Ventilated brake rotors

Abstract

A brake rotor for attachment to a wheel of a vehicle may include outer and inner friction members, and a plurality of fin elements connecting the outer friction member to the inner friction member. Each fin element may include radially spaced first and second pillars that are connected by a single bridge portion to define an opening in the fin element. The opening may also be defined by an interior surface of one of the annular disks. The opening may be tapered along an entire length between a first pillar and a second pillar. A width of each fin element may taper toward a center of the brake rotor.

Claims

1. A brake rotor, comprising: outer and inner friction members; and a plurality of fin elements connecting the outer friction member to the inner friction member, each fin element comprising radially spaced first and second pillars that are connected by a single bridge portion to define an opening in the fin element; and a hub mounting surface connected to the outer and/or inner friction member via a neck portion disposed along an inner portion of the brake rotor, the neck portion extending adjacent to the fin elements such that a space is formed between the neck portion and the fin elements, wherein a width of each fin element tapers toward a center of the brake rotor, and wherein the opening is defined by the first and second pillars, the bridge portion, and an interior surface of one of the friction members.

2. The brake rotor of claim 1, wherein the outer and inner friction members respectively comprise outer and inner annular disks, and wherein each fin element extends radially between the outer and inner disks.

3. The brake rotor of claim 1, wherein the plurality of fin elements includes first and second alternating fin elements, and wherein the bridge portion of each first fin element is coupled to the inner friction member and the bridge portion of each second fin element is coupled to the outer friction member.

4. The brake rotor of claim 1, wherein an orientation of each fin element is the same.

5. The brake rotor of claim 4, wherein the bridge portion of each fin element is coupled to the outer friction member.

6. The brake rotor of claim 4, wherein the bridge portion of each fin element is coupled to the inner friction member.

7. The brake rotor of claim 1, wherein the bridge portion forms a ramp between the first and second pillars.

8. The brake rotor of claim 1, wherein the opening has a straight side and a tapered side.

9. A brake rotor, comprising: outer and inner annular disks; and a plurality of fin elements extending radially between the annular disks and connecting the outer disk to the inner disk, each fin element comprising: first and second pillars disposed between the annular disks within an inner perimeter of each of the annular disks and an outer perimeter of each of the annular disks; a bridge portion connecting the first and second pillars such that a lengthwise direction of the bridge portion extends radially from a center of the brake rotor to an outer perimeter of the brake rotor; and an opening, wherein the opening is defined by the first and second pillars, the bridge portion, and an interior surface of one of the annular disks.

10. The brake rotor of claim 9, wherein the opening has a straight side and a tapered side.

11. The brake rotor of claim 9, wherein each fin element further comprises a radially inner edge and a radially outer edge, and wherein a width of each fin element narrows from the radially outer edge to the radially inner edge.

12. The brake rotor of claim 9, wherein the plurality of fin elements includes first and second alternating fin elements, and wherein the bridge portion of each first fin element is coupled to the inner disk and the bridge portion of each second fin element is coupled to the outer disk.

13. The brake rotor of claim 9, wherein the bridge portion of each fin element is coupled to the outer disk.

14. The brake rotor of claim 9, wherein the bridge portion of each fin element is coupled to the inner disk.

15. A brake rotor, comprising: a plurality of fin elements disposed between outer and inner friction members of the brake rotor such that a lengthwise direction of each fin extends radially from a center of the brake rotor, each fin element comprising an opening such that a lengthwise direction of the opening extends radially, a height and width of the opening being tapered along an entire length between a first pillar and a second pillar.

16. The brake rotor of claim 15, wherein the opening has a tapered side.

17. The brake rotor of claim 15, wherein the opening has a straight side.

18. The brake rotor of claim 15, wherein a width of each fin element narrows along the lengthwise direction towards the center of the brake rotor.

19. The brake rotor of claim 15, wherein: the first and second pillars are connected by a bridge portion to define the opening in each fin element, each bridge portion extends from an interior surface of one of the friction members, and each opening is further defined by an opposing interior surface of the other of the friction members.

20. The brake rotor of claim 19, wherein the plurality of fin elements includes first and second alternating fin elements, and wherein the bridge portion of each first fin element is coupled to the inner friction member and the bridge portion of each second fin element is coupled to the outer friction member.

