Wave-Shaped Brake Pad Shim for Disk Brake Squeal Reduction
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Solution Overview
Problem
Existing brake pad assemblies in disk brake systems struggle to effectively suppress squeal noises across a wide range of braking conditions, with prior solutions often being condition-specific and inadequate.
Innovation Solution
A brake pad assembly featuring a shim with a wave-shaped metal layer on its front side, bonded to a back plate via an adhesive layer, which enhances structural and friction damping properties by allowing deformation in multiple directions during braking, thereby improving noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional shims with flat surfaces are used, then the brake pad assembly structure is simple, but squeal noise suppression is ineffective across wide braking conditions
Solution Approach 1:
The patent applies curvature by forming the shim surface with wave-shaped crests and troughs instead of a flat surface. This curved geometry creates variable contact points with the brake disk, improving noise suppression across different braking conditions while maintaining structural simplicity
Solution Approach 2:
The patent changes the geometric parameters of the shim by defining specific wave characteristics including amplitude (0.1-1.0 mm), wavelength (5-50 mm), and crest angle (15-45 degrees). These parameter variations enable the shim to adapt to different braking conditions and frequency ranges, effectively suppressing squeal noise
2Object-affected harmful factors
If condition-specific solutions are applied, then noise suppression works under specific braking conditions, but effectiveness is limited across wide ranges of conditions
Solution Approach 1:
The wave-shaped shim design serves multiple functions simultaneously: it provides structural damping, friction damping, and adapts to various braking conditions (low/high frequency, cold/warm temperature). This universal design eliminates the need for condition-specific solutions and maintains effectiveness across wide operating ranges
3Object-affected harmful factors
If the shim uses a wave-shaped surface, then structural damping and noise reduction are improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent defines specific parameter ranges for the wave-shaped surface (amplitude 0.1-1.0 mm, wavelength 5-50 mm, crest angle 15-45 degrees) that balance noise reduction effectiveness with manufacturability. These optimized parameters ensure sufficient damping performance while remaining achievable through conventional manufacturing processes
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 wave-shaped shim effectively reduces squeal noises across various braking conditions by enhancing structural and friction damping, providing improved noise suppression and dynamic behavior.
Implementation Method 1
an adhesive layer is arranged between the back side of the back plate and the front side of the shim. The shim is fixed to the back plate by adhesive bonding provided by the adhesive layer
Implementation Method 2
The wave-shaped surface of the metal layer of the shim leads to an improved structural damping effect of the brake pad assembly. The structural damping properties of the brake pad are improved due to the wave-shaped surface of the shim
Implementation Method 3
the wave-shaped surface of the metal layer of the shim leads to improved friction damping characteristics. the metal layer of the shim may be configured to be deformed in a normal direction upon brake application due to the wave-shaped surface the metal layer of the shim. improved dissipation of energy (both kinetic and deformation energy)
Data Source
AI summary
The application relates to a brake pad assembly for a disk brake system. In addition, the application relates to a disk brake system. The proposed brake pad assembly comprises a back plate having a front side for facing a brake disk of the disk brake system and a back side. A friction layer is arranged at the front side of the back plate for contacting a friction surface the brake disk. Further, a shim is arranged on the back side of the back plate. The shim has a front side facing the back plate. Further, an adhesive layer is arranged between the back side of the back plate and the front side of the shim. The shim further comprises a metal layer having a wave-shaped surface on its front side.