Variable Height Barbs on Brake Backing Plates
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Solution Overview
Problem
Existing brake backing plates with uniformly sized barbs fail to provide consistent retention of friction material, leading to poor friction retention and exposure of barbs during shear forces, indicating weak attachment of the friction element.
Innovation Solution
A differentially textured workpiece with a disc brake backing plate featuring multiple rows of integral raised barbs, where a first group of barbs is at least 10% higher than a second group, and the height variation forms a regular pattern, achieved through texturing and reshaping using toothed blades and lobed rollers to create and modify barb heights and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If uniformly sized barbs are used on brake backing plates, then the manufacturing process is simple, but the friction material retention is inconsistent and barbs are exposed during shear forces
Solution Approach 1:
The patent applies local quality by creating different barb heights in different regions of the brake backing plate. Specifically, a first plurality of barbs has a first height while a second plurality of barbs has a second height that is less than the first height. This regional differentiation allows friction material to be retained more effectively at different locations, preventing uniform barb exposure during shear forces while maintaining manufacturing feasibility through localized texturing processes.
2Strength
If all barbs are made to the same height, then the texturing process is straightforward, but friction material breaks off easily during shear forces
Solution Approach 1:
The patent segments the barb structure into two distinct groups: a first plurality of barbs with a first height and a second plurality of barbs with a second height. This segmentation is achieved through a two-stage texturing process where initial barbs are formed and then a subsequent operation modifies selected barbs to different heights. The segmentation provides enhanced attachment strength by creating a more complex fracture path that prevents easy break-off of friction material during shear forces.
3Reliability
If variable height barbs are implemented, then friction material retention is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by first forming all barbs to an initial uniform height through a first texturing operation, and then subsequently modifying selected barbs to different heights through a second texturing operation. This sequential approach allows the base barb structure to be established uniformly before introducing the height variation, thereby improving friction element attachment while managing manufacturing complexity through a systematic two-step process rather than attempting to create variable heights in a single complex operation.
Data Source
AI summary
A workpiece includes a material with a face and a first plurality of barbs and a second plurality of barbs extending integrally from the face. Each barb has a height above the face. The barbs of the first plurality are at least 10% higher than the barbs of the second plurality. The first plurality of barbs includes at least 10% of the barbs on the face and the second plurality of the barbs includes at least 10% of the barbs on the face. The barbs of the second plurality of barbs are bent and pointed.