Vehicle Brake Disc

Abstract

A disk brake for a motor vehicle includes an internally ventilated brake disk, a brake disk nave, and radially directed bores. In the radially directed first bores the connecting means are introduced such that they extend further into radially directed second bores in the friction ring into the friction ring. The brake disk nave forms the fit with a single friction ring half and this fit has material convexities, which point inward toward the cooling channels or the ribs, at the points at which the second bores are introduced for the connecting means.

Claims

1-16. (canceled)

17. A disk brake for a motor vehicle, comprising: an internally ventilated brake disk having a friction ring with an external friction surface on each one of two friction ring halves connected by ribs which are located therebetween, the ribs forming cooling channels between the friction ring halves; a brake disk nave, which is connected to the friction ring via radially directed connecting means and has on its casing a collar, which extends in the radial direction and forms a fit to an external diameter of the friction ring by way of an outer circumferential surface and to an internal diameter of the friction ring by way of an inner circumferential surface; and radially directed first bores, in which the connecting means are introduced such that they extend further into radially directed second bores in the friction ring into the friction ring, wherein the brake disk nave forms the fit with a single friction ring half and this fit has material convexities, which point inward toward the cooling channels or the ribs, at the points at which the second bores are introduced for the connecting means.

18. The disk brake according to claim 17, wherein the single friction ring half forming the fit to the brake disk nave, as seen in the axial direction of the brake disk one of the two friction ring halves which lies closer to a nave base of the brake disk nave.

19. The disk brake according to claim 18, wherein the connecting means between the brake disk nave and the friction ring half are blind rivets.

20. The disk brake according to claim 18, wherein the connecting means between the brake disk nave and the friction ring half are clamping sleeves.

21. The disk brake according to claim 18, wherein the connecting means between the brake disk nave and the friction ring half are locating pins, which have a central passage bore in their axial direction.

22. The disk brake according to claim 21, wherein the connecting means have in the circumferential direction a surface structure configured to improve force transfer, in particular a corrugation or a grooved profile.

23. The disk brake according to claim 22, wherein the fit between the brake disk nave and the friction ring half is an oversize fit.

24. The disk brake according to claim 22, wherein the fit between the brake disk nave and the friction ring half is a transition fit.

25. The disk brake according to claim 24, wherein the brake disk nave consists of light metal or of steel or of a non-metal material.

26. The disk brake according to claim 25, wherein the material convexities are configured such that they have in their cross section constant wall thicknesses which transition into one another by means of radii.

27. The disk brake according to claim 26, wherein the second bores for the connecting means have at their radially outer end a cooling-air outlet channel into a cooling channel.

28. The disk brake according to claim 27, wherein the internal diameter of the cooling-air outlet channel corresponds at least to a free internal diameter of a connecting means.

29. The disk brake according to claim 28, wherein the internal diameter of the friction ring half which has the fit to the brake disk nave is smaller than the internal diameter of the friction ring half which does not have a fit.

30. The disk brake according to claim 29, wherein the number of the connecting means over the brake disk circumference corresponds to a prime number or an even number.

31. A method for producing a brake disk comprising: producing corresponding fitting surfaces on the external diameter of a collar of a brake disk nave and on an internal diameter of a friction ring half which, as seen in the axial direction of a brake disk, is located closer to a nave base of the brake disk nave; pressing the brake disk nave into the friction ring half in the axial direction of the brake disk, with the nave base in front, from the side of the friction ring with the friction ring half which does not have a fit; ending the pressing of the brake disk nave into the friction ring half when shape parity is reached between the inner side of the friction ring half which has a fit and the brake disk nave collar, as seen in the axial direction of the brake disk, on the inner side of the friction ring half which has a fit; boring the first and second bores, at least in a respective work step per bore pair composed of a first and a second bore, and boring the cooling-air outlet channel; and introducing a respective connecting means into each bore pair composed of a first and a second bore.

32. The method according to claim 31, wherein the connecting means are clamping sleeves, which are fixed in place in each bore pair after being introduced therein.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIG. 1 shows a brake disk in a radially directed partial cross section, having a clamping sleeve as connecting means; and

[0025] FIG. 2 shows a detail from the brake disk according to FIG. 1 in the form of an enlarged partial section of the fitting surface of the friction ring in the radial direction, on a region of two radially directed second bores, lying next to one another, for two clamping sleeves (which are not depicted) at the parting surface between the friction ring and the brake disk nave.

DETAILED DESCRIPTION OF THE DRAWINGS

[0026] The brake disk 1, illustrated in part in the figures, of a disk brake for a motor vehicle consists of a brake disk nave 3 and a friction ring 2, and is provided for mounting on a wheel hub (which is not depicted), for rotation therewith. The one-piece, internally cooled or ventilated friction ring 2, manufactured in gray cast iron, consists of two friction ring halves 2′, 2″, each having an external friction surface 4′, 4″ and ribs 5, which lie between the friction ring halves 2′, 2″, connect the latter to one another on their inner side, and form cooling channels 6 of a cooling-air guide through the friction ring 2. The annular friction ring half 2′ which is closer to the brake disk nave 3 as viewed in the axial direction, i.e. in the direction of an axis of rotation D of the brake disk 1, extends as seen in the radial direction R (with respect to the axis of rotation D) by way of what is known as a fastening projection 7 by a certain amount further toward the axis of rotation D than the other friction ring half 2″, which is more remote from the brake disk nave 3 in the axial direction.

