Brake Pad Shim Retention Tabs to Prevent Lateral Shifting
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Solution Overview
Problem
The existing shims in vehicle disc brake assemblies experience reduced adhesive bond strength due to lateral loading and increased temperature, leading to lateral shifting and reduced effectiveness in noise, vibration, and harshness reduction.
Innovation Solution
A shim design with a base and tabs extending into openings in the backing plate, where each tab has a first portion extending away from the base and a curved second portion forming an acute angle, providing a secure and resilient retention system to prevent shifting under high loads and temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive bond is used to secure shim to backing plate, then ease of manufacture is improved, but reliability deteriorates under lateral loading and high temperature
Solution Approach 1:
The patent replaces the chemical adhesive bonding system with a mechanical retention system using tabs that extend into openings in the backing plate. This mechanical system provides reliable retention under lateral loading and high temperature conditions without the viscosity and strength degradation problems that affect adhesive bonds.
Solution Approach 2:
The shim is segmented with multiple tabs extending from its periphery, each tab fitting into corresponding openings in the backing plate. This segmentation allows the shim to be securely retained through multiple discrete mechanical engagement points rather than relying on a continuous adhesive bond.
2Reliability
If adhesive bond strength is maintained under high temperature, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent eliminates the need for temperature-resistant adhesive formulations and complex bonding processes by using a simple mechanical tab-and-opening retention system. The mechanical system maintains constant retention characteristics regardless of temperature variations.
3Reliability
If shim is secured with mechanical retention, then reliability under lateral loading is improved, but ease of manufacture deteriorates
Solution Approach 1:
The patent merges the shim and backing plate into an integrated assembly where tabs are formed as integral parts of the shim and openings are formed as integral parts of the backing plate. This merging eliminates the need for separate retention components while providing reliable mechanical retention.
Solution Approach 2:
The tabs and openings are pre-formed during the manufacturing of the shim and backing plate respectively, so that the mechanical retention system is already in place before assembly. This preliminary action simplifies the final assembly process while ensuring reliable retention.
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
The secure connection between the shim and backing plate prevents lateral shifting, maintaining the shim's effectiveness in reducing noise, vibration, and harshness, even under high loads and temperatures.
Implementation Method 1
Each tab including a first portion extending away from the base and a curved second portion extending from the first portion back towards the base such that the second portion forms an acute angle with the first portion
Data Source
AI summary
A brake pad for a vehicle disk brake assembly includes a backing plate configured to support a brake lining. A plurality of openings extend through the backing plate to define retaining members. A shim includes a base and tabs extending into the openings to secure the shim to the backing plate. Each tab includes a first portion extending away from the base and a curved second portion extending from the first portion back towards the base.