BRAKE ROTOR ASSEMBLY FOR USE WITH AN ANTI-LOCK BRAKING SYSTEM
A brake rotor assembly for use with an anti-lock braking system. The brake rotor assembly includes a brake rotor having a pair of braking surfaces; a tone ring having a first end having a plurality of spaced sensing formations disposed thereon and a second end for circumferentially contacting a surface of the brake rotor assembly, the first end thermally insulated from the brake rotor; and a snap ring for connecting the tone ring to the brake rotor assembly. A method of forming a brake rotor assembly is also provided.
1 . A brake rotor assembly comprising:
a) a brake rotor having a pair of braking surfaces;
b) a tone ring having a first end having a plurality of spaced sensing formations disposed thereon and a second end for circumferentially contacting a surface of the brake rotor assembly, the first end thermally insulated from the brake rotor; and
c) a snap ring for connecting the tone ring to the brake rotor assembly.
2 . The brake rotor assembly of claim 1 , wherein the tone ring is molded from powder metal.
3 . The brake rotor assembly of claim 1 , wherein an outer surface of the tone ring has a corrosion resistant coating formed thereon
4 . The brake rotor assembly of claim 3 , wherein the corrosion resistant coating comprises electroless plating.
5 . The brake rotor assembly of claim 4 , wherein the electroless plating comprises, electroless nickel.
6 . The brake rotor assembly of claim 1 , wherein the brake rotor further comprises a hat portion for mounting to a wheel hub, wherein the hat portion includes a cylindrical body and a radial mounting flange.
7 . The brake rotor assembly of claim 6 , further comprising a cylindrical spacer, the cylindrical spacer having a first end having a surface for circumferentially contacting the second end of the tone ring and a second end for coupling to the hat portion of the brake rotor assembly.
8 . The brake rotor assembly of claim 7 , wherein the cylindrical spacer and the tone ring are formed of different materials.
9 . The brake rotor assembly of claim 8 , wherein the cylindrical spacer is formed of cast iron.
10 . The brake rotor assembly of claim 1 , the brake rotor assembly in combination with a vehicle having a gross vehicle weight of at least 5,000 pounds.
11 . A method of forming a brake rotor assembly comprising:
a) providing a brake rotor having a pair of braking surfaces;
b) providing a tone ring having a first end having a plurality of spaced sensing formations disposed thereon and a second end for circumferentially contacting a surface of the brake rotor assembly, the first end thermally insulated from the brake rotor; and
c) connecting the tone ring to the brake rotor assembly with a snap ring.
12 . The method of claim 11 , wherein the tone ring is molded from powder metal.
13 . The method of claim 11 , wherein an outer surface of the tone ring has a corrosion resistant coating formed thereon
14 . The method of claim 13 , wherein the corrosion resistant coating comprises electroless plating.
15 . The method of claim 14 , wherein the electroless plating comprises, electroless nickel.
16 . The method of claim 11 , wherein the brake rotor further comprises a hat portion for mounting to a wheel hub, wherein the hat portion includes a cylindrical body and a radial mounting flange.
17 . The method of claim 16 , further comprising providing a cylindrical spacer, the cylindrical spacer having a first end having a surface for circumferentially contacting the second end of the tone ring and a second end for coupling to the hat portion of the brake rotor assembly.
18 . The method of claim 17 , wherein the cylindrical spacer and the tone ring are formed of different materials.
19 . The method of claim 18 , wherein the cylindrical spacer is formed of cast iron.
20 . The method of claim 11 , further comprising installing at least one brake rotor assembly on a vehicle having a gross vehicle weight of at least 5,000 pounds.