Disc brake rotor assembly

In one aspect of the present disclosure, a disc brake rotor assembly is provided that includes a disc brake rotor and a wheel hub. One of the disc brake rotor and the wheel hub includes a plurality of pairs of partial keyways and the other of the disc brake rotor and the wheel hub includes intermediate partial keyways configured to fit intermediate the pairs of partial keyways to form keyways. The disc brake rotor assembly further includes a plurality of fasteners configured to be received in the keyways to secure the disc brake rotor and the wheel hub together.

FIELD

This disclosure relates generally to a disc brake rotor assembly, and more particularly, to a disc brake rotor assembly including a wheel hub and a disc brake rotor.

BACKGROUND

Disc brake rotors are known for their use in braking systems to slow down or stop commercial vehicles. Such disc brake rotors are typically made of cast iron and are mounted to wheel hubs which are typically made of ductile iron or aluminum. During a braking operation, a braking force is applied to the disc brake rotor which in turn translates rotational torque to the wheel hub of the vehicle to reduce the vehicle speed.

Some commercially available disc brake assemblies rely on either friction or mechanical interference to secure the disc brake rotor to the wheel hub. For example, friction constrained disc brake assemblies may utilize multiple fasteners to clamp the disc brake rotor to the wheel hub. With sufficient clamping force in the joint between the disc brake rotor and wheel hub, the rotor may withstand braking torque without slipping on the mating plane between the rotor and wheel hub. In a clamped joint, friction prevents rotor rotation relative to the wheel hub and fastener tension prevents axial displacement of the rotor relative to the wheel hub. However, over time, the clamping force applied to the rotor may be lost (e.g., as caused by nuts backing off of fasteners, or fasteners backing out of threads in the wheel hub) which may lead to problematic joint relaxation between the rotor and the wheel hub.

In contrast, mechanical interference joints typically utilize a splined connection between the disc brake rotor and the wheel hub. In a splined connection, rotation of the rotor relative to the wheel hub is prevented by the interaction of splines on the hub with corresponding splines on the rotor. Further, axial displacement of the disc brake rotor relative to the wheel hub may be achieved using fasteners in connection with various washers and clips. However, the mating components required for such a splined joint require extensive machining operations to form the splined profiles and the assembly requires use of many different types of clips and fasteners. Additionally, splined joint designs may be more sensitive to heat cycling, and may further use complex mating geometry on the disc brake rotor and wheel hub that may be expensive to manufacture.

SUMMARY

In one aspect of the present disclosure, a disc brake rotor assembly is provided that includes a disc brake rotor and a wheel hub. One of the disc brake rotor and the wheel hub includes a plurality of pairs of partial keyways and the other of the disc brake rotor and the wheel hub includes intermediate partial keyways configured to fit intermediate the pairs of partial keyways to form keyways. The disc brake rotor assembly further includes a plurality of fasteners configured to be received in the keyways to secure the disc brake rotor and the wheel hub together. In this manner, the fasteners are placed in a double shear configuration which reduces the peak shear stress experienced by the fasteners during a braking operation compared to a single shear configuration. The lower peak shear stress improves the durability of the disc brake rotor-wheel hub joint.

In one embodiment, the fasteners include spring pins. The spring pins provide compliance within the disc brake rotor-wheel hub joint by taking up dimensional variations and expanding or contracting during loading which more evenly distributes load and stress throughout the disc brake rotor-wheel hub joint. The spring pins may also expand or contract to accommodate thermal expansion and contraction of the disc brake rotor. The keyways may be sized to slightly compress the outer diameter of the spring pins as the spring pins are installed in the keyways such that the spring pins are resiliently held in the keyways. Spring pins may be installed in the keyways without having to apply a set torque to the spring pins which simplifies installation.

