Two-piece brake disc for a vehicle and method for manufacturing the brake disc

Abstract

The present invention relates to a two-piece brake disc (1) for a vehicle, the brake disc comprising: a brake drum (2) formed by deformation of a sheet metal and having external teeth (3) on its outer circumferential surface; and a friction ring (4) formed by molding of gray cast iron and having internal teeth (5) on its inner circumferential surface, the internal teeth engaging with the external teeth (3) of the brake drum (2) to form a torsional connection, wherein the friction ring (4) has a plurality of axial notches (6) and the brake drum (2) has a plurality of insertion elements (7), each notch (6) receiving a insertion element (7), the insertion element extending from a first end face of the friction ring (4) through the corresponding notch (6) to a second end face of the friction ring (4), and the insertion element being configured to axially fix the friction ring (4) to the brake drum (2).

Description

Technical Field

[0001] This invention relates to a two-piece brake disc for vehicles. It also relates to a method for manufacturing such a two-piece brake disc. Furthermore, it relates to a vehicle having such a two-piece brake disc. Background Technology

[0002] Typically, one-piece cast brake discs are known, in which both the friction rings and the brake drum are made of cast material. A disadvantage of this one-piece implementation is its heavy weight. To reduce weight, two-piece composite brake discs have been developed, which have a brake drum made of steel or aluminum and friction rings made of gray cast iron.

[0003] For example, EP2673525A1 discloses a two-piece composite brake disc for motor vehicles, comprising a brake disc drum and at least one mating brake ring, the brake disc drum and brake ring being interconnected by a joining process. In the joining region, the inner brake ring tooth profile is engaged with the brake disc drum tooth profile. In this joining region, the brake disc drum tooth surface of the brake disc drum tooth profile and the brake ring tooth surface of the brake ring tooth profile have different mating forms. The brake disc drum has a basic conical shape before the joining process. The inner brake ring tooth profile and / or the brake disc drum tooth profile undergo elastic-plastic deformation at least in the region of their respective tooth surfaces due to the joining process. Summary of the Invention

[0004] The object of this invention is to provide an alternative two-piece brake disc for vehicles. Specifically, the manufacturing process of such a brake disc is to be optimized. This object is achieved by a two-piece brake disc having the features of independent claim 1. Advantageous embodiments are the subject matter of the dependent claims, the following description, and the accompanying drawings.

[0005] The present invention provides a two-piece brake disc for a vehicle comprising: a brake drum formed by deforming a sheet metal and having external teeth on its outer circumferential surface; and a friction ring formed by molding gray cast iron and having internal teeth on its inner circumferential surface, the internal teeth engaging with the external teeth on the brake drum to form a torsional connection, the friction ring having a plurality of axial notches, and the brake drum having a plurality of insertion elements, each notch receiving one insertion element, the insertion element extending from a first end face of the friction ring through the corresponding notch to a second end face of the friction ring, and the insertion element being configured to axially fix the friction ring to the brake drum.

[0006] Thus, the anti-torsional connection for transmitting torque between the brake drum and the friction ring is achieved by the meshing of internal and external teeth, which are axially inserted into each other during the assembly of this two-piece brake disc. Therefore, the internal and external teeth are constructed as interlocking teeth, each having radially configured teeth and grooves. The teeth and grooves of each tooth are alternately constructed in the circumferential direction. Specifically, the teeth of the external teeth and the grooves of the internal teeth are complementary, and the teeth of the internal teeth and the grooves of the external teeth are also complementary.

[0007] The friction ring is axially fixed to the brake drum by inserting a connector into a notch. Specifically, the end section of each connector is deformed to prevent undamaged removal from the notch. For example, the end section of each connector, particularly the free end, is deformed, especially by hot riveting, pressing, or folding, to create at least a form-locking and / or force-locking connection for axial fixation.

