Disc Brake Pad Shim Segmentation for Caliper Stability
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Solution Overview
Problem
Existing disc brake pad assemblies face issues with uneven wear and noise due to unstable caliper movement, particularly when the pressure plate has low roughness precision, leading to difficulties in achieving desired sliding characteristics and increased costs from complex shim plate structures.
Innovation Solution
A pad assembly design featuring an inner shim plate with locking pieces bent toward one side and an outer shim plate with matching locking pieces, allowing smooth circumferential movement and preventing axial separation, thereby stabilizing caliper movement and improving assembly workability while reducing the number of bent parts and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single shim plate is provided between the caliper and pad, then the structure is simple, but sliding characteristics cannot be achieved when the pressure plate has low roughness precision
Solution Approach 1:
The shim plate is divided into an inner shim plate and an outer shim plate that slide relative to each other. The inner shim plate contacts the pressure plate while the outer shim plate provides the sliding interface. This segmentation allows the system to achieve reliable sliding characteristics even when the pressure plate has low roughness precision, as the sliding occurs between the two shim plates rather than directly between the shim plate and pressure plate.
2Reliability
If multiple shim plates with guiding parts and locking parts are provided, then sliding characteristics are improved, but the number of bent parts increases and costs increase
Solution Approach 1:
The guiding function and locking function are merged into a single integrated structure. The outer shim plate has guiding parts at its ends that extend in the radial direction, which simultaneously provide guidance and locking functions. This eliminates the need for separate guiding parts and locking parts, reducing the number of bent parts while maintaining reliable sliding characteristics.
Solution Approach 2:
The guiding parts of the outer shim plate serve multiple functions: they guide the relative circumferential movement between the inner and outer shim plates, lock the radial position, and prevent axial separation. This multi-functionality reduces the overall complexity of the shim plate assembly while achieving the desired sliding characteristics.
3Device complexity
If the caliper and pad are directly contacted, then the structure is simple, but uneven wear occurs due to unstable caliper movement
Solution Approach 1:
The inner and outer shim plates serve as intermediary elements between the caliper and pad. The inner shim plate contacts the pressure plate while the outer shim plate contacts the caliper, allowing the caliper to slide relative to the pad through the coordinated movement of the two shim plates. This intermediary structure stabilizes caliper movement and prevents uneven wear of the pad lining.
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 design ensures stable caliper movement during braking, preventing uneven wear and noise, while enhancing the ease of assembly and reducing production costs by minimizing the complexity and number of bent parts in the shim plates.
Implementation Method 1
frictional force applied between the inner shim plate (2a) and the outer shim plate (1a) can be easily made smaller than frictional force applied between the rear surface of the pressure plate and the inner shim plate (2a)
Implementation Method 2
inner locking pieces (12 to 14) which are provided at both ends of the inner shim plate (2a) in a radial direction of the rotor so as to be bent toward one side of the inner shim plate (2a), and which lock an outer peripheral surface of the pressure plate
Data Source
AI summary
First to third inner locking pieces 12 to 14 are provided at both ends of an inner shim plate 2a in a radial direction of a rotor so as to be bent toward the pad, respectively. First to third outer locking pieces 15, 17 and 18 are provided at both ends of an outer shim plate 1a in the radial direction of the rotor so as to be bent in the same direction as the locking pieces 12 to 14. An inner shim plate 2a is mounted on a pressure plate 10, and the first to third outer locking pieces 15, 17 and 18 are superimposed on the first to third inner locking pieces 12 to 14 such that main body parts 7 and 8 of the respective shim plates 2a and 1a are locked in the pad in the axial direction of the rotor.