Abstract:
The floating brake rotor assembly with non-load bearing pins includes a brake rotor and hub that are coplanar and are interconnected by pin and spring assemblies such that the pins do not bear rotational torque being transferred between the brake rotor and hub. The rotor has tooth-like protruding members along its inner edge that mate with recessess along the outer edge of the hub. When aligned, each protruding member and corresponding recess forms an aperture through which a pin is positioned, and allows for transfer of rotational torque without applying load force to the pin.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates to disc brake assemblies, and more particularly to a floating brake rotor assembly in which the connecting pins are not subject to torque forces transferred from the brake rotor to the hub.  
         [0003]     2. Description of the Related Art  
         [0004]     Various designs for floating brake rotor assemblies have been proposed. Examples of such designs are provided by U.S. Pat. No. 4,848,521, issued Jul. 18, 1989 to Z. Izumine; U.S. Pat. No. 5,520,269, issued May 28, 1996 to S. Yamamoto et al.; U.S. Pat. No. 5,921,633, issued Jul. 13, 1999 to P. Neibling et al.; U.S. Pat. No. 6,267,210, issued Jul. 31, 2001 to D. L. Burgoon et al.; U.S. Pat. No. 6,305,510, issued Oct. 23, 2001 to K. J. Bunker; and U.S. Pat. No. 6,374,956, issued Apr. 23, 2002 to E. Naeumann et al.  
         [0005]     In general, a floating brake rotor assembly is comprised of a brake rotor and a hub. The brake rotor is annular with two flat sides that provide surfaces to which brake pads can be applied. The hub provides a means for mounting the brake rotor to the wheel of a vehicle. The two sections are interconnected in a manner that allows the brake rotor to move, or “float,” axially relative to the hub. One of the main advantages of a floating rotor is that binding of the rotor with a brake pad, due to heat distortion of the rotor, is minimized or avoided. Hence, as the rotor warps slightly due to thermal expansion, it floats relative to the brake pad.  
         [0006]     Typically, the brake rotor and the hub are interconnected in one of two manners. In one manner, as taught by Yamamoto et al., and particularly referring to FIG. 1 thereof, the inner aspect of the brake rotor and the outer aspect of the hub have mating semi-circular indentations that form apertures through which a pin is passed to connect the rotor and hub. In the other manner, as taught by Burgoon et al., and particularly referring to FIG. 4 thereof, overlapping portions of the brake rotor and the hub have mating apertures that align to form a single continuous aperture through which a pin or bolt is passed.  
         [0007]     Significantly, in each of the aforementioned manners for interconnecting a brake rotor and a hub, the load transfer between the two components is transferred solely across the connecting pins. Consequently, several known problems are associated with each manner. First, because load thrust transfer must occur across a relatively small surface area, localized wear and deformation of the brake rotor, hub and pins occur frequently. Second, the maximum load transfer between the brake rotor and the hub is constrained by the load capacity of the pins. Third, thermal transfer capacity from the brake rotor to the hub is constrained, thereby lessening heat dissipation and increasing the likelihood of thermal induced distortion of the brake rotor.  
         [0008]     U.S. Pat. No. 4,848,521, issued to Z. Izumine; U.S. Pat. No. 5,921,633, issued to P. Neibling et al.; and U.S. Pat. No. 6,267,210, issued to Burgoon et al. each teach a rotor and hub assembly wherein the rotor and hub are connected by a number of pins that pass through apertures in overlapping portions of the rotor and the hub, with the pins being oriented parallel to the axis of rotation. As discussed above, this configuration results in the entire load transfer between the rotor and hub being transferred via the pins and further results in the aforementioned problems.  
         [0009]     On the other hand, U.S. Pat. No. 5,520,269, issued to S. Yamamoto et al., and U.S. Pat. No. 6,305,510, issued to K. J. Bunker, each teach a rotor and hub assembly wherein corresponding semicircular indentations along the inner edge of the rotor and the outer edge of the hub mate to form apertures through which pins secure the rotor and hub together. However, this configuration also results in the entire load transfer between the rotor and hub being transferred via the pins. Additionally, Bunker uses a combined pin and leaf spring, which complicates assembly and replacement of the rotor.  
         [0010]     U.S. Pat. No. 6,374,956, issued to E. Naeumann et al., teaches a brake rotor and hub assembly wherein the rotor and hub are connected in a non-coplanar configuration with an insulating layer between the two components. However, due to lateral torque forces, the non-coplanar configuration of the rotor and hub is more prone to produce warping and excessive wear.  
