Granted Patent B2

US 7,975,750 · App. 10/961,813 · Granted Jul 12, 2011

Abstract

Claims (35)

1. A method for manufacturing a Coulomb friction damped disc brake rotor, comprising the steps of:

providing at least one insert having a coating sprayed thereon; and

forming a disc brake rotor in a mold comprising casting molten metal substantially surrounding the at least one insert, wherein a rotor cheek of the disc brake rotor is formed over the at least one insert so that the insert is embedded in the rotor cheek, wherein the rotor cheek has at least one braking surface, and wherein the at least one insert is substantially coextensive with the at least one braking surface;

wherein the at least one insert and the rotor cheek provide at least two interfacial boundaries, each interfacial boundary defining an interstice between a rotor cheek inner surface and a surface of the insert and providing a mechanically distinguishable surface boundary between the rotor cheek inner surface and the surface of the insert which are in mutual contact such that a state of Coulomb friction exists therebetween.

2. The method of claim 1 , wherein:

said step of providing provides at least two inserts; and

said step of forming forms a disc brake rotor having a vented cheek configuration comprising two rotor cheeks, wherein each of the two rotor cheeks is formed over at least one insert of the at least two inserts, respectively, and wherein each rotor cheek has a respective braking surface, and wherein the at least two inserts are substantially coextensive with the braking surfaces.

3. A method of manufacturing a coulomb friction damped disc brake rotor as set forth in claim 1 , wherein the forming a disc brake rotor comprises surrounding at least three sides of the insert with the rotor cheek.

4. A method for manufacturing a damped article comprising the steps of:

providing at least one insert; and

forming the article, wherein the article is formed over the at least one insert so that the at least one insert is substantially surrounded and embedded in the article;

wherein the at least one insert provides at least four interfacial boundaries, the interfacial boundaries providing a mechanically distinguishable surface boundary between two surfaces which are in mutual contact such that a state of Coulomb friction exists therebetween.

5. A method as set forth in claim 4 wherein the insert includes flat portion and a bulbous positioned to interferingly engage the rotor cheek.

6. A method comprising:

providing at least one insert; and

casting a disc brake rotor that comprises at least one substantially solid rotor cheek having at least one braking surface over the at least on insert so that the at least one insert is embedded in the rotor cheek and surrounded on at least five sides by the rotor cheek;

wherein the at least one insert provides at least one interfacial boundary, the interfacial boundary providing a mechanically distinguishable surface boundary between two surfaces which are in mutual contact such that a state of Coulomb friction exists therebetween.

7. A method as set forth in claim 6 , wherein the at least one insert is substantially coextensive with the at least one braking surface of the rotor cheek.

8. A method for manufacturing a damped article comprising the steps of:

providing at least one insert; and

forming the article, wherein the article is formed over the at least one insert so that the at least one insert is substantially surrounded and embedded in the article;

wherein the at least one insert provides at least three interfacial boundaries, the interfacial boundaries providing a mechanically distinguishable surface boundary between two surfaces which are in mutual contact such that a state of Coulomb friction exists therebetween.

9. A method as set forth in claim 8 , wherein the article comprises a brake rotor having at least one braking surface and wherein the at least one insert is substantially coextensive with the at least one braking surface of the rotor cheek.

10. A method as set forth in claim 8 wherein the insert includes a bulbous positioned to interferingly engage the rotor cheek.

11. A method comprising:

providing at least one insert; and

casting a disc brake rotor that comprises at least one substantially solid rotor cheek having at least one braking surface over the at least one insert so that the at least one insert is embedded in the rotor cheek and surrounded on at least five sides by the rotor cheek;

wherein the at least one insert provides at least one interfacial boundary, the interfacial boundary providing a mechanically distinguishable surface boundary between two surfaces which are in mutual contact such that a state of Coulomb friction exists therebetween.

12. A method comprising:

providing at least one insert; and

placing the at least one insert in a casting mold half and supporting the at least one insert in the mold half by at least one post or chaplet;

casting a disc brake rotor that comprises at least one substantially solid rotor cheek having at least one braking surface over the at least one insert, and wherein the insert includes an upper face, a lower face and an inner radial side connecting the upper face and lower face, and so that the at least one insert is embedded in the rotor cheek and surrounded on the upper face, the lower face and the inner radial side by the rotor cheek;

wherein the at least one insert provides at least one interfacial boundary, the interfacial boundary providing a mechanically distinguishable surface boundary between two surfaces which are in mutual contact such that a state of Coulomb friction exists therebetween.

13. A method as set forth in claim 12 , wherein the at least one insert is substantially coextensive with the at least one braking surface of the rotor cheek.

14. A method as set forth in claim 12 wherein the insert includes a bulbous positioned to interferingly engage the rotor cheek.

Assignments (13)