Disc Brake Shim Coupling Hook and Pad Plate Hole

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional methods for coupling shims to pad plates in disc brakes either complicate manufacturing with adhesives or result in poor coupling force due to mechanical attachment, leading to potential separation issues.

Innovation Solution

A disc brake design featuring a coupling hook on the shim and a corresponding coupling hole in the pad plate, allowing for easy and secure attachment by inserting the hook into the hole, with the hook's protrusion ensuring strong coupling and preventing separation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If adhesive is used to attach shim to pad plate, then coupling strength is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvecoupling strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces the chemical bonding method (adhesive) with a mechanical coupling system consisting of a coupling protrusion on the shim that fits into a coupling hole in the pad plate. This mechanical substitution eliminates the need for adhesives while maintaining coupling strength and simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If bent rim portion of shim is caught by pad plate, then manufacturing is simplified, but coupling force becomes poor causing separation

Engineering Contradiction:

Improveease of manufactureVSAvoidcoupling force

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The coupling system is segmented into distinct components: a coupling protrusion on the shim and a corresponding coupling hole in the pad plate. This segmentation allows for precise fitting and strong mechanical coupling while maintaining ease of manufacture through simple geometric features.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The coupling protrusion of the shim is inserted into and nested within the coupling hole of the pad plate, creating a secure interlocking connection. This nesting mechanism provides strong coupling force while keeping the manufacturing process simple.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Reliability

If coupling hole is perforated through both surfaces of pad plate, then coupling reliability is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvecoupling reliabilityVSAvoidmanufacturing precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The coupling hole serves multiple functions: it provides a pathway for the coupling protrusion, acts as a mechanical interlock feature, and ensures proper alignment of the shim with the pad plate. This multi-functionality improves coupling reliability while the simple through-hole geometry keeps manufacturing precision requirements manageable.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8657081B2Disc brake

Publication Date: 2014.02.25 HL MANDO CORP

AI summary

Disclosed herein is a disc brake to allow a shim to be easily coupled to a pad plate and to maintain strong coupling between the shim and the pad plate so as to prevent separation of the mounted shim. The disc brake includes pad plates each having frictional pads, a piston and a caliper housing to press the pad plates toward a disc, a shim attached to one surface of each of the pad plates to be pressed by the piston or the caliper housing, a coupling hook protruding from the shim and having a coupling protrusion at an end thereof, and a coupling hole perforated in each of the pad plates to allow the coupling hook to be inserted and coupled into the coupling hole.