Wheel hub with integrated circular brake element

1. A wheel hub apparatus for a commercial vehicle, the wheel hub apparatus comprising:

a wheel hub having a unitary, one-piece construction;

a tubular side wall of the wheel hub;

the wheel hub rotatable about a central axis and having an inboard end portion, an outboard end portion, and a through opening extending from the inboard end portion to the outboard end portion;

a wheel mounting flange of the wheel hub axially intermediate the inboard and outboard end portions of the wheel hub, the wheel mounting flange extending radially outward from the tubular side wall of the wheel hub;

a circular brake element having a unitary, one-piece construction and extending about the wheel hub;

the inboard end portion of the wheel hub axially spaced from the wheel mounting flange by the tubular side wall of the wheel hub;

engaged portions of the inboard end portion of the wheel hub and the circular brake element securing the wheel hub and the circular brake element together, the engaged portions of the inboard end portion of the wheel hub and the circular brake element inboard of the wheel mounting flange of the wheel hub and spaced axially therefrom along the wheel hub;

the engaged portions of the wheel hub and the circular brake element fixing the circular brake element against axial movement along the wheel hub;

the engaged portions of the wheel hub and the circular brake element including projections of one of the wheel hub and the circular brake element received in recesses of the other of the wheel hub and the circular brake element;

wherein the recesses include neckdown portions and the projections have neck portions that extend in the neckdown portions; and

wherein the recesses have enlarged recess portions and the projections have corresponding enlarged portions in the enlarged recessed portions.

2. The wheel hub apparatus of claim 1 wherein one of the wheel hub and the circular brake element is formed in situ on the other of the wheel hub and the circular brake element.

3. The wheel hub apparatus of claim 1 wherein the engaged portions of the wheel hub and circular brake element include confronting surfaces of the wheel hub and circular brake element extending transverse to the central axis that fix the circular brake element against axial movement along the wheel hub.

4. The wheel hub apparatus of claim 1 wherein the engaged portions of the wheel hub and the circular brake element directly mechanically join the wheel hub and the circular brake element together.

5. A wheel hub apparatus for a commercial vehicle, the wheel hub apparatus comprising:

a wheel hub having a unitary, one-piece construction;

the wheel hub rotatable about a central axis and having an inboard end portion, an outboard end portion, and a through opening extending from the inboard end portion to the outboard end portion;

a wheel mounting portion of the wheel hub configured to have a wheel mounted thereon, the wheel mounting portion axially intermediate the inboard and outboard end portions of the wheel hub;

a circular brake element having a unitary, one-piece construction and extending about the wheel hub;

engaged portions of the wheel hub and the circular brake element securing the wheel hub and the circular brake element together;

the engaged portions of the wheel hub and the circular brake element fixing the circular brake element against axial movement along the wheel hub;

wherein the engaged portions of the wheel hub and the circular brake element include projections of one of the wheel hub and the circular brake element having free end portions fixed in recesses of the other of the wheel hub and the circular brake element; and

wherein the projections include resilient portions that bend to facilitate thermal expansion and contraction of the circular brake element during operation of the commercial vehicle.

6. A wheel hub apparatus for a commercial vehicle, the wheel hub apparatus comprising:

a wheel hub having a unitary, one-piece construction;

the wheel hub rotatable about a central axis and having an inboard end portion, an outboard end portion, and a through opening extending from the inboard end portion to the outboard end portion;

a wheel mounting portion of the wheel hub configured to have a wheel mounted thereon, the wheel mounting portion axially intermediate the inboard and outboard end portions of the wheel hub;

a circular brake element having a unitary, one-piece construction and extending about the wheel hub;

engaged portions of the wheel hub and the circular brake element securing the wheel hub and the circular brake element together;

the engaged portions of the wheel hub and the circular brake element fixing the circular brake element against axial movement along the wheel hub; and

the engaged portions of the wheel hub and the circular brake element including projections of one of the wheel hub and the circular brake element having free end portions fixed in recesses of the other of the wheel hub and the circular brake element;

wherein the engaged portions of the wheel hub and the circular brake element form a plurality of slide connections between the wheel hub and the circular brake element, the plurality of slide connections including cooperating surface portions of the wheel hub and circular brake element that permit relative sliding movement therebetween.

7. The wheel hub apparatus of claim 1 wherein the engaged portions include pin portions of one of the wheel hub and the circular brake element extending in openings of the other of the wheel hub and circular brake element.