[0008] According to the method for manufacturing a two-piece brake disc of the present invention, a brake drum is first formed by deforming a sheet metal, wherein external teeth and a plurality of insert elements are constructed on the outer circumferential surface of the brake drum. Preferably, the brake drum with external teeth is formed by deep drawing a sheet metal, and the insert elements are formed by bending flat tabs on the outer circumferential surface of the brake drum. In particular, the brake drum is cylindrical, i.e., non-conical, and thus has a substantially constant diameter. Simultaneously or staggered in time, a friction ring can be formed by molding gray cast iron, wherein the friction ring has internal teeth on its inner circumferential surface, which engage with external teeth on the brake drum to form a torsional connection, and the friction ring has a plurality of axial notches. The brake drum and the friction ring are then joined, wherein the brake drum is axially inserted through the friction ring, such that the external teeth and internal teeth form a torsional connection and the insert elements are axially guided through the corresponding notches from the first end face of the friction ring to the second end face of the friction ring. Finally, the brake drum and friction ring are axially fixed by deforming at least one end section of each plug element.

[0009] For example, the brake drum is made of steel, particularly 35CrMn5. For example, the friction ring is made of cast iron with flake graphite, particularly EN-GJL-200 or EN-GJL-150.

[0010] According to one embodiment, at least three to a maximum of fourteen plug-in elements are constructed substantially parallel to the outer peripheral surface of the brake drum. Preferably, at least four to a maximum of ten plug-in elements are constructed substantially parallel to the outer peripheral surface of the brake drum. In particular, the plug-in elements on the brake drum, and thus the notches on the friction ring, are uniformly distributed in the circumferential direction. This allows for uniform axial fixation. "Substantially parallel to the outer peripheral surface of the brake drum" means that a large portion of each plug-in element extends parallel to the outer peripheral surface with a minor deviation of no more than five degrees.

[0011] According to one embodiment, the insertion element is constructed on a surrounding flange of the brake drum. This flange extends radially outward and is configured as an axial stop surface for the friction ring. Specifically, the friction ring axially abuts against this flange in a surrounding manner.

[0012] According to one embodiment, each plug-in element has three arms integrally connected to each other. A first arm is configured to axially abut against a first end face of the friction ring, a second arm is configured on the brake drum to be disposed in a corresponding notch, and a third arm is configured to axially abut against a second end face of the friction ring. Specifically, the first arm is integrally connected to a flange on the brake drum, and the second arm is disposed between and integrally connected to both the first and third arms. The friction ring is thus axially fixed between the first and third arms, with the first end face of the friction ring abutting against the first arm and the second end face abutting against the third arm. The second arm axially passes through a corresponding notch and integrally connects the first and third arms to each other.

[0013] According to one embodiment, the first and third arms are constructed substantially perpendicular to the second arm. Specifically, the first and third arms are constructed substantially perpendicular to the outer peripheral surface of the brake drum. For example, the third arm is constructed by bending the second arm, such that the resulting shape approximates a plug, particularly a T-shaped structure.

[0014] According to one embodiment, the friction ring has a circumferential recess in the notch region on at least one of the two end faces. For example, the circumferential recess is provided on the second end face. At the second end face, the brake drum protrudes axially and thus extends along the axis of rotation. Alternatively or additionally, the circumferential recess is provided on the first end face. In particular, the at least one recess is provided to improve the ventilation performance of the friction ring.

[0015] According to one embodiment, on the second end face of the friction ring, each notch has a recessed cavity for receiving the end segment of the corresponding plug element. For example, the end segment of each plug element, particularly the free end of each plug element, is deformed, especially by hot riveting, pressing, and / or folding, to form at least a form-locking and / or force-locking connection for axial fixation. The deformed end segment of each plug element rests against the friction ring and forms a third arm of the plug element. If a cavity is constructed at each notch, the deformed material of the end segment of the corresponding plug element can be received in the cavity and thus will not protrude beyond the second end face of the friction ring.

[0016] The vehicle of the present invention includes at least one two-piece brake disc of the present invention. Specifically, one two-piece brake disc of the present invention is correspondingly located at each wheel. The vehicle is preferably configured as a motor vehicle. The definitions and descriptions above regarding the technical effects, advantages, and preferred embodiments of the transmission device of the present invention, after necessary modifications, also apply to the drive unit of the present invention and the vehicle of the present invention. Attached Figure Description

[0017] Advantageous embodiments of the invention, as described below, are illustrated in the accompanying drawings, wherein like or similar elements are represented by the same reference numerals. In the drawings:

[0018] Figure 1 A simplified schematic perspective view of the height of the two-piece brake disc of the present invention according to a first embodiment is shown.