21. The brake rotor of claim 19, wherein the bridge portion of each fin element is coupled to the inner friction member.

22. The brake rotor of claim 19, wherein the bridge portion of each fin element is coupled to the outer friction member.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) At least some features and advantages will be apparent from the following detailed description of embodiments consistent therewith, which description should be considered with reference to the accompanying drawings, wherein:

(2) FIG. 1 is a perspective view of an exemplary embodiment of a ventilated brake rotor in accordance with the present disclosure, with a portion of an inner friction member of the rotor broken away to show fin elements;

(3) FIG. 2 is a side view of the brake rotor of FIG. 1;

(4) FIG. 3 is a cross-sectional view of the brake rotor of FIG. 1 taken through line 3-3 of FIG. 2;

(5) FIGS. 4A and 4B show detailed views of a fin element of the brake rotor of FIG. 1;

(6) FIG. 5 is an enlarged, partial perspective view of the brake rotor of FIG. 1, with the inner friction member removed to show the fin elements;

(7) FIG. 6 is a perspective view of another exemplary embodiment of a ventilated brake rotor in accordance with the present disclosure, with a portion of an inner friction member of the rotor broken away to show fin elements;

(8) FIG. 7 is a side view of the brake rotor of FIG. 6;

(9) FIG. 8 is a cross-sectional view of the brake rotor of FIG. 6 taken through line 8-8 of FIG. 7; and

(10) FIG. 9 is an enlarged, partial perspective view of the brake rotor of FIG. 6, with the inner friction member removed to show the fin elements.

(11) Although the following detailed description makes reference to illustrative embodiments, many alternatives, modifications, and variations thereof will be apparent to those skilled in the art. Accordingly, it is intended that the claimed subject matter be viewed broadly.

DESCRIPTION OF THE EMBODIMENTS

(12) Reference will now be made in detail to various embodiments, examples of which are illustrated in the accompanying drawings. The various exemplary embodiments are not intended to limit the disclosure. To the contrary, the disclosure is intended to cover alternatives, modifications, and equivalents.

(13) In accordance with various exemplary embodiments, the present disclosure contemplates a ventilated brake rotor having an innovative fin design that may both reduce the mass of the rotor and improve the heat dissipation capacity of the rotor. For instance, the exemplary embodiments described herein utilize fin elements having an increased heat dissipation area (i.e., the area of each fin that is in contact with air flowing through each ventilation channel of the rotor). Various exemplary embodiments described herein, for example, contemplate a ventilated brake rotor comprising a plurality of fin elements, each fin element having first and second pillars that are connected by a bridge portion to define an opening in the fin element that may allow air to pass through the fin element. In this manner, as the rotor is rotated, an air flow path may be created both along a length of each fin element (i.e., between the fin elements) and across a width of each fin element (i.e., through the fin elements), thereby also generating turbulence across the fin elements to dissipate heat from the rotor. Furthermore, removing a portion of each fin element (i.e., to form the opening in each fin element) reduces the mass of each fin element, and the overall mass of the rotor itself.

(14) FIGS. 1-5 illustrate an exemplary embodiment of a ventilated brake rotor 100 in accordance with the present disclosure. The brake rotor 100 includes an outer friction member 102 that is connected to an inner friction member 104 by a plurality of fin elements 106, 108. The brake rotor 100, for example, further includes a hub mounting surface 110 that extends from the outer friction member 102 to connect the brake rotor 100 to a wheel (not shown) of a motor vehicle (not shown). As best shown in the cross-sectional view of FIG. 3, the hub mounting surface 110 may be connected to the outer friction member 102 of the rotor 100 via, for example, a neck portion 111. The hub mounting surface 110 may, for example, include a plurality of bore holes 113, which are configured to receive lug bolts (not shown) to attach the rotor 110 to the wheel of the motor vehicle. In this manner, the outer friction member 102 is configured to face away from the vehicle when the rotor 100 is attached to the wheel, and the inner friction member 104 is configured to face towards the vehicle when the rotor 100 is attached to the wheel.

(15) As illustrated in FIGS. 1-3, in various embodiments of the present disclosure, the outer and inner friction members 102 and 104 may respectively comprise outer and inner annular disks, and the fin elements 106, 108 may extend radially between the outer and inner disks to create a plurality of ventilation channels 130 between the disks. In this manner, as shown in FIGS. 1 and 5, the fin elements 106, 108 are arranged so that, as the rotor 100 is rotated (e.g., when the rotor 100 is attached to a wheel of a motor vehicle), an air flow path F.sub.1 is created within the ventilation channels 130 along a length of each fin element, 106, 108. In accordance with various embodiments, for example, as shown in FIG. 5, air inlets 132 to the ventilation channels 130 are provided at inner edges of the outer and inner friction members 102 and 104 so that the rotor 100 functions as a centrifugal fan driving air outwardly through the ventilation channels 130 to air outlets 134 at outer edges of the outer and inner friction members 102 and 104.

