Abstract:
A dual-structure brake disk assembly includes a first disk, a second disk and a hollow area located between the first and second disks. The brake disk has high strength, high efficiency for dissipating heat and lightweight. The brake disk is manufactured quickly and has high production efficiency.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to a brake disk assembly, and more particularly, to a lightweight dual-structure brake disk assembly with multiple holes defined therethrough, connectors are connected between the holes to form cooling paths. The brake disk assembly is made by way of pressing/stamping/impact molding. 
       BACKGROUND OF THE INVENTION 
       [0002]    The conventional braking method is to clamp the brake disk by two lining plates, and the friction between the brake disk and the lining plates transfers the kinetic energy into heat to stop the vehicle. 
         [0003]    It is noted that the brake disk is applied by high friction so that it is required to have sufficient strength. The brake disk has to bear higher temperature when transferring the kinetic energy into heat. The abilities to bear high temperature and structural strength are basic features for a brake disk. 
         [0004]    TW Patent No. I274818 discloses multiple fins formed on the inner and outer peripheries of the brake disk and at least one pair of the fins have multiple paths defined therebetween. Each path has a first opening and a second opening, wherein the entrance is located at the central portion of the path and the outlet is located at the periphery of the disk. By the openings, the efficiency for bringing heat away from the brake disk is increased. U.S. Pat. No. 5,224,572 discloses a “Lightweight Brake Rotor with a Thin, Heat Resistant Ceramic Coating” wherein the brake rotor has a plurality of circumferentially spaced radially spaced cooling apertures so as to increase the efficiency for bringing heat away from the brake disk. 
         [0005]    The present invention intends to provide a dual-structure brake disk with high strength and high efficiency for bringing heat away from the brake disk. 
       SUMMARY OF THE INVENTION 
       [0006]    The present invention relates to a brake disk assembly and comprises a first disk and a second disk, wherein the first disk has multiple first holes defied therethrough and the second disk has multiple second holes defined therethrough. The first holes are located corresponding to the second holes. A separation member is located between the first and second disks. Preferably, the separation member comprises multiple protrusions pressing from the first and second disks. A hollow area is defined between the first and second disks. The first and second disks each have a friction face formed on outside thereof. Multiple connectors are connected between the first and second disks and located corresponding to the first and second holes so as to define a cooling path between the first and second holes. The connectors do not extend beyond the first and second friction faces. 
         [0007]    The primary object of the present invention is to provide a brake disk assembly which has connectors connected between the respective holes of the first and second disk to form multiple cooling paths such that the connection strength and the heat dissipating efficiency are increased. The cooling paths also reduce the weight of the brake disk assembly. 
         [0008]    Another object of the present invention is to provide a brake disk assembly which is easily manufactured by way of pressing. Preferably, the first and second disks are connected to each other by one time pressing such that the production rate of the brake disk assembly is fast. 
         [0009]    The present invention will become more obvious from the following description when taken in connection with the accompanying drawings which show, for purposes of illustration only, a preferred embodiment in accordance with the present invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1A  is an exploded view to show the brake disk assembly of the present invention; 
           [0011]      FIG. 1B  shows the enlarged view of the second disk of the brake disk assembly of the present invention; 
           [0012]      FIG. 1C  shows the enlarged view of the first disk of the brake disk assembly of the present invention; 
           [0013]      FIG. 2  is a perspective view to show the brake disk assembly of the present invention; 
           [0014]      FIG. 3  is a cross sectional view, taken along line A-A of  FIG. 2 ; 
           [0015]      FIG. 4  shows the second embodiment of the brake disk assembly of the present invention; 
           [0016]      FIG. 5  is a cross sectional view, taken along line BB of  FIG. 4 , and 
           [0017]      FIG. 6  shows the third embodiment of the brake disk assembly of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0018]    Referring to  FIGS. 1A to 1C , the brake disk assembly of the present invention comprises a first disk  1  and a second disk  2 . The first disk  1  has a first friction face  11 . Multiple first protrusions  12 , multiple first holes  13  and multiple connectors  14  are pressed from the first friction face  11 . The first holes  13  are defined in the first protrusions  12 . The connectors  14  are connected to the first protrusions  12  and located along the periphery of the first holes  13 . The connectors  14  are tubular members. Multiple first apertures  15  are defined through the first disk  1  by way of pressing. The second disk  2  has a second friction face  21 . Multiple second protrusions  22 , multiple second holes  23  are pressed from the second friction face  21 . The second holes  23  are defined in the second protrusions  22 . The second friction face  21  has multiple recessed areas  24  formed therein at the positions where the second protrusions  22  are located. Multiple second apertures  25  are defined through the second disk  2  by way of pressing. 
