BRAKE ROTOR WITH WORKING SURFACE INSERTS
A brake rotor assembly can include a structural part having a receiving surface and at least one friction surface parts having a contact surface. The friction surface part can be fixably attached to the receiving surface of the structural part such that the contact surface faces away from the receiving surface of the structural surface to form at least part of an annular braking surface arranged concentrically around an axis of rotation of the structural part.
1 - 21 . (canceled)
22 . A brake rotor assembly, comprising:
a structural part comprising:
a receiving surface positioned perpendicular to an axis of rotation of the structural part, the structural part being formed of at least one bulk material that is not stainless steel; and
an outer structural surface positioned parallel to the axis of rotation;
a friction surface part comprising:
a contact surface defining a surface of the friction surface part; and
an outer friction surface positioned parallel to the axis of rotation;
wherein the friction surface part comprising stainless steel;
wherein the friction surface part is fixably attached to the receiving surface of the structural part such that the contact surface faces away from the receiving surface to form at least part of an annular braking surface arranged concentrically around the axis of rotation; and
wherein the outer friction surface and the outer structural surface are co-planar and abut one another.
23 . The brake rotor assembly of claim 22 , further comprising: a wear and corrosion resistant coating applied onto the contact surface of the friction surface part.
24 . The brake rotor assembly of claim 22 , wherein the friction surface part comprises a plurality of friction surface parts arranged on the receiving surface to form the at least part of the annular braking surface.
25 . The brake rotor assembly of claim 22 , wherein the contact surface of the friction surface part comprises one or more levels of surface topography.
26 . The brake rotor assembly of claim 25 , wherein the one or more levels of surface topography comprise a first level comprising island formations separated by channels.
27 . The brake rotor assembly of claim 26 , wherein the one or more levels of surface topography further comprise a second level comprising raised peaks with spaced valleys between the peaks.
28 . The brake rotor assembly of claim 27 , wherein the second level of surface topography assists in retaining a transferred film or layer of brake pad material on the contact surface.
29 . The brake rotor assembly of claim 28 , wherein the transferred film or layer of brake pad material enhances braking by participating in adhesive friction with a brake pad.
30 . The brake rotor assembly of claim 22 , wherein the at least one bulk material comprises at least one of a ceramic, a composite material, cast iron, and carbon fiber.
31 . The brake rotor assembly of claim 22 , wherein the structural part comprises a physical structure to enhance cooling.
32 . The brake rotor assembly of claim 31 , wherein the physical structure comprises a vane and/or a channel.
33 . The brake rotor assembly of claim 22 , further comprising an attachment feature for fixably attaching the friction surface part to the receiving surface.
34 . The brake rotor assembly of claim 33 , wherein the attachment feature comprises at least one of a screw, a bolt, a connecting pin, an adhesive, a weld, a braze, a retaining ridge and, an at least partially recessed or indented area on the receiving surface into which at least part of the friction surface part is seated.
35 . The brake rotor assembly of claim 22 , wherein the friction surface part further comprises an inner friction surface, a first side surface, and a second side surface, wherein the outer friction surface and the inner friction surface are aligned parallel to the axis of rotation and separated by the contact surface, wherein the first side surface and the second side surface extend between the outer friction surface and the inner friction surface and are configured to be aligned perpendicular to the axis of rotation, and wherein the first side surface includes a concave portion and the second side surface includes a convex portion.
36 . The brake rotor assembly of claim 22 , wherein the friction surface part comprises a first friction surface part and a second friction surface part, wherein each of the first friction surface part and the second friction surface part are separately arranged on the receiving surface to form the at least part of the annular braking surface, and wherein the first friction surface part comprises a first surface topography and the second friction surface part comprises a second surface topography that is different from the first surface topography.
37 . A braking system comprising:
the brake rotor assembly of claim 22 ;
a brake pad comprising a friction material; and
an apparatus for urging the friction material of the brake pad against the annular braking surface to slow rotation of the brake rotor assembly and a vehicle axle to which the brake rotor assembly is rotationally fixed.
38 . The braking system of claim 37 , wherein the friction material comprises at least one of cast iron, a ceramic, and a composite; and wherein the friction surface part comprises a brake pad material.
39 . The braking system of claim 37 , wherein the friction material of the brake pad comprises a wear and corrosion resistant coating.
40 . The braking system of claim 37 , wherein the contact surface of the friction surface part comprises a same material as the friction material of the brake pad.
41 . A method for assembling a brake rotor assembly, the method comprising:
positioning a friction surface part on a receiving surface of a structural part;
wherein the structural part further comprises: an outer structural surface positioned parallel to an axis of rotation of the structural part, the receiving surface being positioned perpendicular to the axis of rotation, and the structural part being formed of at least one bulk material that is not stainless steel; and
wherein the friction surface part comprises: a contact surface defining a surface of the friction surface part; and an outer friction surface that is parallel to the axis of rotation, the friction surface part comprising stainless steel; and
fixably attaching the friction surface part to the receiving surface of the structural part such that the contact surface faces away from the receiving surface of the structural part to form at least part of an annular braking surface arranged concentrically around an axis of rotation of the structural part; wherein the outer friction surface and the outer structural surface are co-planar and abut one another.