(16) As shown best perhaps in FIGS. 4A, 4B, and 5, each of the fin elements 106, 108 includes respective first and second pillars 112 and 114 that are connected by a bridge portion 116. The pillars 112, 114 and bridge portion 116 define an arched-shaped opening 118 in each respective fin element 106, 108 that is configured to allow air (i.e., from the ventilation channels 130) to pass through the fin elements 106, 108. In various embodiments, for example, the bridge portion 116 forms a ramp 120 between the first and second pillars 112 and 114, such that the opening 118 has a rounded triangular shape. As shown in FIGS. 1 and 5, for example, the openings 118 in the fin elements 106, 108 are configured such that, as the rotor 100 is rotated (e.g., when the rotor 100 is attached to the wheel of the motor vehicle) an air flow path F.sub.2 is created across a width of each fin element 106, 108. For example, in various embodiments, multiple airflow paths F.sub.2 are created around the rotor 100, including, for example, a separate airflow path F.sub.2 for each fin element 106, 108; and an airflow path F.sub.2 that extends through multiple fin elements 106, 108 as shown in FIGS. 1 and 5. In this manner, turbulence is also created across the fin elements 106, 108 to dissipate heat from the rotor 100.

(17) In other words, the fin elements 106, 108 are configured such that, as the rotor 100 is rotated, air flows partially within each ventilation channel 130 (along the airflow path F.sub.1), and then partially though each opening 118 in the fin elements 106, 108 (along the airflow path F.sub.2). The air flowing through the openings 118 (along the airflow path F.sub.2) may then both partially continue through the adjacent openings 118 (i.e., around the rotor 100) and partially out through the adjacent ventilation channel 130. In this manner, the fin elements 106, 108 are configured such that, as the rotor 100 is rotated, an airflow path F.sub.3 is also created that is a combination of airflow paths F.sub.1 and F.sub.2 (e.g., the airflow path F.sub.1 may be extended by a length corresponding to the airflow path F.sub.2) in order to dissipate more heat from the rotor 100.

(18) As illustrated in FIGS. 1-5, in accordance with various exemplary embodiments, the plurality of fin elements may include first and second alternating fin elements 106 and 108 arranged around a rotation axis of the rotor 100, such that the bridge portion 116 of each first fin element 106 is coupled to the inner friction member 104 of the rotor 100 and the bridge portion 116 of each second fin element 108 is coupled to the outer friction member 102 of the rotor 100. The present disclosure, however, contemplates brake rotors including any number, configuration (i.e., dimension and/or geometry), and/or orientation of fin elements 106, 108. Those of ordinary skill in the art would understand, therefore, that the brake rotor 100 illustrated in FIGS. 1-5 is exemplary only and intended to illustrate one embodiment of the present disclosure. Accordingly, brake rotors in accordance with the present disclosure may have various configurations and/or orientations of friction members and fin elements without departing from the scope of the present disclosure and claims, and are not bound by any specific geometries and/or orientations.

(19) For example, in accordance with various additional embodiments of the present disclosure, a ventilated brake rotor may include a plurality of fin elements all having the same orientation. As illustrated in FIGS. 6-9, for example, in various embodiments, a brake rotor 200 may include an outer friction member 202 that is connected to an inner friction member 204 by a plurality of fin elements 206 arranged around a rotation axis of the rotor 200 to create a plurality of ventilation channels 230. As shown in FIG. 9, similar to the embodiment of FIGS. 1-5, each of the fin elements 206 includes respective first and second pillars 212 and 214, which are connected by a bridge portion 216 to define an arched-shaped opening 218 in each fin element 206. And, in various embodiments, the bridge portions 216 each form a ramp 220 between respective first and second pillars 212 and 214.

(20) Similar to the openings 118 described above, the openings 218 are configured to allow air (i.e., from the ventilation channels 230) to pass through the fin elements 206. Thus, similar to the rotor 100 of FIGS. 1-5, as the rotor 200 is rotated (e.g., when the rotor 200 is attached to a wheel of a motor vehicle), the fin elements 206 create an air flow path F.sub.1 within the ventilation channels 230 along a length of each fin element 206, and the openings 218 in the fin elements 206 create an air flow path F.sub.2 across a width of each fin element 206 to create turbulence across the fin elements 206. As above, in various embodiments, multiple airflow paths F.sub.2 are created around the rotor 200, including, for example, a separate airflow path F.sub.2 for each fin element 206; and an airflow path F.sub.2 that extends through multiple fin elements 206 as shown in FIGS. 6 and 9.