[0019] Figure 2 A partial detail view of the two-piece brake disc according to the first embodiment is shown;

[0020] Figure 3 An exploded view of a two-piece brake disc according to the first embodiment is shown;

[0021] Figure 4 A partial detail view of the friction ring of the two-piece brake disc according to the first embodiment is shown;

[0022] Figure 5 A partial detail view of the brake drum of the two-piece brake disc according to the first embodiment is shown;

[0023] Figure 6 A partial detail view of the two-piece brake disc according to the first embodiment is shown;

[0024] Figure 7 A simplified schematic perspective view of the height of the two-piece brake disc of the present invention according to a second embodiment is shown.

[0025] Figure 8A partial detail view of the two-piece brake disc according to the second embodiment is shown;

[0026] Figure 9 A highly simplified schematic diagram of a vehicle having multiple two-piece brake discs of the present invention is shown. Detailed Implementation

[0027] Figure 1 Showing the use of Figure 9 The vehicle 100 shown has a two-piece brake disc 1 according to the present invention. The two-piece brake disc 1 includes a brake drum 2 and a friction ring 4. Figure 2 Show Figure 1 Partial details of the two-piece brake disc 1 of the present invention. The brake drum 2 is formed from a steel plate by deformation processing, and has corresponding external teeth 3 on its outer circumferential surface. The friction ring 4 is formed from gray cast iron, and has corresponding internal teeth 5 on its inner circumferential surface. In order to achieve a torsional connection between the brake drum 2 and the friction ring 4, the internal teeth 5 are fitted into the external teeth 3 of the brake drum 2 in a form-locking manner, which is particularly evident in… Figure 2 As clearly shown in the diagram, the internal toothed portion 5 and the external toothed portion 3 are configured as interlocking teeth, enabling torque transmission between the brake hub 2 and the friction ring 4.

[0028] As shown in the exploded view of the two-piece brake disc 1 Figure 3 It is particularly clear that the friction ring 4 has a total of eight axial notches 6. Furthermore, the brake drum 2 has a total of eight insertion elements 7, although only six of these elements 7 are visible from a three-dimensional perspective. In the assembled state of the two-piece brake disc 1, the brake drum 2 axially inserts through the friction ring 4, forming an anti-torsional connection between the external teeth 3 and the internal teeth 5, and the insertion elements 7 extend axially from the first end face of the friction ring 4 through each notch 6 to the second end face of the friction ring 4. The brake drum 2 and the friction ring 4 are axially fixed by deforming, particularly bending, the end sections of each insertion element 7 at 90°, so that each end section abuts against the second end face of the friction ring. The end sections of each insertion element 7 can be manufactured, for example, by hot riveting, pressing, or folding.

[0029] Furthermore, the friction ring 4 has a surrounding recess 9 on its second end face in the area of ​​the notch 6, which is designed to improve ventilation of the friction ring 4. When the two-piece brake disc 1 is assembled on a vehicle, particularly on a vehicle wheel, the two-piece brake disc 1 (i.e., the brake drum 2 and the friction ring 4) rotates about a common axis of rotation 11. When braking torque is introduced onto the friction ring 4 through the brake shoes (not shown in detail) of the braking device, the vehicle is decelerated.

[0030] Figure 4A portion of the friction ring 4 of the two-piece brake disc 1 is shown, with particular emphasis on the internal tooth portion 5, which is constructed as an interlocking tooth, and the notches 6. The internal tooth portion 5 consists of radially arranged teeth and grooves, which are alternately arranged in the circumferential direction. All notches 6 are constructed as identical angular through holes, i.e., voids. Each notch 6 extends axially through the entire friction ring 4, i.e., from the first end face of the friction ring 4 to the second end face.