In another aspect, the present disclosure provides a disc brake rotor assembly configured to rotate about a central axis. The disc brake rotor assembly includes a disc brake rotor having rotor bosses and a wheel hub having wheel hub bosses. The disc brake rotor has a center opening that receives the wheel hub and permits the disc brake rotor to be positioned at an initial position on the wheel hub. The disc brake rotor bosses and the wheel hub bosses have a clearance configuration wherein the bosses permit relative axial movement and assembly of the disc brake rotor and the wheel hub. For example, the wheel hub may be stationary and the disc brake rotor is shifted axially along the wheel hub from the initial position to an installation position.

The disc brake rotor bosses and the wheel hub bosses also have an interference configuration wherein the disc brake rotor bosses and wheel hub bosses limit relative axial movement of the disc brake rotor and the wheel hub. The assembled disc brake rotor and the wheel hub are configured to be turned or clocked relative to one another to shift the rotor bosses and the wheel hub bosses from the clearance configuration to the interference configuration. In this manner, a technician may readily install the disc brake rotor on the wheel hub by shifting the disc brake rotor in a first axial direction along the wheel hub to an installation position of the disc brake rotor on the wheel hub and clocking the disc brake rotor relative to the wheel hub to reconfigure the bosses to the interference configuration wherein the bosses keep the disc brake rotor on the wheel hub. The disc brake rotor assembly further includes a plurality of fasteners to secure the disc brake rotor and the wheel hub together with the rotor bosses and the wheel hub bosses in the interference configuration.

In one embodiment, the bosses include a plurality of pairs of bosses of one of the disc brake rotor and the wheel hub and gaps between the pairs of bosses. The bosses further include intermediate bosses of the other the of disc brake rotor and the wheel hub configured to fit between the pairs of bosses. The pairs of bosses overlap the intermediate bosses in an axial direction such that the bosses engage and limit relative axial movement of the disc brake rotor and the wheel hub in two opposite axial directions.

The present disclosure also provides a disc brake rotor assembly including a disc brake rotor, a wheel hub, and a plurality of spring pins to connect the disc brake rotor and the wheel hub. Each spring pin has opposite end portions and an intermediate portion between the end portions. One of the disc brake rotor and the wheel hub has female mounting portions to engage the end portions of the spring pins and the other of the disc brake rotor and the wheel hub has male mounting portions to cooperate with the female mounting portions and engage the intermediate portions of the spring pins. The spring pins are configured to transfer torque from the disc brake rotor to the wheel hub during a braking operation with the female mounting portions of the one of the disc brake rotor and the wheel hub engaging the end portions of the spring pins and the male mounting portions of the other of the disc brake rotor and the wheel hub engaging the intermediate portions of the spring pins. In this manner, the spring pins absorb torque from the brake rotor and transfer the torque to the wheel hub. The resiliency of the spring pins facilitates even distribution of the brake load across the wheel hub. For example, one or more of the spring pins may initially compress upon a brake caliper engaging the disc brake rotor and urging the brake rotor in a rotary manner relative to the wheel hub. The one or more spring pins subsequently expand as the spring pins resiliently urge the brake rotor and wheel hub back to an initial rotary position relative to one another. In some embodiments, the spring pins may be the only component of the disc brake assembly for transferring torque between the disc brake rotor and the wheel hub during a braking operation.

In yet another aspect of the present disclosure, a method is provided for assembling a disc brake rotor assembly including a disc brake rotor and a wheel hub. One of the disc brake rotor and the wheel hub includes a plurality of first partial keyways and a plurality of third partial keyways and the other of the disc brake rotor and the wheel hub includes a plurality of second partial keyways. The method includes positioning the second partial keyways intermediate the first partial keyways and the third partial keyways to form keyways. The method further includes advancing leading end portions of fasteners through the first partial keyways, through the second partial keyways, and into the third partial keyways so that the fasteners extend in the keyways and connect the disc brake rotor and the wheel hub. In this manner, the disc brake rotor and the wheel hub are assembled to form a keyway configured to place the fasteners in a double shear configuration. Further, the fasteners may include spring pins that are pressed into the keyways and provide a compliant disc brake rotor-wheel hub joint which improves the durability of the disc brake rotor-wheel hub joint.

