A friction disk includes a friction disk core having an inner diameter edge, an outer diameter edge, and a first surface with multiple mortises extending radially across the first surface, each of the multiple mortises having a different dimension at the inner diameter edge than at the outer diameter edge. The friction disk further includes a first wear liner having two wear liner segments each including a wear surface and a non-wear surface having a tenon with a complimentary shape to each of the multiple mortises, the tenon being configured to be received by a corresponding mortise of the multiple mortises to couple the wear liner segments to the friction disk core to form an annular liner.

A friction disk includes a friction disk core having an inner diameter edge, an outer diameter edge, and a first surface with multiple mortises extending radially across the first surface. The friction disk further includes a first wear liner having two wear liner segments each including a wear surface and a non-wear surface having a tenon with a complimentary shape to each of the multiple mortises, the tenon of each wear liner segment being configured to be received by a corresponding mortise of the multiple mortises to couple the wear liner segments to the friction disk core to form an annular liner.

A rotor assembly for a disc brake system is provided with a central mounting section having a hub, a flange connected to a radially outer edge of the hub, and a first set of connection elements formed in or on the flange. The rotor assembly also includes an outer friction ring section including a radially inner flange and a second set of connection elements formed in or on the radially inner flange. The hub of the central mounting section is configured for connection to a wheel/axle of a vehicle. The outer friction ring section includes surfaces configured for contact with one or more brake pads of a caliper. Also, the first and second sets of connection elements are configured to be press fit together to connect the central mounting section with the outer friction ring section. The outer friction ring section may be implemented as attachable ring members.

An arrangement and method for mounting a brake disc to an axle hub of a vehicle is provided. The arrangement includes wedge-shaped holes at an radially inner region of the brake disc, corresponding wedge-shaped key inserts, a retaining device such as a retaining ring, and mounting devices such as bolts or studs and nuts that pass through the retaining ring and keys to bias the keys against the axle hub. The circumferential sides of the wedge shapes are aligned with radial lines extending from the rotation axis of the axle hub. This arrangement and method provides a simple, robust and easily installed brake disc mounting that minimizes heat transfer between the brake disc and the axle hub and accommodates thermal expansion of the brake disc and the axle hub to minimize thermal expansion-induced stresses to the brake disc.

A friction disk includes a friction disk core having an inner diameter edge, an outer diameter edge, and a first surface with multiple mortises extending radially across the first surface. The friction disk further includes a first wear liner having two wear liner segments each including a wear surface and a non-wear surface having a tenon with a complimentary shape to each of the multiple mortises, the tenon of each wear liner segment being configured to be received by a corresponding mortise of the multiple mortises to couple the wear liner segments to the friction disk core to form an annular liner.

A friction disk includes a friction disk core having an inner diameter edge, an outer diameter edge, and a first surface with multiple mortises extending radially across the first surface, each of the multiple mortises having a different dimension at the inner diameter edge than at the outer diameter edge. The friction disk further includes a first wear liner having two wear liner segments each including a wear surface and a non-wear surface having a tenon with a complimentary shape to each of the multiple mortises, the tenon being configured to be received by a corresponding mortise of the multiple mortises to couple the wear liner segments to the friction disk core to form an annular liner.

A friction disk includes a friction disk core having a first surface with multiple channels extending radially across the first surface. The friction disk may further include a first wear liner having two wear liner segments each configured to be coupled to the first surface of the friction disk core to form an annular liner and each including a wear surface, a non-wear surface, and a rib extending from the non-wear surface and configured to be received by one of the multiple channels.

A brake rotor, includes at least one friction element and one adapter element, wherein the brake rotor is configured to rotate about an axis of rotation, wherein the friction element has at least one friction surface and one connection region, wherein the adapter element has an installation region and a transfer region, wherein the installation region is configured for fixing the brake rotor to a hub, wherein the connection region indirectly or directly engages in positively locking fashion in a circumferential direction with the transfer region such that a torque about the axis of rotation can be transferred between the connection region and the transfer region from the friction element to the adapter element.

A rotor assembly for a disc brake system is provided with a central mounting section having a hub, a flange connected to a radially outer edge of the hub, and a first set of connection elements formed in or on the flange. The rotor assembly also includes an outer friction ring section including a radially inner flange and a second set of connection elements formed in or on the radially inner flange. The hub of the central mounting section is configured for connection to a wheel/axle of a vehicle. The outer friction ring section includes surfaces configured for contact with one or more brake pads of a caliper. Also, the first and second sets of connection elements are configured to be press fit together to connect the central mounting section with the outer friction ring section. The outer friction ring section may be implemented as attachable ring members.

A vehicle disc brake unit comprises a rotatable brake rotor and non-rotatable brake pad of caliper. During the vehicle braking, the non-rotatable brake pad presses against the rotating brake rotor, producing friction heat on frictional contact bands where the brake rotor and the brake pad engages with each other. A plurality of longitudinal vortex generators configured in fins is mounted either to a rotatable vehicle component such as hat of a brake rotor, or a non-rotatable vehicle component such as a protective plate, generating longitudinal vortices in the cooling air flows around the brake rotor, especially across the hottest frictional contact bands. The induced longitudinal vortices in the cooling air flows optimize the heat dissipation from brake rotor into atmosphere.