Patent ID: 7594568

Claim:
A method for producing a rotor assembly for a vehicle brake system comprising: providing an upper tool having an upper sealing lip, and a lower tool having a lower sealing lip; disposing a rotor having a radially internal flange within said lower tool; engaging the upper and lower tools such that a cavity is formed therebetween; heating the upper tool, the lower tool and the rotor; applying a compressive force to draw the upper and lower tools together and thereby clamp the rotor flange between the upper sealing lip and the lower sealing lip; transferring material into the cavity formed between the upper and lower tools such that a hub section is formed onto the rotor, and wherein the upper sealing lip and lower sealing lip are constructed and arranged to produce radially extending upper and lower portions of a radially extending flange of the hub to capture the radial internal flange of the rotor and wherein the plurality of rotor teeth are in the same plane as a frictional surface of the rotor.