Rivetless Friction Disc Structure for Lower-Cost Damper Assembly
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Solution Overview
Problem
Existing friction discs for damper devices are costly to produce due to the need for rivets and additional processing steps to secure the friction materials.
Innovation Solution
A friction disc design that eliminates the use of rivets by incorporating engaging protrusions and recesses on the support plate and friction materials, allowing for unitary rotation without the need for additional fastening or processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rivets are used to attach friction materials to the support plate, then the friction materials can be securely fixed, but the production cost increases and the device complexity increases
Solution Approach 1:
The support plate and friction materials are merged into a single integrated component where the friction materials are directly formed as integral parts of the support plate structure, eliminating the need for separate fastening elements like rivets. This reduces production cost and device complexity while maintaining secure fixation through the unified structure.
Solution Approach 2:
The rivets and associated fastening mechanisms are extracted/removed from the system. The friction materials are designed to be directly attached to the support plate without requiring separate fastening components, thereby eliminating the need for holes, rivets, and associated processing steps.
2Reliability
If rivets are used to attach friction materials to the support plate, then the friction materials can be securely fixed, but the device complexity increases
Solution Approach 1:
The support plate and friction materials are merged into a single integrated component, reducing the total number of parts. The friction materials are directly formed as integral parts of the support plate structure, eliminating separate fastening elements and simplifying the overall device architecture.
Solution Approach 2:
Rivets and associated fastening components are extracted from the system. The design eliminates holes, rivets, and related processing requirements, thereby reducing device complexity and the number of components needed for assembly.
3Reliability
If holes are provided in friction materials for rivet insertion, then the friction materials can be securely attached, but the friction materials must be wider increasing production cost
Solution Approach 1:
Holes for rivet insertion are extracted/removed from the friction materials. The friction materials are designed without holes, allowing them to be narrower and reducing material usage and production cost while maintaining secure attachment through the integrated design.
Solution Approach 2:
The friction materials are merged with the support plate structure, eliminating the need for separate attachment holes. This integration allows the friction materials to be narrower since they don't require additional space for hole formation and rivet accommodation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces production costs by eliminating the need for rivets and associated processing, while also allowing for a narrower width of the friction materials, further lowering production expenses.
Implementation Method 1
The first engaging protrusion engages with the first engaging recess, whereby the first friction material is made unitarily rotatable with the support plate
Implementation Method 2
The second engaging protrusion engages with the second engaging recess, whereby the second friction material is made unitarily rotatable with the support plate
Implementation Method 3
Devices such as a damper device include a friction disc for engagement by friction
Data Source
AI summary
A friction disc producible at a low cost is disclosed. A first friction material is attached to a first lateral surface of a support plate. A second friction material is attached to a second lateral surface of the support plate. The support plate includes first and second engaging protrusion and first and second through-holes. The first engaging protrusion protrudes from the first lateral surface to a first side in an axial direction. The first through-hole extends inside the first engaging protrusion in the axial direction. The second engaging protrusion protrudes from the second lateral surface to a second side in the axial direction. The second through-hole extends inside the second engaging protrusion in the axial direction. The first friction material includes a first engaging recess engaged with the first engaging protrusion. The second friction material includes a second engaging recess engaged with the second engaging protrusion.