(21) Similar to the fin elements 106, 108, the fin elements 206 are also configured such that, as the rotor 200 is rotated, an airflow path F.sub.3 is created that is a combination of airflow paths F.sub.1 and F.sub.2 (e.g., the airflow path F.sub.1 may be extended by a length corresponding to the airflow path F.sub.2) in order to dissipate more heat from the rotor 200.

(22) In various embodiments, as shown in FIGS. 6-9, the bridge portion 216 of each fin element 206 is coupled to the inner friction member 204. Although not shown, those of ordinary skill in the art would understand that in various additional embodiments, the bridge portion 216 of each fin element 206 may instead be coupled to the outer friction member 202.

(23) To verify and optimize the expected heat dissipation improvement and mass reduction of the ventilated brake rotors in accordance with the present disclosure versus conventional ventilated brake rotors, ventilated brake rotors in accordance with the present disclosure, similar to the brake rotors 100 (i.e., alternating fin elements) and 200 (i.e., one-way fin elements) illustrated and described above with reference to FIGS. 1-9 were modeled in a computational fluid dynamic (CFD) model using FLUENT® software. A reference conventional ventilated brake rotor was also modeled in a CFD model for comparison purposes. All CAD (Computer Aided Design) models were created using CATIA®.

(24) Using the models, a design of experiment (DOE) was developed based on conventional manufacturing parameters (i.e., for molding the rotors) to test various rotor dimensions for optimization of: (1) mass flow rate of air through the fin elements, and (2) heat flux from the fin elements. Exemplary dimensions and tolerances A-H (see, e.g., FIGS. 4A and 4B) for the rotors 100 and 200 based on this analysis are presented below in Tables 1-3.

(25) TABLE-US-00001 TABLE 1 Optimization of Mass Flow Rate Inner Outer Inner Outer Width Width Height from Height from Friction Friction Friction Friction of of Inner Friction Outer Friction Predicted Member Member Member Member Second First Member to Member to Max Mass Width, Width, Angle, Angle, Pillar, Pillar, Ramp, Ramp, Flow A [mm] B [mm] C [deg] D [deg] E [mm] F [mm] G [mm] H [mm] [kg/s] 10.6 10.6 88 88 9.3 12.8 1.2 5.3 0.054

(26) TABLE-US-00002 TABLE 2 Optimization of Mass Heat Flux Inner Outer Inner Outer Width Width Height from Height from Friction Friction Friction Friction of of Inner Friction Outer Friction Predicted Member Member Member Member Second First Member to Member to Max Width, Width, Angle, Angle, Pillar, Pillar, Ramp, Ramp, Heat Flux A [mm] B [mm] C [deg] D [deg] E [mm] F [mm] G [mm] H [mm] [kWatts] 10.6 10.6 88 88 9.3 11.2 1.2 5.3 14.374

(27) TABLE-US-00003 TABLE 3 Manufacturing Variations Inner Outer Inner Outer Width Width Height from Height from Friction Friction Friction Friction of of Inner Friction Outer Friction Member Member Member Member Second First Member to Member to Width, Width, Angle, Angle, Pillar, Pillar, Ramp, Ramp, A [mm] B [mm] C [deg] D [deg] E [mm] F [mm] G [mm] H [mm] +/−0.4 +/−0.4 +/−1 +/−1 +/−0.8 +/−0.8 +/−0.8 +/−0.8

(28) The heat dissipation and mass of the optimized models were then compared with the reference model (i.e., of the conventional ventilated brake rotor) to verify the expected heat dissipation improvement and mass reduction of each of the rotor designs (i.e., the alternating fin elements and the one-way fin elements). Based on this comparison, it was predicted that the rotors with alternating fin elements (i.e., rotor 100) would exhibit about 5.5% to about 8.3% more heat dissipation than the conventional rotor, and would weigh about 2.2% to about 12.3% less than the conventional rotor. Similarly, it was predicted that the rotors with one-way fin elements (i.e., rotor 200) would exhibit about 7% to about 9.8% more heat dissipation than the conventional rotor, and would weigh about 1.3% to about 11.3% less than the conventional rotor.

(29) As above, the present disclosure contemplates brake rotors having various dimensions and/or orientations of friction members and fin elements. Accordingly, the above dimensions and tolerances are not intended to be limiting of the present disclosure or the scope of the invention herein. Rather, the dimensions and tolerances represent exemplary embodiments of the various components depicted. Those having ordinary skill in the art would understand that modifications to such dimensions and tolerances may be made as desired and in accordance with the present disclosure without departing from the scope of the present disclosure.