8. A wheel hub apparatus for a commercial vehicle, the wheel hub apparatus comprising:

a wheel hub having a unitary, one-piece construction;

a tubular side wall of the wheel hub;

the wheel hub rotatable about a central axis and having an inboard end portion, an outboard end portion, and a through opening extending from the inboard end portion to the outboard end portion;

a wheel mounting flange of the wheel hub axially intermediate the inboard and outboard end portions of the wheel hub, the wheel mounting flange extending radially outward from the tubular side wall of the wheel hub;

a circular brake element having a unitary, one-piece construction and extending about the wheel hub;

the inboard end portion of the wheel hub axially spaced from the wheel mounting flange by the tubular side wall of the wheel hub;

engaged portions of the inboard end portion of the wheel hub and the circular brake element securing the wheel hub and the circular brake element together, the engaged portions of the inboard end portion of the wheel hub and the circular brake element inboard of the wheel mounting flange of the wheel hub and spaced axially therefrom along the wheel hub;

the engaged portions of the wheel hub and the circular brake element fixing the circular brake element against axial movement along the wheel hub;

wherein the engaged portions include meshed teeth of the wheel hub and the circular brake element.

9. The wheel hub apparatus of claim 1 further comprising:

fasteners protruding from the wheel mounting flange for connecting a wheel to the wheel hub.

10. The wheel hub apparatus of claim 1 wherein the wheel hub includes a pair of wheel bearing seats, the wheel hub apparatus further comprising:

a pair of wheel bearings having openings to receive a vehicle spindle, the wheel bearings supported on the bearing seats;

a spacer separating the wheel bearings; and

a spindle lock to engage the spindle and retain the wheel hub on the spindle.

11. A wheel hub apparatus comprising:

a wheel hub having a unitary, one-piece construction and configured to have a wheel mounted thereon;

a pair of wheel bearings having openings to receive a vehicle spindle;

wheel bearing seats of the wheel hub to support the wheel bearings;

a circular brake element;

one of the wheel hub and the circular brake element formed in situ on the other of the wheel hub and the circular brake element; and

projections and recesses of the wheel hub and the circular brake element, the projections extending in the recesses to transfer loading between the circular brake element and the wheel hub during a braking operation,

wherein the projections each include a free end fixed in one of the recesses and a resilient portion configured to bend to accommodate thermal expansion and contraction of the circular brake element.

12. The wheel hub apparatus of claim 11 wherein the projections and recesses of the wheel hub and circular brake element form a direct mechanical joint between the wheel hub and circular brake element that permanently joins the wheel hub and the circular brake element together.

13. The wheel hub apparatus of claim 11 wherein the recesses have an undercut configuration and the projections include enlarged portions that fill the corresponding recesses in which the projections are received and fix the enlarged portions of the projections in the recesses.

14. A wheel hub apparatus comprising:

a wheel hub having a unitary, one-piece construction and configured to have a wheel mounted thereon;

a pair of wheel bearings having openings to receive a vehicle spindle;

wheel bearing seats of the wheel hub to support the wheel bearings;

a circular brake element;

one of the wheel hub and the circular brake element formed in situ on the other of the wheel hub and the circular brake element;

projections and recesses of the wheel hub and the circular brake element, the projections extending in the recesses to transfer loading between the circular brake element and the wheel hub during a braking operation; and

wherein the projections and recesses form slide connections between the wheel hub and the circular brake element that facilitate expansion and contraction of the circular brake element during vehicle operation, the slide connections including cooperating surface portions of the wheel hub and circular brake element that permit relative sliding movement therebetween.

15. The wheel hub apparatus of claim 11 wherein the recesses include neckdown portions and the projections have neck portions that extend in the neckdown portions; and

wherein the recesses have enlarged recess portions and the projections have corresponding head portions in the enlarged recessed portions.

16. The wheel hub apparatus of claim 11 wherein the projections each extend in a radial direction into an associated one of the recesses; and

wherein the recesses each have a width perpendicular to the radial direction that varies along the radial direction so that the recess has a neckdown portion and an enlarged portion, the neckdown portion resisting pull-through of the associated projection in the radial direction.

17. The wheel hub apparatus of claim 11 wherein the projections include a first plurality of teeth and the recesses include a second plurality of teeth; and

wherein the first and second pluralities of teeth are meshed.

18. The wheel hub apparatus of claim 14 wherein the projections and recesses include engaged rail portions and grooves that include the cooperating surface portions.