DETAILED DESCRIPTION

Referring toFIGS.1-2, a disc brake rotor assembly10is provided having a wheel hub20and a disc brake rotor30secured to the wheel hub20using one or more fasteners40such as spring pins50. The wheel hub20includes a wheel hub body21having an inboard end portion71and an outboard end portion73. The wheel hub body21as shown has a unitary, one-piece construction but may alternatively be formed of multiple individually assembled components. As described in further detail below, each of the disc brake rotor30and the wheel hub20includes one or more mounting portions, such as partial keyway portions, having partial keyways that are configured to be aligned with one another to form completed keyways when the wheel hub20and disc brake rotor30are assembled such that spring pins50may be received therein to secure the disc brake rotor30to the wheel hub20. In some forms, the disc brake assembly10includes a retainer such as a retaining ring60to inhibit backout of the spring pins50once received in the completed keyways. With the disc brake rotor30secured to the wheel hub20via the spring pins50, the disc brake rotor assembly10may be configured to rotate about a central axis A during, for example, movement of an associated commercial vehicle. In some embodiments, the commercial vehicle may be a class2vehicle or greater. The disc brake rotor30may be made of cast iron and the wheel hub body21may be made of ductile iron or aluminum.

In the illustrated form, the outboard end portion73of the wheel hub20includes a flange portion22having a plurality of studs24for receiving a wheel. In some embodiments, the studs24may be threaded for receiving a corresponding lugnut to secure the wheel to the wheel hub20. As illustrated, the wheel hub20also includes a plurality of studs25for receiving a drive flange of the vehicle. For non-drive wheel embodiments, the wheel hub may not include studs25. The wheel hub20also includes a pair of bearing assemblies70A, a spacer70B, and a central through opening70for receiving a spindle of a vehicle. A central wheel hub axis H (FIG.3) extends through a center of the central through opening70.

As shown inFIG.3, the inboard end portion71of the wheel hub20has a plurality of supports or mounting portions for connecting to the disc brake rotor30. In one embodiment, the mounting portions include female mounting portions80that include partial keyway portions81. The partial keyway portions81include pairs of outboard partial keyway portions85and inboard partial keyway portions83having partial keyways111,113(seeFIG.10). As illustrated, the outboard partial keyway portions85include the outboard bosses82and the inboard partial keyway portions83include the inboard bosses86. The outboard bosses82and inboard bosses86extend radially outward from a wall23of the wheel hub body21.

The partial keyways111,113include openings84,88having inner, arcuate surfaces95,96configured to extend about a portion of the outer surface of the spring pins50. The inboard bosses86are axially spaced from the plurality of outboard bosses82by axial gaps97, and the openings84,88are shown aligned along an axis63extending through the centers99,101of the openings84,88. The axis63extends parallel to the central axis H and the openings84,88overlap in an axial direction along the axis63. In other embodiments, the axis63extending through the openings84,88of the bosses82,86may extend transversely relative to the central axis A such that the spring pins50may be installed in a generally angled manner and a length of each of the spring pins50extends at an angle between about 0 degrees to about 90 degrees relative to central axis A. The outboard and inboard bosses82,86are generally shown as protruding radially outward of the wall23of the central opening70of the wheel hub20. As shown, a wheel hub pilot surface90is located between the outboard and inboard bosses82,86for engaging with the disc brake rotor30as explained in further detail below. The female mounting portions80may include the inboard and outboard bosses82,86, the gaps97therebetween, and surface portion90A of the wheel hub pilot surface90which receive male mounting portions104of the disc brake rotor30.

Referring toFIG.3, the wheel hub20includes an annular channel140extending about the wall23that is at least partially defined by opposite surfaces of the outboard and inboard bosses82,86facing one another. The channel140is configured to receive a center flange39of the disc brake rotor30and has radially extending stop surface92and a radially extending stop surface92A. By radially extending, it is intended that the stop surfaces92,92A extend along the radial direction, such as a flat radial surface, but may encompass other shapes and orientations such as slightly conical surface having an angle of 0.5 to 5 degrees relative to the radial direction. The stop surface92includes stop surface portions92B of inboard faces of the outboard bosses82, stop surface portions92C extending between the outboard bosses82, and stop surface portions92D of outboard faces of the inboard bosses86.