[0027] An inner circumferential surface 7′ of the fastening projection 7 of the friction ring half 2′ forms a fit with an outer circumferential surface 9′ of the brake disk nave 3 and both the friction ring half 2′ and the brake disk nave 3 are additionally connected to one another via radially directed, slitted clamping sleeves 8, which are introduced in a collar 9 on the casing 10 in radially directed first bores 16, and from there extend further in likewise radially directed, coaxial second bores 17 in the friction ring half 2′ into the friction ring half. In this respect, the friction ring half 2′ which forms the fit to the brake disk nave 3 is closer, as seen in the axial direction of the brake disk, in the direction of a nave base 11 of the brake disk nave 3 and the number of the clamping sleeves 8, used to connect the friction disk 2′ and the brake disk nave 3, over the brake disk circumference corresponds to a prime number or an even number.

[0028] On its cooling channel side, the friction ring half 2′ is thickened for the purpose of placing the clamping sleeves 8 in that it has material convexities 18, which point inward, depending on the position of the clamping sleeves 8, toward the cooling channels 6 or toward the ribs 5, at the points at which the second bores 17 for the clamping sleeves 8 are introduced. Here, the material convexities 18 are configured such that they have in their cross section constant wall thicknesses (FIG. 2, arrows 12) which transition into one another via radii 13, 14. This keeps the cross section, weakened by the first and second bores 16, 17, of the brake disk nave 3 and the friction disk half 2′ constant by means of wall depressions 21 for the better distribution of stress. The wall cross section 12 of the friction ring half 2′ between its friction surface 4′ and the bore walls 17′ of the bores 17 for the clamping sleeves 8 is also the same as the wall cross section of the friction ring half 2′ between its friction surface 4′ and the wall depression 21 of the material convexity 18 for placing the clamping sleeves 8.

[0029] At their radially outer end, the second bores 17 for the clamping sleeves 8 have a cooling-air outlet channel 15, which opens out into a cooling channel 6. As a result, air flows through the clamping sleeves 8. This is particularly advantageous for cooling when the internal diameter of the cooling-air outlet channel 15 corresponds at least to the internal diameter of a mounted clamping sleeve 8, with the result that between the two friction ring halves 2′, 2″ there is an unthrottled guidance of air flow in the region of the clamping sleeves 8 both through them and parallel thereto via a still-open region 6′ of the cooling channel 6 between the ribs 5, from the interior of the brake disk 1 through the cooling channels 6 to the outside.

[0030] The brake disk nave 3 consists of light metal or of steel or of a non-metal material, that is to say materials considered for the brake disk nave 3 are preferably higher-strength high-strength light metals (magnesium, among other things) or a high-strength, thin-walled steel sheet or aluminum and other non-iron or non-metal materials. The brake disk nave can therefore be produced for example by a casting method or a forging method or by flow pressing or in particular by deep drawing. When use is made of a brake disk nave 3 according to the invention that is made from a lightweight material, the use of steel wheels is possible in addition to aluminum wheels.

[0031] The brake disk is produced in method steps which follow one another by [0032] producing corresponding fitting surfaces of an oversize fit or a transition fit on an outer circumferential surface 9′ of the collar 9 of the brake disk nave 3 and on an inner circumferential surface 7′ of the fastening projection 7 of the friction ring half 2′ which, as seen in the axial direction of the brake disk 1, is located closer to the nave base 11 of the brake disk nave 3; [0033] pressing or sliding, depending on the fit selected, the brake disk nave 3 into the friction ring half 2′ in the axial direction of the brake disk 1, with the nave base 11 in front, from the side of the friction ring 2 with the friction ring half 2″ which does not have a fit and the internal diameter of which is larger than that of the friction ring half 2′ with the fit to the brake disk nave 3 on the fastening projection 7; [0034] ending the pressing of the brake disk nave 3 into the friction ring half 2′ when shape parity is reached between the inner side of the friction ring half 2′ which has a fit and the brake disk nave collar 9, as seen in the axial direction of the brake disk 1 in the pressing-in direction of the brake disk nave 3; [0035] boring the first and second bores 16, 17, at least in a respective work step per bore pair composed of a first and a second bore 16, 17, and the outlet channel 15; [0036] introducing and fixing in place the clamping sleeves 8 in the form of connecting means into the bore pairs composed of a first and a second bore 16, 17.

[0037] In this way, the in particular deep drawn brake disk nave 3 of light metal is pressed into the friction ring half 2′ advantageously in a slightly pretensioned manner. Then, bores are jointly made in the brake disk nave 3 and the friction ring half 2′ and the brake disk nave and friction ring half are connected to the connecting means, preferably clamping sleeves 8, and thereupon secured against falling out by means of being fixed in place. If blind rivets are used as connecting means instead of the clamping sleeves 8, the method step of fixing in place is omitted.