(30) The present disclosure further contemplates methods of manufacturing a brake rotor, such as, for example, the brake rotors 100 and 200 described above with reference to FIGS. 1-9 in order to increase the convective heat dissipation of the rotor. In accordance with various exemplary embodiments, to increase the amount of heat dissipated from the brake rotor 100, 200, a plurality of fin elements 106, 108, 206 may be positioned between an outer friction member 102, 202 of the brake rotor 100, 200 and an inner friction member 102, 202 of the brake rotor 100, 200. As above, each fin element 106, 108, 206 includes first and second pillars 112, 212 and 114, 214 that are connected by a bridge portion 116, 216 to define a single arch-shaped opening 118, 218 in the fin element 106, 108, 206.

(31) Thus, as the rotor 100, 200 is rotated (e.g., when the rotor 100, 200 is attached to a wheel of a motor vehicle), the fin elements 106, 108, 206 may create an air flow path F.sub.1 along a length of each fin element 106, 108, 206 (i.e., within ventilation channels 130, 230), and the openings 118, 218 in the fin elements 106, 108, 206 may create an air flow path F.sub.2 across a width of each fin element 106, 108, 206 to create turbulence across the fin elements 106, 108, 206. In various embodiments, for example, the openings 118, 218 in the fin elements 106, 108, 206 may create multiple airflow paths F.sub.2 around the rotor 100, 200, including, for example, a separate airflow path F.sub.2 for each fin element 106, 108, 206; and an airflow path F.sub.2 that extends through multiple fin elements 106, 108, 206. In other words, in various embodiments, air flow moves partially within each ventilation channel 130, 230 (along an airflow path F.sub.1), and then partially though each opening 118, 218 in the fin elements 106, 108, 206 (along an airflow path F.sub.2). The air flowing through the openings 118, 218 (along the airflow path F.sub.2) may then both partially continue through the adjacent openings 118, 218 (i.e., around the rotor 100, 200) and partially out through the adjacent ventilation channel 130, 230. In this manner, an airflow path F.sub.3 is created that is a combination of airflow paths F.sub.1 and F.sub.2 (e.g., the airflow path F.sub.1 may be extended by a length corresponding to the airflow path F.sub.2) in order to dissipate more heat from the rotor 100, 200.

(32) As shown in the embodiment of FIGS. 1-5, in various embodiments, the plurality of fin elements may include first and second alternating fin elements 106 and 108, and the fin elements 106 and 108 may be positioned between the outer and inner friction members 102 and 104 such that the bridge portion 116 of each first fin element 106 is coupled to the inner friction member 104 and the bridge portion 116 of each second fin element 108 is coupled to the outer friction member 102.

(33) As shown in the embodiment of FIGS. 6-9, in various additional embodiments, the plurality of fin elements may include fin elements 206 with the same orientation, and the fin elements may be positioned between the outer and inner friction members 202 and 204 such that the bridge portion 216 of each fin element is coupled to the inner friction member 204. Although not shown, in various further embodiments, the fin elements 206 may also be positioned between the outer and inner friction members 202 and 204 such that the bridge portion 216 of each fin element is coupled to the outer friction member 202.

(34) The brake rotors 100, 200 may be manufactured using any known methods and/or techniques known to those of ordinary skill in the art. In various embodiments, for example, the brake rotors 100, 200 may be cast from a molten metal, such as, for example, iron that is poured into a mold. In various additional embodiments, the brake rotors 100, 200 may be molded from a composited material, such as, for example, reinforced carbon-carbon, or a ceramic matrix composite.

(35) While the present disclosure has been disclosed in terms of exemplary embodiments in order to facilitate better understanding of the disclosure, it should be appreciated that the disclosure can be embodied in various ways without departing from the principle of the disclosure. Therefore, the disclosure should be understood to include all possible embodiments which can be embodied without departing from the principle of the disclosure set out in the appended claims. Furthermore, although the present disclosure has been discussed with relation to automotive vehicles, those of ordinary skill in the art would understand that the present teachings as disclosed would work equally well for any type of vehicle having a braking system that utilizes brake rotors.

(36) For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing quantities, percentages or proportions, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the written description and claims are approximations that may vary depending upon the desired properties sought to be obtained by the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

(37) It is noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the,” include plural referents unless expressly and unequivocally limited to one referent. Thus, for example, reference to “a sensor” includes two or more different sensors. As used herein, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.

(38) It will be apparent to those skilled in the art that various modifications and variations can be made to the system and method of the present disclosure without departing from the scope its teachings. Other embodiments of the disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the teachings disclosed herein. It is intended that the specification and embodiment described herein be considered as exemplary only.