Disc Brake Shim Plate Mechanical Embedding
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Solution Overview
Problem
Conventional disc brake pads with shim plates face issues of shim slippage and detachment due to adhesive failure under high temperatures, leading to unwanted brake squeal noise and potential damage.
Innovation Solution
A brake pad assembly where a 'T'-shaped tab on the shim plate is embedded within friction material on the backing plate, securing the shim plate as an integral part of the pad, using the friction material to harden around the tab for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesives are used to attach the shim plate to the backing plate, then the shim plate can be secured in place, but the adhesive fails under high temperatures causing shim slippage and detachment
Solution Approach 1:
The patent replaces the chemical bonding mechanism (adhesive) with a mechanical embedding system. A tab extending from the shim plate is inserted through an opening in the backing plate, and the friction material is molded around the tab to mechanically secure it. This mechanical embedding system remains effective under high temperatures where adhesives fail.
Solution Approach 2:
The patent creates a composite structure where the tab (metal), backing plate (metal), and friction material (composite of organic/inorganic binders and friction particles) work together as an integrated assembly. The friction material itself acts as the bonding medium, combining structural support with friction functionality, eliminating the need for separate adhesive layers.
2Object-generated harmful factors
If the shim plate is securely fastened to the backing plate, then brake squeal noise is reduced, but the attachment method must withstand extreme thermal and mechanical conditions
Solution Approach 1:
The patent replaces adhesive bonding with a mechanical embedding system where the tab is physically surrounded by the friction material. This mechanical constraint prevents shim movement that causes squeal, while the friction material's thermal and mechanical properties ensure the attachment survives extreme braking conditions.
Solution Approach 2:
The patent merges the attachment function with the friction material itself. Instead of using a separate adhesive layer, the friction material is molded around the tab during assembly, integrating the bonding function into the primary friction component. This unified structure ensures consistent performance under thermal and mechanical loading.
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 solution effectively prevents shim slippage and detachment, reducing brake squeal noise and ensuring the shim plate remains securely attached even under heavy-duty conditions.
Implementation Method 1
the friction material, when plastic, embeds the tab inside the opening by flowing through the opening, and subsequently hardens around the tab
Data Source
AI summary
A brake pad assembly is provided that includes a backing plate including a first surface, a second surface opposite to the first surface, and at least one opening. Also included are a friction material associated with the backing plate and a shim plate having a first shim surface and a second shim surface, and a tab projecting from the second shim surface. The shim plate is securely fastened to the backing plate by inserting the tab into the opening such that the friction material, when plastic, embeds the tab inside the opening by flowing through the opening, and subsequently hardens around the tab.