Brake Pad Shim Alignment Structure for Faster Quiet Assembly
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Solution Overview
Problem
Existing brake assemblies face challenges in efficient assembly and alignment of brake pad shims, leading to increased complexity, weight, and potential noise and vibration during braking operations.
Innovation Solution
The brake assembly incorporates alignment surfaces and protrusions on the brake backing plate and shim, allowing for precise alignment and simplified assembly, while maintaining an unobstructed passage for mechanical forces, and utilizing materials like steel, aluminum, and polymers for vibration dampening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional brake pad shim assembly methods are used, then assembly complexity increases and alignment precision deteriorates, but manufacturing simplicity is maintained
Solution Approach 1:
The brake pad shim incorporates asymmetric alignment features including a single arc-shaped alignment protrusion that engages with a corresponding alignment groove on the brake pad. This asymmetric design provides unique alignment characteristics that ensure precise positioning while simplifying the assembly process, as the asymmetric features guide the components into correct alignment automatically during installation.
Solution Approach 2:
The brake pad shim design creates an equipotential assembly state where the arc-shaped alignment protrusion and groove, combined with the positioning holes and pins, establish a natural equilibrium position. This allows the components to self-align during assembly without requiring complex alignment procedures or additional adjustment mechanisms, thereby reducing assembly complexity while maintaining high alignment precision.
2Productivity
If traditional brake pad shim assembly methods are used, then assembly time increases, but manufacturing simplicity is maintained
Solution Approach 1:
The brake pad shim is pre-formed with integrated alignment features including the arc-shaped alignment protrusion, positioning holes, and vibration damping structures during the manufacturing process. This preliminary incorporation of alignment mechanisms eliminates the need for separate alignment operations during assembly, significantly reducing assembly time while improving productivity. The components are designed to self-align, requiring minimal manual intervention or additional assembly steps.
3Object-affected harmful factors
If brake pad shim is attached to brake backing plate, then vibration attenuation is improved, but weight increases
Solution Approach 1:
The brake pad shim is designed as a thin, flexible component with optimized geometry including arc-shaped features and positioning structures. This thin-film approach provides effective vibration attenuation through its damping properties and geometric configuration while minimizing material usage and overall weight. The shim's flexibility allows it to conform to the brake pad surface, enhancing vibration damping efficiency without adding significant mass to the brake assembly.
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 configuration enhances assembly efficiency, reduces weight and cost, and effectively attenuates vibrations and noise, ensuring precise alignment and improved braking performance.
Implementation Method 1
The brake pad shim is configured to attenuate a vibration during a braking process
Data Source
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AI summary
The present invention relates to a brake assembly (1) comprising a brake backing plate (3) configured for attachment of a brake pad and a brake pad shim (2) configured for attenuating a vibration during a braking process. One of the brake backing plate (3) and the brake pad shim (2) comprises two alignment surfaces (12, 13) formed by at least one opening (8; 9). The other one of the brake backing plate (3) and the brake pad shim (2) comprises two alignment protrusions (5, 6). The alignment protrusions (5, 6) are configured to engage with the two alignment surfaces (12, 13) for aligning the brake backing plate (3) and the brake pad shim (2) in a predetermined alignment state. Further, the opening (8; 9) is substantially unobstructed by the engagement of the protrusions (5, 6) with the alignment surfaces (12, 13) in the alignment state. The invention also relates to a vehicle comprising such a brake assembly, and a method for assembling such a brake assembly.