Brake rotor assembly for use with an anti-lock braking system

Abstract

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.

What is claimed is: 
     
         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.