         [0019]    As shown in  FIGS. 2 and 3 , the first protrusions  12  of the first disk  1  contact the second protrusions  22  of the second disk  2  so as to define a hollow area “A” between the first and second disks  1 ,  2 . The connectors  14  extend through the second holes  23  of the second disk  2  and beyond the second friction face  21 . The distal end of each connector  14  extending beyond the second friction face  21  is bent to form a bent portion  141  which contacts the recessed area  24  of the second disk  2 . Therefore the first and second disks  1 ,  2  are connected to each other and multiple cooling paths “B” are formed between the first and second holes  13 ,  23 . After the bent portions  141  are forming, the connectors  14  do not extend beyond the first and second friction faces  11 ,  21 . When the first and second disks  1 ,  2  are connected to each other, a first gap C is formed between the first and second disks  1 ,  2  and located along the periphery of the first and second disk  1 ,  2 . The first gap “C” communicates with the hollow area “A”. The first apertures  15  are located corresponding to the second apertures  25 . A second gap “D” is formed between the first and second disks  1 ,  2  and located along the periphery of the first and second apertures  15 ,  25 . The second gap “D” communicates with the hollow area “A”. The first gap “C”, the second gap “D” and the hollow area “A” form a heat convection path. It is noted that the heat convection path is not limited as the above-mentioned configuration and can be obtained by any possible way as long as the hollow area “A” communicates with outside of the brake disk assembly. For example, the convection path can be obtained by drilling holes in the first and second disks  1 ,  2 . 
         [0020]    By the connectors  14  connected between the first and second holes  13 ,  23  of the first and second disks  1 ,  2 , the first and second disk  1 ,  2  are securely connected to each other and hence formed multiple connecting points therebetween, so that the connection between the first and second disks  1 ,  2  has excellent strength. Consequently, the first and second disks  1 ,  2  can bear great friction force and high temperature, generated from braking in a high speed, without great deformation and damages. The heat convection paths are formed by the first gap “C”, the second gap “D” and the hollow area “A”, so that the heat generated between the first and second friction faces  11 ,  21  and the lining plates can be quickly brought away by the heat convection phenomena of the heat convection paths. The cooling paths “B” between the first and second holes  13 ,  23  can boost the heat convection phenomena so as to increase the heat dissipating efficiency. The first apertures  15  of the first disk  1  and the second apertures  25  of the second disk  2  reduce the weight of the brake disk assembly. 
         [0021]    The first and second disks  1 ,  2  are connected to each other by way of pressing can be quickly manufactured. Preferably, after the first and second disks  1 ,  2  are made, the first and second disks  1 ,  2  are connected to each other by one time pressing. As shown in  FIG. 1 , before the first and second disks  1 ,  2  are connected to each other, a washer  3  is located between two respective central portions of the first and second disks  1 ,  2 . Multiple bolts  4  are used to extend through the first disk  1 , the washer  3  and the second disk  2 , and connected with nuts  5  to increase the connection between the first and second disks  1 ,  2 . 
         [0022]      FIGS. 4 and 5  show the second embodiment of the present invention, wherein the first disk  1  has some of the first holes  13  defined in the first protrusions  12 . The connectors  14  are connected to the first protrusions  12  and located along the periphery of the first holes  13 . The second disk  2  has some of the second holes  23  defined in the second protrusions  22 . Some of the first holes  13  are pressed to form the third protrusions  16 , and some of the second holes  23  are pressed to form the fourth protrusions  26 . When the first and second disks  1 ,  2  are connected to each other, the third protrusions  16  contact the fourth protrusions  26 . A cooling path “E” is formed between the first and second holes  13 ,  23 . This embodiment is suitable used to bicycles or motorbikes which are operated at lower speed. 
         [0023]      FIG. 6  shows the third embodiment of the present invention, and the third embodiment has a first disk  1 A and a second disk  2 A. The first disk  1 A has a first friction face  11 A. Multiple first protrusions  12 A and multiple first holes  13 A are pressed from the first friction face  11 A. The first friction face  11 A has multiple first recessed areas  14 A formed therein which are located at the positions where the first protrusions  12 A are located. The second disk  2 A has a second friction face  21 A. Multiple second protrusions  22 A and multiple second holes  23 A are pressed from the second friction face  21 A. The second friction face  21 A has multiple second recessed areas  24 A formed therein which are located at the positions where the second protrusions  22 A are located. The first and second protrusions  12 A,  22 A are in contact with each other when the first and second disks  1 A,  2 A are connected to each other. A distance is formed between the first and second disks  1 A,  2 A. The connectors  3 A are tubular members and extend through the first holes  13 A of the first disk  1 A and the second holes  23 A of the second disk  2 A. Two distal ends of each of the connectors  3 A are bent to form two bent portions  31 A which contact the first and second recessed areas  14 A,  24 A of the first and second disks  1 A,  2 A so as to connect the first and second disks  1 A,  2 A. A cooling path “F” is formed between the first and second holes  13 A,  23 A. Therefore, the configuration/arrangement of the third embodiment can achieve the same effects as that of the first embodiment. 
         [0024]    While we have shown and described the embodiment in accordance with the present invention, it should be clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention.