet 72 and the recess 170 narrow the transition portion 42 such that the outer connecting portion 150 has a thickness 174 that is less than half, such as less than one-third, or such as less than one-quarter, of the thickness 175 of the brake disc 12 measured between the inner and outer brake surfaces 22, 24.

[0052] about Figure 8B The radial portion 162 of the inner connecting portion 160 has a thickness 182 that can be greater than, less than, or equal to the thickness 175 of the brake disc 12 measured between the inner and outer brake surfaces 22, 24. This includes the height and radius 103 of the ABS voice coil mounting boss 70 (see...). Figure 4 The thickness 175 of the radial portion 162 contributes to the rigidity of the connection between the inner brake portion 18 and the mounting flange 40. In this way, the outer and inner connecting portions 150, 160 can provide a robust connection between the mounting flange 40 and the inner and outer brake portions 18, 20, while preventing the propagation of surface cracks in the brake disc 12.

[0053] about Figure 8C The transition portion 42 of the brake disc 12 includes a radially connecting portion 161 extending radially along the centerline 151 of the brake disc 12. The radially connecting portion 161 connects the mounting flange 40 to the inner and outer brake portions 18, 20. In one embodiment, the radially connecting portion 161 connects to the axially inner extension 163 and the axially outer extension 165 of the brake portion 17. The radially connecting portion 161 and the axially inner and outer extensions 163, 165 form a T-shape, providing rigidity to the brake disc 12 along the centerline 151. The brake disc 12 has an outer recess 171 communicating with the outer air inlet 120 and axially aligned with the inner recess 169. The recesses 169, 171 narrow the brake disc 12, causing the radially connecting portion 161 to be recessed from the inner and outer brake surfaces 22, 24.

[0054] In addition, the brake disc 12 at each inner connecting portion 160 (see Figure 8A , 8B The brake disc 12 has a radial connecting portion 161 on its opposite side, which cooperates with the inner connecting portion 160 to provide rigidity to the inside of the brake disc 12. Figure 8C As shown, radius 103A transitions between the radial connecting portion 161 and the axially inner extension portion 163. The larger the radius 103A, the greater the rigidity provided by the radial connecting portion 161.

[0055] about Figures 10-12 The outer air intake 120A allows airflow to travel in the inward direction into the brake disc 12 and into the channel 90. (Regarding...) Figure 11 The radial portion 162 of the inner connecting portion 160 is in Figure 10 The radial portion 152 of the outer connecting portion 150 extends radially beyond the outer air intake 120 at a position above the cross-section, thus narrowing the outer air intake 120. The radial portion 152 of the outer connecting portion 150 and the radial portion 162 of the inner connecting portion 160 alternately surround the brake disc 12.

[0056] about Figure 12 The ABS voice coil mounting boss 70 has a base 200, and the base 200 has sides 202 and 204, which form at least a portion of the inner air intake 72. Regarding Figure 10 and Figure 12 Airflow from the inner and outer sides 74, 75 of the brake disc 12 is provided through the inner and outer air inlets 72, 120 to provide airflow through the brake disc 12 and heat transfer between the brake disc 12 and the air.

[0057] The brake disc 12 can take various forms. In one embodiment, the body 14 of the brake disc 12 has a uniform, one-piece structure. The body 14 may comprise metallic materials such as cast iron, ceramic materials, steel, and / or composite compacted graphite iron. In some other embodiments, the body 14 may be made of two or more components made of the same or different materials, which are fixed together, for example, by welding. Regarding Figures 9-12 The blades 30 of the brake disc are shown as straight. The blades 30 may have other configurations, such as curved configurations.

[0058] The brake disc 12 can be connected to the wheel hub 14 in a variety of ways. In one embodiment, the mounting flange 40 can be connected to the wheel hub 14 using a spring pin instead of studs and nuts.

