Vehicle brake rotor and method of making same

Abstract

A vehicle brake rotor is provided, including manufacturing a friction ring with an opening, an annular flange projecting axially relative to a face of the friction ring, and a plurality of spaced lugs projecting radially from the flange. A hub is manufactured with a plurality of recesses integrally upon the friction ring. Next, the hub is manufactured or machined so that outermost ends of the lugs are visible from an exterior of the hub.

1 . A vehicle brake rotor, comprising:
 a friction ring with an opening, an annular flange projecting axially relative to a face of the friction ring that defines the opening, and a plurality of spaced lugs projecting radially from the flange; and,   a hub with a plurality of recesses matingly engaging said lugs and an endcap covering said opening integrally joined to said friction ring,   wherein one of said annular flange and said hub includes an annular groove radially spaced from the lugs and surrounded by the other of said annular flange and said hub and the annular groove matingly engaging an annular tongue in the other of said annular flange and said hub,   wherein outermost ends of said lugs are visible from an exterior of said hub, and,   wherein the outermost ends of said lugs do not extend radially beyond the hub.   
     
     
         2 . The vehicle brake rotor of  claim 1 , wherein the friction ring is made of gray iron. 
     
     
         3 . The vehicle brake rotor of  claim 1 , wherein the hub is made of aluminum. 
     
     
         4 . The vehicle brake rotor of  claim 1 , wherein said hub is integrally joined to said friction ring by embed casting. 
     
     
         5 . The vehicle brake rotor of  claim 4 , wherein said hub is provided with an endcap covering said opening. 
     
     
         6 . The vehicle brake rotor of  claim 5 , wherein the hub is made of aluminum 
     
     
         7 . The vehicle brake rotor of  claim 1 , wherein the outermost ends of the lugs are visible from an exterior of said hub after manufacturing said hub is made by machining said hub, and said ends are circular. 
     
     
         8 . The vehicle brake rotor of  claim 1 , wherein said hub is manufactured on said friction ring so that said outermost ends of the lugs are not visible from an exterior of said hub friction ring, and then said hub is manufactured on said friction ring so that said outermost ends of the lugs are visible from an exterior of said hub. 
     
     
         9 . The vehicle brake rotor of  claim 1 , wherein the lugs of the friction ring are concentric with the recesses on the hub and are spaced equidistantly. 
     
     
         10 . A vehicle brake rotor obtained by a process comprising:
 manufacturing a friction ring with an opening, an annular flange projecting axially relative to a face of the friction ring, and a plurality of spaced lugs projecting radially from the flange;   manufacturing a hub with a plurality of recesses upon said friction ring, joining said hub integrally to said friction ring so that outermost ends of said lugs are not visible from an exterior of said hub; and   manufacturing said hub on said friction ring so that outermost ends of said lugs are visible from an exterior of said hub to form the vehicle brake rotor, wherein said vehicle brake rotor comprises:   one of said annular flange and said hub including an annular groove radially spaced from the lugs and surrounded by the other of said annular flange and said hub and the annular groove matingly engaging an annular tongue in the other of said annular flange and said hub and, wherein the outermost ends of said lugs do not extend radially beyond the hub.   
     
     
         11 . The vehicle brake rotor of  claim 10 , wherein the friction ring is made of gray iron. 
     
     
         12 . The vehicle brake rotor of  claim 10 , wherein the hub is made of aluminum. 
     
     
         13 . The vehicle brake rotor of  claim 10 , wherein said hub is integrally joined to said friction ring by embed casting. 
     
     
         14 . The vehicle brake rotor of  claim 10 , wherein said hub is provided with an endcap covering said opening. 
     
     
         15 . The vehicle brake rotor of  claim 10 , wherein manufacturing said hub until said outermost ends of said lugs are visible from an exterior of said hub occurs by machining said hub. 
     
     
         16 . The vehicle brake rotor of  claim 15 , wherein the hub is made of aluminum 
     
     
         17 . The vehicle brake rotor of  claim 10 , wherein the outermost ends of the lugs are visible from an exterior of said hub after manufacturing said hub is made by machining said hub, and said ends are circular. 
     
     
         18 . The vehicle brake rotor of  claim 10 , wherein the lugs of the friction ring are concentric with the recesses on the hub, and are spaced equidistantly. 
     
     
         19 . The vehicle brake rotor of  claim 10 , wherein the hub is made of aluminum and wherein said hub is integrally joined to said friction ring by embed casting. 
     
     
         20 . The vehicle brake rotor of  claim 19 , wherein manufacturing said hub until said outermost ends of said lugs are visible from an exterior of said hub occurs by machining said hub.