Composite Brake Pad Shim Structure for Noise and Pressure Stability
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Solution Overview
Problem
Conventional shims for brake pads are ineffective in reducing noise across all temperature and frequency ranges and can separate from the back plate under high pressure, leading to unstable surface pressure and deteriorated braking performance.
Innovation Solution
A shim comprising a single sheet shape formed by alternating plastic or rubber first wires and metal second wires, spaced at predetermined intervals, with a curvature surface for attachment to the back plate using adhesive, enhancing rigidity and damping effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a conventional thin shim made of rubber layer and steel plate is used, then the shim is effective in terms of dynamics and very light in weight, but it is effective in removing noise only at a specific temperature and in a specific frequency range
Solution Approach 1:
The patent applies composite materials by combining plastic or rubber wires with metal wires in a grid pattern within a single sheet. This composite structure integrates the light weight and damping properties of plastic/rubber with the strength and temperature stability of metal, enabling effective noise reduction across broader temperature and frequency ranges while maintaining low weight
2Device complexity
If a conventional thin shim with adhesive layer is used, then the shim structure is simple, but under high pressure (30 bar or more) all components may be compressed causing the shim to separate from the back plate or be pushed to one side
Solution Approach 1:
The patent segments the shim structure into a grid pattern formed by intersecting plastic/rubber wires and metal wires. This segmentation creates multiple small reinforcement zones distributed across the shim, allowing the structure to resist compression forces more effectively without increasing overall complexity, preventing separation and pushing under high pressure
Solution Approach 2:
The combination of plastic/rubber and metal wires creates a composite structure where the metal wires provide structural integrity and resistance to compression under high pressure, while the plastic/rubber wires maintain the lightweight and damping characteristics. This composite approach enhances reliability without significantly increasing device complexity
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 new shim design provides improved weight reduction, rigidity, and damping, preventing separation from the back plate and enhancing braking performance by maintaining stable surface pressure under high pressure conditions.
Implementation Method 1
The adhesive may fill cavities between the plurality of first wires and the plurality of second wires, and the rear surface of the back plate
Implementation Method 2
One surface of the shim that comes into contact with the rear surface of the back plate may be formed with a plurality of curvatures
Data Source
AI summary
Disclosed herein is a shim for a brake pad including a plurality of first wires made of a plastic material or a rubber material and a plurality of second wires made of a metal material, and the plurality of first wires and the plurality of second wires may be formed in a single sheet shape.