Abstract: A process for producing a textured laminate sheet includes a) positioning a substrate material adjacent a barbed face of a metal sheet. The barbed face has a plurality of barbs, and the metal sheet has an opposed face opposite the barbed face. The process further includes b) forcing the metal sheet and the substrate material together to impale the substrate material on the barbs and secure the substrate material and the metal sheet together as a laminate sheet, and c) debossing the opposed face to form a plurality of depressions in the laminate sheet and texture the laminate sheet.

Abstract: 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.

Abstract: A composite panel includes a core having at least one core element. The core element includes a shell defining a cavity. A pair of skins sandwich the core. Each skin has a first face facing away from the core and an opposed second face facing the core. The second face has a plurality of barbs extending therefrom. The barbs penetrate the shell to secure the core element between the skins. A method for making a composite panel includes positioning a core element against a barbed face of a first skin, where the core element includes a shell defining a cavity, and pressing the core element and first skin together to force barbs of the barbed face to penetrate the shell.

Abstract: A brake backing plate is provided in which a non-compressible core material is sandwiched between two sheet metal stampings to make a lightweight, composite brake backing plate. Each of the stampings has a textured face with a plurality of integrally formed piercing members. By rolling or pressing, the piercing members of the textured faces are fully embedded in the core material, and thus lock the stampings and the core material together.

Abstract: A brake backing plate includes first and second sheet metal stampings. Each sheet metal stamping has a respective textured face with a plurality of integrally formed piercing members. A solid non-porous metal core is sandwiched between the first sheet metal stamping and the second sheet metal stamping. The piercing members of the first sheet metal stamping penetrate into the metal core, and the piercing members of the second sheet metal stamping penetrate into the metal core, to secure the first sheet metal stamping, the second sheet metal stamping, and the metal core together.

Abstract: A process is provided for making stiff, lightweight laminate materials. At least one sheet of textured lamina having raised pointed structures is forced against a softer plain lamina so as to embed the structures therein. The pointed structures raised from grooves carved into the surface of the sheet material by means of a set of teeth carried on a knife element. The pointed structures may pierce through the softer lamina such that the protruding tips may be bent over or clinched to prevent their easy withdrawal. Two such texturized lamina may be used to sandwich and pierce through the softer lamina and are co-clinched by the other. In this way a light and stiff laminate is created.

Abstract: A brake backing plate includes first and second sheet metal stampings. Each sheet metal stamping has a respective textured face with a plurality of integrally formed piercing members. A solid non-porous metal core is sandwiched between the first sheet metal stamping and the second sheet metal stamping. The piercing members of the first sheet metal stamping penetrate into the metal core, and the piercing members of the second sheet metal stamping penetrate into the metal core, to secure the first sheet metal stamping, the second sheet metal stamping, and the metal core together.

Abstract: A brake backing plate is provided in which a non-compressible core material is sandwiched between two sheet metal stampings to make a lightweight, composite brake backing plate. Each of the stampings has a textured face with a plurality of integrally formed piercing members. By rolling or pressing, the piercing members of the textured faces are fully embedded in the core material, and thus lock the stampings and the core material together.

Abstract: A process is provided for making bulk textured material sheeting. As a continuous supply of flat material sheeting is fed, the sheeting is repeatedly impacted with toothed knives, each knife creating a row of raised and generally pointed structures on the sheeting to texture the sheeting.

Abstract: A process is provided for making bulk textured material sheeting. As a continuous supply of flat material sheeting is fed, the sheeting is repeatedly impacted with toothed knives, each knife creating a row of raised and generally pointed structures on the sheeting to texture the sheeting.

Abstract: A method of making a hybrid laminate whereby a first, thick base lamina has a plurality of piercing members or barbs and a second, onto which a second, thin interface lamina is impaled. The exposed tips of the barbs are clinched over to form rivet-like heads that clamp the two laminae together. By choosing the materials for the lamina, an interface surface can be provided for a wide range of other materials or objects to be attached by, for example, adhesive bonding. A disc brake pad is disclosed made from the instant hybrid laminate.

Abstract: A brake backing plate is provided in which a non-compressible core material is sandwiched between two sheet metal stampings to make a lightweight, composite brake backing plate. Each of the stampings has a textured face with a plurality of integrally formed piercing members. By rolling or pressing, the piercing members of the textured faces are fully embedded in the core material, and thus lock the stampings and the core material together.

Abstract: A layered brake backing plate is provided made of stampings in which a softer, lighter metal core, such as aluminum, is sandwiched between skins of harder metal stampings, such as steel, to make a lightweight composite brake backing plate. The harder stampings are textured with integrally raised piercing barbs. By rolling or pressing, the barbs are made to embed in the core, locking the layers together.

Abstract: The present invention is a method of making laminated material comprising the steps of providing a base lamina with pointed tipped piercing members, impaling successive layers of thin laminae thereon using a resilient pad, clinching the protruding tips down onto the top lamina with a hard pad.

Abstract: A process is provided for making stiff, lightweight laminate materials. At least one sheet of textured lamina having raised pointed structures is forced against a softer plain lamina so as to embed the structures therein. The pointed structures raised from grooves carved into the surface of the sheet material by means of a set of teeth carried on a knife element. The pointed structures may pierce through the softer lamina such that the protruding tips may be bent over or clinched to prevent their easy withdrawal. Two such texturized lamina may be used to sandwich and pierce through the softer lamina and are co-clinched by the other. In this way a light and stiff laminate is created.