60/512,849 filed October 22,2003, which is hereby incorporated by reference.

The present invention is concerned with a method of replacing the rotor disk of a full contact annular disk brake assembly. It also relates to a full contact annular disk brake assembly designed to allow the rotor disk thereof being easily replaced.

The concept of full contact annular disk brake is described and shown in U. S.

Patents Nos. 5,205, 380 and 5,330, 034, which are hereby incorporated by reference.

Like the brake pads, the rotor disk or disks of such disk brake assemblies must be replaced when they reach or about to reach their maximum wear limit. This generally happens a number of times during the years a vehicle is in service. However, replacing a rotor disk currently requires that the vehicle be removed from service for a large number of hours. It also requires relatively skilled mechanics to undertake the job because each disk brake assembly needs to be completely removed from the axle, which is usually a complex and time consuming task, partly because internal rotating parts are supported by sealed bearings filled with grease and oil. These bearings must be perfectly manipulated and re-assembled for the vehicle to operate correctly.

Considering this background, there was clearly a need to provide a full contact annular disk brake assembly which would not require that it be completely removed in order to replace a worn rotor disk.

It is an aspect of the present invention to provide a full contact annular disk brake assembly for a vehicle, the disk brake assembly comprising a hub to be journaled on an axle of the vehicle ; a housing to be mounted to the vehicle ; an annular rotor disk; and means for mounting the rotor disk around the hub, the disk brake assembly being characterized in that the hub includes a removable side flange ; and the housing includes the removable external cover; whereby the rotor disk is removable from the disk brake assembly upon removal of the side flange and the external cover.

It is another aspect of the present invention to provide a method of removing a rotor disk from a full contact annular disk brake assembly for a vehicle, the disk brake assembly comprising a hub to be journaled on an axle of the vehicle and a housing to be mounted to the vehicle, the method being characterized in that it comprises removing a side flange from the hub; removing an external cover from the housing; and sliding the rotor disk out of the disk brake assembly.

The present invention will be better understood from the following detailed description and accompanying figures in which: FIG. 1 is a perspective side view of a full contact annular disk brake assembly in accordance with a preferred embodiment of the present invention.

FIG. 2 is a partly exploded view of the disk brake assembly shown in Fig. 1, showing the side flange of the hub being removed.

FIG. 3 is a view similar to Fig. 2, showing the external cover of the housing being removed.

FIG. 4 is a view similar to Fig. 2, showing the rotor disk being removed.

FIG. 5 is a partially exploded view of the disk brake assembly shown in Fig. 1, showing various removable parts.

FIG. 1 shows a full contact annular disk brake assembly (10) in accordance with one possible embodiment of the present invention. The disk brake assembly (10) comprises a central hub (14) journaled on an axle of a vehicle by means of bearings (not shown). This hub (14) extents from the side of the disk brake assembly (10) and includes a removable annular side flange (12) connected to the remainder of the hub (14) by means of a plurality of bolts (16). This side flange (12) preferably supports a number of mounting bolts (18) provided to secure the corresponding wheel or wheels to the vehicle (not shown). Of course, before for servicing the disk brake assembly (10), the corresponding wheel or wheels are removed.

The disk brake assembly (10) comprises a housing (22) which is a non-rotating part mounted to the vehicle. It is preferably either directly or indirectly rigidly connected the axle of the vehicle. The housing (22) covers most parts of the disk brake assembly (10). This housing (22) includes an external annular cover (20) that is secured to the remainder of the housing (22) by means of plurality of bolts (24).

FIG. 2 shows the side flange (12) of the hubs (14) being removed. Once the bolts (16) are removed, the side flange (12) is pulled sideways.

FIG. 3 shows the external cover (20) of the housing (22) being removed. Once the corresponding bolts (24) are removed, the external cover (20) can be pulled away from the remainder of the housing (22) and thus from the disk brake assembly (10).

This will reveal the rotor disk (30).

FIG. 4 shows the rotor disk (30) being pulled away from its original position. As can be seen, the rotor disk (30) is slidably mounted around the hub (14) using an appropriate arrangement which also allows a rotational engagement between the hub (14) and the rotor disk (30). This arrangement preferably includes a set of axial splines (14a) provided on the hub (14) and corresponding inner teeth (30a) provided on the interior of the rotor disk (30), as best shown in FIG. 5. Other arrangements are possible as well.

As can be appreciated, a new rotor disk (30) can be installed in the disk brake assembly (10) by performing the same steps in the reverse order. The new rotor disk (30) will simply be positioned around the hub (14), against the other remaining parts still present. The external cover (20) will be bolted back to its original position and the side flange (12) will be bolted to its original position against the hub (14).

Overall, this method of replacing the rotor disk (30) of the disk brake assembly (10) can significantly reduce the time and costs associated with the task because the whole disk brake assembly (10) is not completely removed from the axle. Changing the rotor disks (30) of the vehicle more quickly allows reducing the down time. In a large vehicle fleet, for instance in the case of buses of a public transport agency, it can even reduce the number of standby vehicles needed to replace those under maintenance. The method also requires less skilled mechanics compared to a design where the complete disk brake assembly must be removed.

Although a preferred embodiment of the invention has been described in detail herein and illustrated in the accompanying figures, it is to be understood that the invention is not limited to this precise embodiment and that various changes and modifications may be effected therein without departing from the scope or spirit of the present invention defined by the appended claims. For instance, although the illustrated disk brake assembly (10) is designed to be used on a large truck or bus with a pneumatic braking system, slightly different versions can be designed for other kinds of vehicles, including vehicles with a hydraulic braking system. The side flange (12) can be connected to the remainder of the hub (14) using another mechanical connector than bolts. It can also have another shape than what is shown and described. Similarly, the external cover (20) can be attached to the remainder of the housing (22) using another mechanical connector. Its shape can be different than what is shown and described. The order of removal and of the re-assembly between the side flange (12) and the external cover (20) can be reversed. The disk brake assembly may comprise more than one rotor disk and also other disks mounted around the hub (14).