The plurality of inboard bosses86include circumferential gaps96extending therebetween that are sized and configured to receive corresponding male mounting portions104of the disc brake rotor30. Specifically, the male mounting portions104may be axially advanced onto the inboard end portion71of the wheel hub20until the disc brake rotor30reaches an installation position on the wheel hub20and abuts the stop surface92. The stop surface92inhibits outboard axial movement of the disc brake rotor30beyond the channel140.

As shown inFIG.4, the disc brake rotor30is generally annular and has an inboard cheek100, an outboard cheek102, and a central opening103. A central axis R extends through the central opening103at a center31thereof. The disc brake rotor30includes structures along its center flange39that are configured to interact and engage with structures of the wheel hub20. These structures include a plurality of mounting portions such as male mounting portions104having partial keyways portions109that include lugs or bosses105. In one embodiment, the bosses105extend radially inward into the opening103and each have an intermediate keyway115(seeFIG.10) including an opening106. More specifically, the bosses105are configured to be positioned intermediate the outboard and inboard bosses82,86of the wheel hub20such that the openings84,88,106may be aligned to form a completed keyway33(FIG.6) extending through the bosses82,86,105for receiving a spring pin50therein.

As described in further detail below, the wheel hub20and the disc brake rotor30may be moved between (1) a clearance configuration where the bosses105of the disc brake rotor30are rotationally offset from the bosses86of the wheel hub20to permit the bosses105,86to slide past one another, and (2) an interference configuration where the bosses105of the disc brake rotor30are outboard of and axially overlapping with the bosses86of the wheel hub20such that the disc brake rotor30is inhibited from moving off of the wheel hub20in an axially inboard direction. In one embodiment, the interference configuration includes the bosses105being positioned between pairs of bosses82,86of the wheel hub20such that the bosses82,86inhibit movement of the disc brake rotor30in inboard and outboard axial directions.

Similar to the female mounting portions80of the wheel hub20, the openings106of the mounting portions104are likewise configured extend about the outer surface of the spring pins50. Each boss105may further include a rotor pilot surface107that is configured to engage with and slide rotationally about the hub pilot surface90in the channel140when the bosses82,86,105are in a clearance configuration as described below. Additionally, the disc brake rotor30may include a retaining structure91such as protrusions or tabs93extending radially inward into the opening103that are configured to retain the retaining ring60once the disc brake rotor assembly10has been assembled in the manner described below. In another embodiment, the disc brake rotor30may include a continuous groove extending about the central opening103for receiving the retaining ring60in the installed state.

To assemble the disc brake rotor30and the wheel hub20, the bosses105of the disc brake rotor30are then rotationally aligned with and superimposed over the gaps96extending between the inboard bosses86of the wheel hub20. In other words, the bosses105of the disc brake rotor30are positioned to overlap the gaps96in an axial direction and be rotationally offset from the inboard bosses86, which may be referred to as a clearance configuration.

Once aligned in this manner, the disc brake rotor30may be moved relative to the wheel hub20in the direction O (FIG.1) such that the bosses105of the disc brake rotor30are moved into and through the gaps96until engaged with and abutting the stop surface92of the wheel hub20. This relative movement is intended to encompass, for example, moving the disc brake rotor30towards the wheel hub20, moving the wheel hub20towards the disc brake rotor30, or moving both the wheel hub20and disc brake rotor30towards one another. For example, the wheel hub20may be advanced in direction I towards the disc brake rotor30and the bosses86of the wheel hub20are moved into and through the gaps32between the bosses105of the disc brake rotor30until the bosses105of the disc brake rotor30engage with and abut the stop surface92. Once the pilot surfaces107of the rotor center flange39are positioned in the channel140and engaged with the wheel hub pilot90, the disc brake rotor30may be turned freely relative to the wheel hub20in the channel140.