         [0011]     U.K. Pat App. No. 2,150,263, published on Jun. 26, 1985, depicts a rotor and hub assembly wherein the rotor and hub are interconnected by a spring. The spring is planar and is disposed in a groove on the outer edge of the hub such that when a pin is passed though a shaft that intersects the groove, the ends of the spring extend into recessed areas on the inner edge of the rotor. This configuration requires precise placement of the spring groove, pin shaft, and recessed areas, and thus complicates manufacture, assembly and replacement of the components.  
         [0012]     Consequently, none of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed. Thus, a floating brake rotor assembly solving the aforementioned problems is desired.  
       SUMMARY OF THE INVENTION  
       [0013]     The floating brake rotor assembly with non-load bearing pins includes a brake rotor and hub that are coplanar and are interconnected by pin and spring assemblies such that the pins do not bear rotational torque being transferred between the rotor and the hub. The rotor has tooth-like protruding members along its inner edge that mate with recessess along the outer edge of the hub. When aligned, each protruding member and corresponding recess form an aperture through which a pin is positioned, and allows for transfer of rotational torque without applying load force to the pin. This coplanar configuration with pin apertures formed between the rotor and hub allows for ease in assembling and replacing the components.  
         [0014]     Furthermore, the multiple tooth-like protruding members and corresponding recessess provide an increased thrust face surface area between rotor and hub, thereby enabling greater load transfer capacity (by as much as 500% as compared to prior art assemblies). By transferring load via the bearing faces of multiple protruding members and recesses, wear of rotor and hub is decreased; localized deformation is minimized; and thermal transfer capability of rotor to hub is increased, thereby improving heat dissipation and lessening thermal induced distortion of the rotor.  
         [0015]     Accordingly, it is a principal object of the invention to provide a floating brake rotor assembly that minimizes localized deformation and decreases wear of rotor, hub and pins by incorporating non-load bearing pins and spreading load transfer forces over a greater area.  
         [0016]     It is another object of the invention to provide a floating brake assembly that increases load transfer capacity between rotor and hub by increasing thrust face surface area between the two.  
         [0017]     It is a further object of the invention to provide a floating brake assembly that increases thermal transfer capability between rotor and hub, thereby improving heat dissipation and lessening thermal induced distortion of the rotor.  
         [0018]     Still another object of the invention is to provide a floating brake assembly that incorporates a configuration using a coplanar rotor and hub assembly, which minimizes or eliminates distortion due to lateral thrust.  
         [0019]     Yet another object of the invention is to provide a floating brake assembly that incorporates pin and spring assemblies that are simple to assemble and replace.  
         [0020]     It is an object of the invention to provide improved elements and arrangements thereof for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.  
         [0021]     These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0022]      FIG. 1  is a side view of a floating brake rotor assembly with non-load bearing pins according to the present invention, the opposite side being symmetrical.  
         [0023]      FIG. 2  is an exploded view of the floating brake assembly of  FIG. 1 .  
         [0024]      FIG. 3  is a perspective view of a pin and spring assembly for the floating brake rotor assembly according to the present invention.  
         [0025]      FIG. 4  is a fragmented, side elevation view of the rotor and hub for the floating brake rotor assembly, the pins not being shown in order to depict alignment of the protruding members on the rotor with indentations on the hub.  
         [0026]      FIG. 5  is a side view of an alternative embodiment of a floating brake rotor assembly with non-load bearing pins according to the present invention.  
         [0027]      FIG. 6  is a fragmented, side view of the rotor and hub of the floating brake rotor assembly of  FIG. 5 , the pins being omitted in order to show alignment of protruding members on the rotor with indentations on the hub.  
         [0028]      FIG. 7  is a side view of a another alternative embodiment of a floating brake rotor assembly with non-load bearing pins according to the present invention, the pins being omitted. 
     
    
       [0029]     Similar reference characters denote corresponding features consistently throughout the attached drawings.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0030]     The present invention is a floating brake rotor assembly with non-load bearing pins designated generally as  10  in the drawings. As shown in  FIGS. 1 and 2 , the invention includes a brake rotor  20  that is secured to a hub  30  by six pin and spring assemblies  40 .  
         [0031]     The brake rotor  20  is an annular disk with two opposing flat sides or faces, and six protruding members  21  or teeth extending from its  20  inner circumferential edge  22 . Each protruding member  21  has two lateral faces  23  and two radially extending bearing faces  24 . Each lateral face  23  is flush with the lateral faces of the brake rotor  20  and each radially extending bearing face  24  is perpendicular to the lateral faces of the brake rotor  20 . The two radially extending bearing faces  24  taper toward each other from the proximal end to the distal end  25  of each protruding member  21 , i.e., from the rim towards the center of the rotor  20 . From a lateral perspective, the distal end  25  of each protruding member  21  is concave.  