19. A wheel hub apparatus comprising:

a wheel hub having a unitary, one-piece construction and configured to have a wheel mounted thereon;

a pair of wheel bearings having openings to receive a vehicle spindle;

wheel bearing seats of the wheel hub to support the wheel bearings;

a circular brake element;

one of the wheel hub and the circular brake element formed in situ on the other of the wheel hub and the circular brake element;

projections and recesses of the wheel hub and the circular brake element, the projections extending in the recesses to transfer loading between the circular brake element and the wheel hub during a braking operation; and

wherein the projections include loops having openings and the recesses include locking portions extending in the openings of the loops.

20. The wheel hub apparatus of claim 11 wherein the circular brake element includes the projections and the wheel hub includes the recesses.

21. A wheel hub apparatus comprising:

a wheel hub having a unitary, one-piece construction and configured to have a wheel mounted thereon;

a pair of wheel bearings having openings to receive a vehicle spindle;

wheel bearing seats of the wheel hub to support the wheel bearings;

a circular brake element;

one of the wheel hub and the circular brake element formed in situ on the other of the wheel hub and the circular brake element;

projections and recesses of the wheel hub and the circular brake element, the projections extending in the recesses to transfer loading between the circular brake element and the wheel hub during a braking operation; and

a spindle lock configured to threadingly engage the spindle and sandwich one of the wheel bearings between the spindle lock and one of the wheel bearing seats.

22. A method of producing a wheel hub apparatus, the method comprising:

casting one of a wheel hub and a circular brake element, the wheel hub having a unitary, one-piece configuration and configured to have a wheel mounted thereon, the wheel hub including and a pair of bearing seats;

positioning the one of the wheel hub and the circular brake element in a mold; and

casting the other of the wheel hub and the circular brake element on the one of the wheel hub and the circular brake element using the mold,

wherein casting the other of the wheel hub and the circular brake element on the one of the wheel hub and the circular brake element includes forming a plurality of slide connections between the wheel hub and the circular brake element, the plurality of slide connections including cooperating surface portions of the wheel hub and circular brake element that permit relative sliding movement of the cooperating surface portions.

23. The method of claim 22 wherein casting the one of the wheel hub and the circular brake element includes casting the one of the wheel hub and the circular brake element using a first mold;

wherein positioning the one of the wheel hub and the circular brake element in the mold includes positioning the one of the wheel hub and the circular brake element in a second mold; and

wherein casting the other of the wheel hub and the circular brake element on the one of the wheel hub and the circular brake element includes using the second mold.

24. The wheel hub apparatus of claim 1 wherein the circular brake element is a brake rotor having internal air flow paths, the wheel hub apparatus further comprising:

axially extending through openings formed between the wheel hub and the brake rotor that permit air to enter the through openings and travel into the internal air flow paths of the brake rotor.

25. The wheel hub apparatus of claim 5 wherein the free end portions include enlarged portions and the recesses include narrowed portions that resist pull-through of the enlarged portions.

26. The wheel hub apparatus of claim 5 wherein the engaged portions include meshed teeth of the wheel hub and circular brake element.

27. The wheel hub apparatus of claim 5 wherein the engaged portions include openings of one of the wheel hub and circular brake element and locking portions of the other of the wheel hub and circular brake element extending in the openings.

28. The wheel hub apparatus of claim 6 wherein the engaged portions include rail portions and grooves that include the cooperating surface portions.

29. The wheel hub apparatus of claim 6 wherein the circular brake element is a brake rotor having internal air flow paths, the wheel hub apparatus further comprising:

axially extending through openings formed between the wheel hub and the brake rotor that permit air to enter the through openings and travel into the air flow paths of the brake rotor.

30. The wheel hub apparatus of claim 6 wherein the slide connections restrict relative movement of the wheel hub and the circular brake element to movement along a radial direction that is orthogonal to the central axis.

31. The wheel hub apparatus of claim 21 wherein the projections include resilient portions that bend to facilitate thermal expansion and contraction of the circular brake element during operation.

32. The wheel hub apparatus of claim 21 wherein the projections and recesses form slide connections between the wheel hub and the circular brake element that facilitates expansion and contraction of the circular brake element during vehicle operation, the slide connections including cooperating surface portions of the wheel hub and circular brake element that permit relative sliding movement therebetween.

33. The wheel hub apparatus of claim 21 wherein the circular brake element is a brake rotor having internal air flow paths, the wheel hub apparatus further comprising:

axially extending through openings formed between the wheel hub and the brake rotor that permit air to enter the through openings and travel into the air flow paths of the brake rotor.

34. The wheel hub apparatus of claim 8 wherein the teeth are triangular.

35. The wheel hub apparatus of claim 21 wherein the projections and recesses include pin portions of one of the wheel hub and the circular brake element extending in openings of the other of the wheel hub and circular brake element.