The assembly of the disc brake rotor30and the wheel hub10next includes turning the disc brake rotor30(e.g., in direction11shown inFIG.5) into an interference configuration where the openings of the bosses82,86,105are aligned. Specifically, the disc brake rotor30is turned relative to the wheel hub20(i.e., clocked) until the bosses105are axially intermediate the pairs of outboard and inboard bosses82,86of the wheel hub20and the openings84,88,106are aligned to form the completed keyway33for receiving a spring pin50therein. When the disc brake rotor30and the wheel hub20are positioned in the interference configuration, inboard and outboard surfaces of the rotor bosses105are positioned in a confronting relationship with the bosses82,86of the wheel hub20so as to inhibit relative axial movement along the axis A.

The assembly process includes inserting spring pins50into the completed keyways33to secure the disc brake rotor30to the wheel hub20. Thereafter, the retaining ring60is installed by radially compressing the retaining ring60and axially advancing the retaining ring60outboard beyond tabs93of the rotor30and permitting the retaining ring60to resiliently radially expand and be held between the tabs93and an inboard surface87of the inboard bosses86. So configured, the retaining ring60extends radially inwardly and at least partially overlaps the opening88of the inboard bosses86to axially constrain the spring pins50within the completed keyways33and inhibit backout of the spring pins50from the keyways33. In a reverse manner, the disc brake rotor30may be removed from the wheel hub20by compressing and removing the retaining ring60, withdrawing the spring pins50from the keyways33, rotating the disc brake rotor30from the interference configuration (FIG.6) to the clearance configuration (FIG.5) in a direction opposite direction11, and axially moving the disc brake rotor30in direction I along the axis A (FIG.1) relative to the wheel hub20. In both the clearance and interference configurations, the central axis R of the disc brake rotor30and the central axis H of the wheel hub20are coaxial with one another along the central axis A.

Additionally or alternatively, the bosses82,86,105may be of different, varying configurations on one or both of the disc brake rotor30and wheel hub20. For example, although the wheel hub20has outboard and inboard pairs of bosses82,86and the disc brake rotor30has bosses105configured to be positioned therebetween, the opposite is also possible. Specifically, in another embodiment, the disc brake rotor30has pairs of outboard and inboard bosses and the wheel hub30has bosses configured to be positioned intermediate the inboard and outboard bosses of the disc brake rotor30. In still further embodiments, each of the wheel hub and disc brake rotor may include arrays of two or more mounting portions or bosses configured to be aligned in an alternating stacked configuration (i.e., a rotor boss, a wheel hub boss, a rotor boss, and a wheel hub boss) such that a spring pin positioned in a completed keyway defined thereby may be in a variety of shear configurations. In the context of the present disclosure, a pair of bosses should be understood to encompass two or more bosses.

Referring now toFIG.7, an example fastener40in the form of a spring pin50for use as a “key” in the completed keyways33of the assembly10is shown. The spring pin50is configured to be used for both securing the disc brake rotor30to the wheel hub20and for transmitting rotational torque therebetween such as during a braking operation. Each spring pin50may be formed by wrapping a strip of material around a mandrel including multiple wrapped layers66,67of the material, such as metal (e.g., steel or nickel) and may include an internal bore51having an internal surface68. So configured, the spring pin50may include multiple wrapped layers66,67of material wrapping around the central bore51and includes an edge69of layer66at least partially in the bore51. The spring pin50has an outer surface53and includes chamfered edges63. The spring pin50has a circumference55that extends around the cylindrical outer surface53of the spring pin50. It should be understood in the context of the present disclosure that the term circumference is intended to refer to a boundary of a curved geometric figure. Thus, the outer surface53is described as a circumference herein despite the outer surface53having a spiral-shape due to the wrapped configuration of the spring pin50.