[0031] Figure 5 A partial view of the brake drum 2 of the two-piece brake disc 1 is shown, with particular emphasis on the outer toothed portion 3, which is constructed as a toothed section, and the inserting element 7. The outer toothed portion 3 consists of radially arranged teeth and grooves, which are alternately arranged circumferentially. The teeth of the outer toothed portion 3 and the grooves of the inner toothed portion 5 are complementary in construction, and the grooves of the outer toothed portion 3 and the teeth of the inner toothed portion 5 are complementary in construction. All inserting elements 7 are identically constructed and are provided on the surrounding flange 8 of the brake drum 2. (See from...) Figure 6 As can be clearly seen, the flange 8 is configured as an axial stop, and the first end face of the friction ring 4 axially abuts against this stop. Each plug-in element 7 has three integrally connected arms 7.1, 7.2, and 7.3. The first arm 7.1 is configured to axially abut against the first end face of the friction ring 4, the second arm 7.2 is configured on the brake drum 2 to be placed in the corresponding notch 6, and the third arm 7.3 is configured to axially abut against the second end face of the friction ring 4. The third arm 7.3 is configured as the free end of the plug-in element 7, and as shown... Figure 6 As shown, in the fully assembled state of the two-piece brake disc 1, the third support arm axially abuts against the second end face of the friction ring 4 to achieve axial fixation of the friction ring 4 on the brake drum 2. The plug-in element 7 is constructed substantially parallel to the outer circumferential surface of the brake drum 2. For example, especially by... Figure 6 It can be seen that the first arm 7.1 and the third arm 7.3 are both basically perpendicular to the second arm 7.2 and thus also perpendicular to the outer peripheral surface of the brake drum 2.

[0032] To manufacture the two-piece brake disc 1, a brake drum 2 and a friction ring 4 are first constructed or provided. The brake drum 2 is formed by deep drawing a steel plate, wherein external teeth 3 and multiple insertion elements 7 are constructed on the outer circumferential surface of the brake drum 2. Specifically, the insertion elements 7 are constructed by bending the flat tabs on the outer circumferential surface of the brake drum 2, i.e., the flange 8, by bending them at 90°. The friction ring 4 is formed by molding gray cast iron, where internal teeth 5 and multiple axial notches 6 are constructed. Subsequently, the brake drum 2 is axially inserted through the friction ring 4, such that the external teeth 3 and the internal teeth 5 form a torsional connection, and the insertion elements 7 of the brake drum 2 are axially guided from the first end face of the friction ring 4 to the second end face through the notches 6 of the friction ring 4. The brake drum 2 and the friction ring 4 are axially fixed by deforming the end sections of each insertion element 7 to form a third arm 7.3 constructed substantially perpendicular to the second arm 7.2. Finally, the two-piece brake disc 1 can be finally fine-tuned or finished. This manufacturing process reduces manufacturing and assembly costs. In particular, it enables the production of lightweight and structurally robust two-piece brake discs.

[0033] Figure 7 and Figure 8 A second embodiment of the two-piece brake disc 1 of the present invention is shown. The two-piece brake disc 1 according to the second embodiment is substantially the same as the two-piece brake disc 1 according to the first embodiment. The difference between the two embodiments is that a cavity 10 is formed in the region of the notch 6 on the second end face of the friction ring 4, and the end section of the corresponding insertion element 7 (i.e., the third arm 7.3) is received in the cavity 10. In other words, the end section of each insertion element 7 is deformed such that the end section substantially fills the notch of the cavity 10, and in particular does not protrude from the cavity 10. For example, the end section of each insertion element 7 is substantially plug-shaped or T-shaped to achieve a particularly reliable and stable axial fixation effect. This is due to Figure 8 It was derived very well.

[0034] Figure 9 The vehicle 100 is shown, having a first axle 101 with two wheels R1 and R2, and a second axle 102 with two wheels R3 and R4. Here, the first axle 101 is configured as the rear axle of the vehicle 100. A drive unit 103 is mounted on the second axle 102 (i.e., the front axle of the vehicle 100) and is drively connected to the wheels R3 and R4 of the second axle 102. Each of the four wheels R1, R2, R3, and R4 has a corresponding two-piece brake disc 1, which is configured to brake the respective wheels R1, R2, R3, and R4.