[0059] about Figure 13The present invention provides another cross-section of brake disc 300. Brake disc 300 is similar to brake disc 12 and includes a mounting flange 302, a brake portion 304 having an inner brake portion 306, and a transition portion 308. The transition portion 308 includes an inner connecting portion 310 connecting the mounting flange 302 to the inner brake portion 306. The inner connecting portion 310 includes a radial portion 312, a lateral portion 314, and an elbow portion 316 connecting the radial and lateral portions 312, 314. Brake disc 300 includes an outer air inlet 320 and at least one recess 322 opposite to the outer air inlet 320. The recess 322 may be formed between each ABS voice coil mounting boss 324 and the inner brake surface 326 of brake disc 300. The outer air intake 320 and the recess 322 operate to narrow the transition portion 308, such that the thickness 330 of the inner connecting portion 310 is less than half, such as less than one-third, or such as less than one-quarter, of the thickness 340 between the inner brake surface 326 and the outer brake surface 327.

[0060] about Figure 14 A brake disc 400 is provided that is similar in many respects to the brake disc 12 described above. The brake disc 400 includes a braking portion 402 and a mounting flange 404. The mounting flange 404 includes a through opening 406 for receiving a stud from a wheel hub and a nut seat 408 extending around the through opening 406. The radial thickness 410 of the nut seat 408 is greater than that of the nut seat 97 of the brake disc 12 (see...). Figure 4 The corresponding radial thickness. A larger radial thickness 410 can provide a larger nut seat area and compensate for changes in the nut seat position that may occur due to manufacturing and / or assembly variations.

[0061] about Figure 15 The braking portion 402 of the brake disc 400 includes blades 412 and ventilation holes 414. The width 416 of the blades 412 may be smaller than the blades 30 of the brake disc 12 (see...). Figure 10 The corresponding width of the blades 412. Narrower blades 412 provide wider ventilation holes 414, which may be easier to manufacture in some applications.

[0062] about Figure 16 A brake disc 500 similar in many respects to the aforementioned brake disc is provided, thus highlighting the differences. The brake disc 500 includes a body 502 having an outer air inlet 504, a braking portion 506, and an annular channel 508. The braking portion 506 includes blades 510 spaced apart by vent holes 512. The width 514 of the blades 510 is greater than that of the blades 30 discussed above (see...). Figure 10 The corresponding width of the vent is narrow, which makes the vent 512 wider than the vent 32. In some applications, the wider vent 512 can facilitate manufacturing.

[0063] about Figure 17 A brake disc 600 similar in many respects to the aforementioned brake disc is shown, thus highlighting the differences. The brake disc 600 includes a body 602 having an outer air inlet 604, a braking portion 606, and an annular channel 608. The braking portion 606 includes pin vanes 610, which may have different dimensions with respect to the brake disc 600. In one embodiment, the pin vanes 610 include an inner pin vane 612, a middle pin vane 614, and an outer pin vane 616. Groups of pin vanes 612, 614, 616 may be radially aligned, such as a first group 620 of pin vanes 610. Pin vanes 610 may include a second group 622 of radially aligned pin vanes 610, such as pin vanes 624, 626. Pin vanes 624, 626 are circumferentially offset from pin vanes 612, 614, 620 such that pin vanes 624, 626 can be tightly fitted with pin vanes 612, 614, 616. In one embodiment, the brake disc 600 includes alternating groups of pin blades 620, 622 arranged around the brake portion 606. Airflow entering the brake disc 600 via the outer air inlet 604 and the inner air inlet can travel along paths 630, 632 around the pin blades 610 before exiting the brake disc 600. The nested pin blades 610 can provide a large amount of brake disc material between the inner and outer cheek plates of the brake disc 600, while providing a path for airflow through the brake portion and cooling the underside of the cheek plates. The pin blades 610 between the cheek plates of the brake disc 600 resist crack propagation in the brake portion 606. The pin blades 610 can also induce turbulence in the airflow within the brake disc 600 to improve heat transfer. In some applications, the pin blades 610 can also resist reduced cooling due to corrosion or debris clogging the vents, due to the number of pin blades 610 and the passages through them.

[0064] about Figure 18 A brake disc 700 similar to the aforementioned brake disc is provided, thereby highlighting the differences. The brake disc 700 includes a body 702, the body 720 having a braking portion 704, which has an inner braking portion 706 and an outer braking portion 708. The braking portion 704 includes a pin vane 710 (see...). Figure 19 The body 702 also includes a mounting flange 714 having a through opening 716 for receiving a stud of a wheel hub and a boss 718 alternating with the through opening 716 around the mounting flange 714. The brake disc 700 includes an inner air inlet 720 at the center of the boss 718 surrounding the brake disc 700.