When a disc brake caliper frictionally engages the disc brake rotor30during a braking operation, the spring pin50is configured to radially compress due to its multi-layer construction to assist in absorbing shock and vibrations that are transferred between the brake rotor30and the wheel hub20. Specifically, the spring pin50may be compressed as forces are applied to the outer surface53thereof and the layers66,67of the spring pin50may shift relative to one another along the direction65such that the edge69shifts along an inner surface of the layer66and the spring pin50constricts in a spiral-like manner. The spring pin50resiliently expands or rebounds with the layers66,67shifting relative to one another when the forces are removed.

In some forms, the spring pin50may be installed in a single shear configuration (i.e., having one shear plane) or a double shear configuration (i.e., having two shear planes; seeFIG.8showing shear planes52,54) to improve the overall shear strength of the pins50. Due to the wrapped and overlapping nature of the spring pins50as described above, the spring pins50may be more flexible and resilient to provide compliance within the disc brake rotor30and wheel hub20coupling joint without slop. That is, for installation into the completed keyways33, the spring pins50may be resiliently compressed during insertion into the keyways33such that the outer circumference55may be partially reduced. For example, the spring pin50has a chamfered surface63that engages a chamfered surface63A of the opening88(seeFIGS.3and7).

Once inserted into the keyways33, the spring pins50may resiliently expand and return to their original circumference55thereby taking up any dimensional variation between the disc brake rotor30and wheel hub20. Further, the spring pins50permit the disc brake rotor30to thermally expand more easily due to the layers66,67of the spring pin50being able to shift relative to one another (e.g., in direction65) as the spring pin50expands and contracts when force is applied thereto. During a braking operation, the spring pins50likewise permit a more even distribution and transfer of torsional forces between the components due to the spring-like nature of the pins50.

In some forms, at an initial point when a brake caliper engages the disc brake rotor30during a braking operation, the brake caliper urges the disc brake rotor30in a rotary direction relative to the wheel hub20. The spring pins50nearest to the brake caliper may initially compress in the manner described above to absorb torque being transferred to the wheel hub20and spring pins50farther away from the brake caliper about the circumference of the disc brake rotor30may take up relative movement of the disc brake rotor50. The compression of the spring pins50quickly evens out such that the spring pins50experience similar compression during the rest of the duration of the braking operation. In some embodiments, the spring pins50may be SPIROL® brand spring pins.

Spring pins50may be sheared in multiple planes, for example, a spring pin50that fails in single shear configuration would result in two broken, separate pieces of the pin, whereas a spring pin that breaks in a double shear configuration would result in three separate pieces. A double shear configuration may be preferable in some instances because the spring pin50experiences approximately half of the peak shear stress applied to the spring pin50at each of two different planes as it would if only a single shear plane were provided. Thus, embodiments of the disc brake rotor assembly having a double shear configuration may be preferable in some applications to reduce the shear stress in the spring pin50and increase durability of the disc brake rotor-wheel hub joint.

Referring now toFIG.8, a cross-sectional view is shown illustrating a spring pin50received in a completed keyway33formed by aligned openings84,88,106of the bosses82,86,105of the disc brake rotor30and wheel hub20. The spring pin50has a first end portion57, a second end portion59, and an intermediate portion61. As shown, the spring pin50is installed in a double shear configuration such that two separate shear planes52,54exist (i.e., one between first end portion57and intermediate portion61and one between intermediate portion61and second end portion59) normal to the central axis A of the assembly10to improve the shear strength of the spring pin50as explained above. When a brake caliper engages the disc brake rotor30during a braking operation, the brake caliper urges the disc brake rotor30in a rotary direction opposite the direction of rotation of the wheel hub20and imparts a torque on the disc brake rotor30.

The torque is transferred from the disc brake rotor30to the spring pins50via the bosses105. The torque load is at least partially absorbed by the spring pins50as described above and transferred to the wheel hub20via the bosses82,86. An example of the forces acting on one of the spring pins50is shown inFIG.8. Specifically, forces56,58are applied to the spring pins50by the bosses82,86,105which imparts shear stress along each of the two shear planes52,54. That is, force58is applied to the intermediate portion61of the spring pin50by the disc brake rotor30and reaction forces56are applied to the end portions57,59of the spring pin50by the wheel hub20.