[0035] List of reference numerals

[0036] 1 brake disc

[0037] 2 Brake Drums

[0038] 3. External teeth on the brake drum

[0039] 4 Friction Rings

[0040] 5. Internal teeth on the friction ring

[0041] 6 gaps

[0042] 7 Connector Components

[0043] 7.1 First arm of the plug-in component

[0044] 7.2 Second arm of the plug-in component

[0045] 7.3 Third arm of plug-in component

[0046] 8 flanges

[0047] 9. Depression

[0048] 10 concave cavities

[0049] 11 Rotation axis

[0050] 100 vehicles

[0051] 101 First Axle

[0052] 102 Second Axle

[0053] 103 drive motor

[0054] R1 wheels

[0055] R2 wheels

[0056] R3 wheels

[0057] R4 wheels

Claims

1. A two-piece brake disc (1) for a vehicle (100), the brake disc comprising: a brake drum (2) formed by deformation of a sheet metal and having external teeth (3) on its outer circumferential surface; and a friction ring (4) formed by molding of gray cast iron and having internal teeth (5) on its inner circumferential surface, the internal teeth engaging with the external teeth (3) on the brake drum (2) to form a torsional connection, characterized in that, The friction ring (4) has a plurality of axial notches (6), and the brake drum (2) has a plurality of plug elements (7), each notch (6) receiving a plug element (7), the plug element (7) extending from the first end face of the friction ring (4) through the corresponding notch (6) to the second end face of the friction ring (4), and the plug element is configured to axially fix the friction ring (4) to the brake drum (2).

2. The brake disc (1) according to claim 1, characterized in that, At least three to a maximum of fourteen plug-in elements (7) are constructed substantially parallel to the outer peripheral surface of the brake drum (2).

3. The brake disc (1) according to any one of the preceding claims, characterized in that, The plug element (7) is constructed on the surrounding flange (8) of the brake drum (2).

4. The brake disc (1) according to any one of the preceding claims, characterized in that, Each plug element (7) has three arms integrally connected to each other. 7.1, 7.2, 7.3), wherein the first arm (7.1) is constructed to axially abut against the first end face of the friction ring (4), the second arm (7.2) is constructed on the brake drum (2) to be arranged in the corresponding notch (6), and the third arm (7.3) is constructed to axially abut against the second end face of the friction ring (4).

5. The brake disc (1) according to claim 4, characterized in that, The first arm (7.1) and the third arm (7.3) are constructed substantially perpendicular to the second arm (7.2).

6. The brake disc (1) according to any one of the preceding claims, characterized in that, The friction ring (4) has a circumferential recess (9) on at least one of its two end faces in the region of the notch (6).

7. The brake disc (1) according to any one of the preceding claims, characterized in that, On the second end face of the friction ring (4), each notch (6) has a recess (10) configured as a recess for receiving the end section of the corresponding plug element (7).

8. A method for manufacturing a two-piece brake disc (1), said brake disc being a brake disc according to any one of the preceding claims, said method comprising the following steps: -The brake drum (2) is constructed by deforming metal sheets, wherein, The outer peripheral surface of the brake drum (2) is provided with external teeth (3) and multiple plug-in elements (7). - A friction ring (4) is formed by molding gray cast iron, wherein the friction ring (4) has an inner toothed portion (5) on its inner circumferential surface, the inner toothed portion engaging with an outer toothed portion (3) on the brake drum (2) to form an anti-torsional connection, and the friction ring has a plurality of axial notches (6). - The brake drum (2) is joined to the friction ring (4), wherein the brake drum (2) is axially inserted through the friction ring (4), such that the external tooth (3) and the internal tooth (5) form an anti-torsional connection and the insertion element (7) is axially guided from the first end face of the friction ring (4) to the second end face of the friction ring (4) through the notches (6). - The brake drum (2) is axially fixed to the friction ring (4) by deforming at least one end section of each plug element (7).

9. The method according to claim 8, characterized in that, A brake drum (2) with external teeth (3) is formed by deep drawing of a metal sheet, and a plug-in element (7) is formed by bending the flat tabs on the outer peripheral surface of the brake drum (2).

10. A vehicle (100), characterized in that, The vehicle includes at least one two-piece brake disc (1) according to any one of claims 1 to 8.

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