[0065] about Figure 19The inner braking portion 706 includes an inner braking surface 730, which may be coplanar with and abut against the upper surface 732 of the boss 718. In one embodiment, surfaces 730 and 732 are portions of a single flat surface. The body 702 includes a channel 740 communicating with an inner air inlet 720 and an outer air inlet 742. The body 702 includes an inner connector portion 744 for connecting a mounting flange 714 to the inner braking surface 730. Furthermore, the body 702 includes an outer braking surface 750 of the outer braking portion 708, which may be spaced apart from a portion 752 of the mounting flange 714 via the outer air inlet 742.

[0066] Unless otherwise stated herein or clearly contradicted by the context, singular terms such as “a” or “one” are used to encompass both singular and plural. The terms “including,” “having,” “containing,” and “comprising” will be interpreted as open-ended terms. The phrase “at least one” as used herein is intended to be interpreted in a separated sense. For example, the phrase “at least one of A and B” is intended to encompass A, B, or A and B.

[0067] Although specific embodiments of the invention have been described and illustrated, it will be understood that many variations and modifications will occur to those skilled in the art, and the invention is intended to cover all such variations and modifications that fall within the scope of the appended claims.

Claims

1. A commercial vehicle brake disc comprising: a unitary annular body having a central axis of rotation; a vent of the annular body; a braking portion of the annular body having an inner braking surface and an outer braking surface; an axially inner extension of the braking portion extending from the inner braking surface toward a midline of the annular body; an axially outer extension of the braking portion extending from the outer braking surface toward the midline of the annular body; a central mounting flange of the annular body; through openings of the central mounting flange to receive studs of a wheel hub, each through opening extending at least partially axially intermediate the inner and outer braking surfaces of the annular body; an inner intake port of the annular body in communication with the vent, the inner intake port being radially aligned with and extending radially outward from the through openings of the central mounting flange; and an outer intake port of the annular body in communication with the vent; outer connecting portions of the annular body connecting the outer braking surface to the central mounting flange and defining at least a portion of the inner intake port, the outer connecting portions each extending outward from the central mounting flange toward the outer braking surface; inner connecting portions of the annular body connecting the inner braking surface to the central mounting flange and defining at least a portion of the outer intake port, the inner connecting portions each extending inward from the central mounting flange toward the inner braking surface; an ABS voice coil mounting boss extending inward from the inner connecting portions, the ABS voice coil mounting boss alternating with the through openings around the central mounting flange of the annular body; radial connecting portions of the annular body extending radially along the midline of the annular body and connecting the axially inner and outer extensions of the braking portion to the central mounting flange; wherein each radial connecting portion is located between a neighboring one of the outer connecting portions and a neighboring one of the inner connecting portions around the annular body, such that the outer connecting portions, the inner connecting portions, and the radial connecting portions alternate around the annular body; and wherein each radial connecting portion forms a T-shape with one of the axially inner extensions and one of the axially outer extensions.

2. The commercial vehicle brake disc of claim 1, wherein: wherein the braking portion comprises vanes; and wherein the inner and outer connecting portions are each radially aligned with one or more vanes of the annular body and extend from the central mounting flange toward the one or more vanes.

3. The commercial vehicle brake disc of claim 2, wherein, the annular body comprises a channel connecting the inner and outer intake ports with the vent; and wherein the channel is radially intermediate the vanes and the inner and outer connecting portions.

4. The commercial vehicle brake disc of claim 1, wherein, the braking portion comprises an inner braking portion comprising the inner braking surface and an outer braking portion comprising the outer braking surface, the vent being axially intermediate the inner and outer braking portions; and wherein the braking portion comprises a first portion extending outward from the inner braking portion and a second portion extending inward from the outer braking portion; wherein the inner and outer connecting portions, the radial connecting portions connect the central mounting flange to the first and second portions of the braking portion.

5. The commercial vehicle brake disc of claim 1, wherein: The annular body includes at least one outer side recess axially aligned with some of the outer side connecting portions such that some of the connecting portions are recessed from the outer side braking surface.

6. The commercial vehicle brake disc of claim 1 wherein, The outer side connecting portions are axially aligned with inner side air inlets.

7. The commercial vehicle brake disc of claim 1 wherein, The inner side connecting portions are axially aligned with outer side air inlets.