FIG.9shows an enlarged perspective view of the disc brake assembly10with the disc brake rotor30in partial cross-section and showing the retaining ring60held between the tabs93of the disc brake rotor30and inboard surface portions87of the inboard bosses86to block axial movement of the spring pins50from the completed keyways33. As illustrated, the retaining ring60is sized to at least partially overlap an end portion64of each spring pin50to constrain and inhibit movement of the spring pins50in direction I (seeFIG.1). The tabs93extending radially inward of the opening103are configured to keep the retaining ring60in position near the spring pins50once the retaining ring60has been installed. As shown, the disc brake assembly10is in the assembled configuration where the rotor bosses105are axially intermediate the outboard and inboard bosses82,86of the wheel hub20and the spring pins50are in a double shear configuration.

FIG.10is a cross-sectional view of the disc brake assembly10in an assembled configuration illustrating a spring pin50received in a completed keyway33formed by the boss105of the disc brake rotor30and the outboard and inboard bosses82,86of the wheel hub20. The retaining ring60is installed and held between the tabs93and the outer surface portion87of the inboard boss86superimposed or overlapping the end surface64of the spring pin50. In this embodiment, the partial keyways111,113,115of the bosses82,86,105respectively are configured to each extend around an entirety of the circumference55of the spring pin50such that the outer surface53of the spring pin50is encircled and the spring pin50functions as a key within the completed keyway33. However, in other embodiments, any or all of the partial keyways111,113,115may extend around less than the entire circumference of the spring pins50(see, e.g.,FIGS.13-16). As illustrated, the partial keyway111of the outboard boss82is a blind bore and includes an internal stop surface89configured to abut the second end portion59of the spring pins50such that the spring pins50are axially constrained between the stop surface89at the second end portion59of the spring pin50and the retaining ring60at the first end portion57thereof in the assembled state.

In one alternative form as shown inFIG.11, the disc brake assembly10may further include a spacer120, such as a wave spring130, to reduce axial play between the retaining ring60and surfaces of the disc brake rotor30and the wheel hub20in the assembled configuration. As shown, the spacer120is positioned axially between the retaining ring60and tabs93of the disc brake rotor30. The spacer120may in some forms be beneficial as it may permit looser machining tolerances such that the spacer120can accommodate and account for any potential gaps between the inboard surface portions87of the inboard bosses86, the retaining ring60, and the tabs93, such that the retaining ring60may be securely held between the inboard surface87and the tabs93.

In still other embodiments, such as inFIG.12, the disc brake rotor assembly10may include a retainer comprising a fastener such as threaded bolt150and a washer160to inhibit back-out of the spring pins50from the completed keyways. In such forms, the wheel hub20′ includes a threaded bore170in which the fastener150is configured to thread into.

Referring now toFIGS.13and14, another disc brake assembly1000is provided that is substantially similar to the disc brake assembly10such that any differences will be described hereinafter. Similar to disc brake assembly10, the disc brake assembly1000includes a wheel hub1020and a disc brake rotor1030configured to be secured to the wheel hub1020using one or more fasteners1040such as spring pins1050. Each of the disc brake rotor1030and the wheel hub1020include one or more mounting portions such as male mounting portions1104and female mounting portions1080. The male and female mounting portions1104,1080include bosses1105,1082,1086having partial keyways1115,1111,1113that are configured to be aligned to form completed keyways upon assembly of the wheel hub1020and disc brake rotor1030such that a spring pin1050may be received therein to secure the disc brake rotor1030to the wheel hub1020and inhibit turning of the disc brake rotor1030relative to the wheel hub1020(e.g., during a braking operation). In contrast with the assembly10described above, the partial keyways1111,1113of the outboard and inboard bosses1082,1086of the wheel hub1020are configured to extend around less than an entire circumference of each of the spring pins1050. For example, as shown inFIG.13, the bosses1082,1086protrude radially outward from a wall1025of the wheel hub1020. The partial keyways1111,1113have a halfpipe-like shape with semi-circular slots or openings1084,1088for receiving a portion of the outer surface of the spring pins1050. Although illustrated as configured to extend around approximately 180 degrees of the circumference of the spring pins1050, in other forms, the partial keyways1111,1113of the outboard and inboard bosses1082,1086may be configured to cover less or more of the circumference of the spring pins1050.