         [0032]     The hub  30  is substantially round and annular with two opposing flat sides or faces, and with six recesses  31  formed along its outer circumferential edge  32 . Each recess  31  has two bearing faces  33  that are perpendicular to the planes in which the faces of the hub  30  lie. From the outer edge  32  of the hub  30 , the two bearing faces  33  taper toward each other and meet to form a curved bottom  34 . From a lateral perspective, the curved bottom  34  of the recess is concave.  
         [0033]     Each of the six pin and spring assemblies  40 , shown more particularly in  FIG. 3 , includes a pin having a head  41  and a shaft  43 , and a spiral retaining spring  42  that is sized to fit snuggly around the pin shaft  43 .  
         [0034]     The brake rotor  20  is mounted on the hub  30  with its six protruding members  21  positioned within the six recesses  31  on the outer circumference  32  of the hub  30 . The bearing faces  24  of the protruding members  21  rest flush against the bearing faces  33  of the recesses  31 , thereby suspending the brake rotor  20  on the hub  30  such that the rotor  20  and hub  30  share a common axis of rotation and are substantially coplanar. Together, the distal end  25  of each protruding member  21  and the bottom  34  of its  21  corresponding recess  31  form an opening  26 , as shown most clearly in  FIG. 4 . A pin and spring assembly  40  is disposed through each opening  26  with the head  41  of the pin on one side of the brake rotor  20  and hub  30 , and with the retaining spring  42  mounted on a portion of the pin shaft  43  extending from the opposite side of the brake rotor  20  and hub  30 . Instead of a retaining spring, a retainer ring may be placed on the shaft  43  to secure the pin. The pin and spring assemblies  40  secure the brake rotor  20  and hub  30  together, while at the same time allowing slight lateral movement of the brake rotor  20  relative to the hub  30 .  
         [0035]     A number of apertures  27  pass laterally through the brake rotor  20  and hub  30  to help dissipate heat, to accommodate a vehicle axle, and to allow for mounting of the assembly  10  to a wheel.  
         [0036]     When the brake rotor assembly  10  is mounted to a vehicle wheel and brake pads are applied to the side faces of the brake rotor  20 , torque force is transferred from the brake rotor  20  to the hub  30  solely via the sides  24  and  33  of the protruding members  21  and indentations  31 , respectively. Hence, the pin and spring assemblies  40  do not bear any torque force transferred from the brake rotor  20  to the hub  30 , and the load is transferred between rotor  20  and hub  30  primarily, if not exclusively, through the mating bearing faces of the protruding members  21  and indentations  31 .  
         [0037]     In an alternative embodiment, designated generally as  50  and shown in  FIGS. 5 and 6 , the distal end  53  of each protruding member  52  is rounded, radially extending side  55  of each protruding member  52  is substantially planar, being linear as viewed from the side of the rotor  51 , and radially extending side  56  has a semi-circular cavity  54  as viewed from the side of the rotor  51 . One side  61  of each of the recesses on the outer edge  63  of the hub  60  is substantially planar, being linear as viewed from the side of the hub  60 , and the other side  62  of each recess has a semi-circular cavity  64 , as viewed from the side of the hub  60 , that mates with the cavity  54  on a corresponding protruding member  52  to form an opening  57  for a pin and spring assembly  58 .  
         [0038]     In a second alternative embodiment, designated generally as  70  in  FIG. 7 , the hub  71  has six protruding members  72  extending radially from its outer edge  73  that mate with six recesses  81  in the inner circumferential edge  82  of the brake rotor  80 . Each protruding member  72  has two radially extending sides  74  and  75  that are substantially parallel to each other, the first side  75  forming a substantially planar bearing face and the opposing side  74  having a cavity  76  defined therein, so that the opposing side  74  is concave. Each recess  81  in the brake rotor  80  has two sides  83  and  84  that are substantially parallel to each other, side  83  being substantially planar in order to form a bearing face that mates with the bearing face  75  of the protruding member  72 , the opposing side  84  having a cavity  85  formed therein so that side  84  is concave, the concave sides  74  and  84  being aligned to form an opening for a pin and spring assembly. The distal end  77  of each protruding member  72  and the bottom  86  of each recess  81  are substantially flat.  
         [0039]     Both of these alternative floating brake rotor assemblies  50  and  70  are designed to work in one direction. Hence, the pin and spring assemblies of each assembly  50  and  70  are non-load bearing only when brake pads are applied to the brake rotors  51  and  80  while either brake rotor assembly  50  and  70 , as shown in  FIGS. 5 and 7 , is spinning in a counter-clockwise rotation. Thus, these assemblies  50  and  70  are useful primarily for vehicles that are driven in only one direction, such as motorcycles.  
         [0040]     It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.