8. The commercial vehicle brake disc of claim 1, wherein, At least one of the inner side connecting portions and the outer side connecting portions has a first portion extending radially outward from the center mounting flange and a second portion extending radially outward from the first portion transverse to the first portion.

9. The commercial vehicle brake disc of claim 8, wherein, At least one of the inner side connecting portions and the outer side connecting portions includes an elbow portion connecting the first portion and the second portion.

10. The commercial vehicle brake disc of claim 1 wherein, wherein The annular body includes a plurality of stepped surfaces intermediate the through openings and the plurality of inner side air inlets.

11. The commercial vehicle brake disc of claim 1, wherein, The annular body includes passages connecting the inner side air inlets and the outer side air inlets with the vent holes.

12. The commercial vehicle brake disc of claim 1, wherein, The inner side air inlets and the outer side air inlets are open to the center mounting flange.

13. A commercial vehicle wheel end assembly comprising: a wheel hub; a plurality of studs of the wheel hub; a brake disc rotatable with the wheel hub about an axis; an inner side braking surface and an outer side braking surface of the brake disc; an axially inner side extending portion of the brake disc extending from the inner side braking surface toward a midline of the brake disc; an axially outer side extending portion of the brake disc extending from the outer side braking surface toward the midline of the brake disc; a center mounting portion of the brake disc having a plurality of through openings to receive the studs of the wheel hub; at least a portion of each through opening extends axially intermediate the inner side braking surface and the outer side braking surface of the brake disc; a vent hole of the brake disc; an inner side air inlet of the brake disc in communication with the vent hole, the inner side air inlet being radially aligned with and radially outward from the through hole of the center mounting portion; an outer side air inlet of the brake disc in communication with the vent hole; outer side connecting portions of the brake disc connecting the outer side braking surface to the center mounting portion and defining at least a portion of the inner side air inlet, the outer side connecting portions each extending from the center mounting portion toward the outer side braking surface; inner side connecting portions of the brake disc connecting the inner side braking surface to the center mounting flange and defining at least a portion of the outer side air inlet, the inner side connecting portions each extending from the center mounting portion toward the inner side braking surface; an ABS voice coil mounting boss extending inward from the inner side connecting portions, the ABS voice coil mounting boss alternating with the through hole about the center mounting portion of the brake disc; radial connecting portions of the brake disc extending radially along the midline of the brake disc and connecting the axially inner side extending portion and the axially outer side extending portion to the center mounting portion; wherein each radial connecting portion is located between an adjacent one of the outer side connecting portions and an adjacent one of the inner side connecting portions around the annular body such that the outer side connecting portions, the inner side connecting portions, and the radial connecting portions alternate around the annular body; and wherein the outer side connecting portions each include a first portion extending radially outward from the center mounting flange and a second portion extending radially outward from the first portion transverse to the first portion. wherein each radial connecting portion forms a T-shape with one of the axially inner extending portions and one of the axially outer extending portions.

14. The commercial vehicle wheel end assembly of claim 13, wherein, The brake disc has a uniform, one-piece construction.

15. The commercial vehicle wheel end assembly of claim 13, wherein, The central mounting portion has an outer side surface and an inner side surface opposite the outer side surface, the through opening extending between the outer side surface and the inner side surface; wherein at least one of the inner and outer side surfaces of the central mounting portion of the brake disc is axially intermediate the inner and outer brake surfaces.

16. The commercial vehicle wheel end assembly of claim 13, wherein, the inner side air inlet is axially aligned with the outer side connecting portion; wherein the outer side air inlet is axially aligned with the inner side connecting portion.

17. The commercial vehicle wheel end assembly of claim 13, wherein, the inner side air inlet and the outer side air inlet alternate around the brake disc.

18. The commercial vehicle wheel end assembly of claim 13, further comprising an insulator configured to be sandwiched between the central mounting portion of the brake disc and the wheel hub.

19. The commercial vehicle wheel end assembly of claim 13, wherein, the ABS voice coil mount boss is axially aligned with the outer side air inlet.

20. The commercial vehicle wheel end assembly of claim 13, wherein, the inner side air inlet and the outer side air inlet comprise air inlet openings proximate the mounting portion of the brake disc.

Images