As shown inFIG.14, the bosses1105of the disc brake rotor1030are substantially similar to the bosses105described above. However, as described above, the partial keyways1111,1113of the outboard and inboard bosses1082,1086of the wheel hub1020extend around less than an entire circumference of the outer surface of the spring pins1050while the partial keyways1115extend around the entire circumference. Additionally, due to the differing construction of the outboard and inboard bosses1082,1086, the inboard surface portion1087of the inboard boss1086does not extend far enough radially outward such that it is able to abut the outboard surface1061of the retaining ring1060, so the retaining ring1060does not abut a surface of the inboard boss1086. Rather, the retaining ring1060is held in place by tabs1093of the rotor1030and the spring pins1050. An additional structure (e.g., a continuous groove in the rotor) may be included to further secure the installed retaining ring1060.

Referring now toFIGS.15and16, another disc brake assembly2000is provided that is substantially similar to the disc brake assembly10such that any differences will be described hereinafter. Similar to assembly10, the disc brake assembly2000includes a wheel hub2020and a disc brake rotor2030configured to be secured to the wheel hub2020using one or more fasteners2040such as spring pins2050. The disc brake rotor2030and the wheel hub2020have male and female mounting portions2104,2080including bosses2105,2082,2086with partial keyways2115,2111,2113that are configured to be aligned to form completed keyways such that spring pins2050may be received therein to secure the disc brake rotor2030to the wheel hub2020and inhibit turning of the rotor2030relative to the wheel hub2020(e.g., during a braking operation). In contrast with the assembly10described above, the bosses2105of the disc brake rotor2030extend around less than an entire circumference of each of the spring pins2050. For example, as shown inFIG.15, the bosses2105protrude radially inward into the central opening2103of the disc brake rotor2030. The partial keyways2115have a halfpipe-like shape with semi-circular slots or openings2106for receiving a portion of the spring pins2050. Although illustrated as configured to extend around approximately 180 degrees of the circumference of the spring pins2050, in other forms, the bosses2105may be configured to cover less or more of the circumference of the spring pins2050.

Further, in contrast with the bosses105, the bosses2105may not include a corresponding rotor pilot surface configured to engage with and slide along a hub pilot surface of the wheel hub2020.

As shown inFIG.16, the female mounting portions2080of the wheel hub2020include outboard and inboard bosses2082,2086that are substantially similar to the bosses82,86described above. However, the boss2105of the disc brake rotor2030extends around less than an entire circumference of the outer surface of the spring pins2050while the bosses2082,2086of the wheel hub2020extend around the entire circumference.

This application describes examples that are meant to be illustrative and not limiting. The various described examples may be modified and/or combined with one another without departing from the scope described herein. For example, in still other embodiments of the assemblies10,1000,2000described herein, other forms of fasteners such as solid or slotted pins may be additionally or alternatively used for coupling the disc brake rotor to the wheel hub. Further, features of one embodiment may be combined with features of other embodiments to provide still further embodiments as appropriate.

Uses of singular terms such as “a,” and “an,” are intended to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms. It is intended that the phrase “at least one of” as used herein be interpreted in the disjunctive sense. For example, the phrase “at least one of A and B” is intended to encompass A, B, or both A and B.

While there have been illustrated and described particular embodiments, it will be appreciated that numerous changes and modifications will occur to those skilled in the art, and it is intended for the present disclosure to cover all those changes and modifications which fall within the scope of the appended claims.