Disk Brake Shim Assembly With Interlocking Plates
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Solution Overview
Problem
Conventional shim assemblies for disk brakes face challenges in reducing brake squeal and uneven abrasion while maintaining design freedom, as they require complex structures that increase manufacturing costs and interference risks with other brake components.
Innovation Solution
A shim assembly comprising an inside shim plate and an outside shim plate that can displace in the peripheral direction relative to each other, with engaging pawls and locking pieces that prevent separation, minimizing projection from the pressure plate's edges and simplifying assembly, thereby reducing interference and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a two-plate structure with inside and outside shim plates is used to reduce brake squeal and uneven abrasion, then the squeal reduction effect is enhanced, but the device complexity and manufacturing cost increase
Solution Approach 1:
The shim assembly is divided into an inside shim plate and an outside shim plate, each with specific locking pieces positioned at different locations. The inside shim plate has locking pieces that engage with the pressure plate, while the outside shim plate has locking pieces that engage with the inside shim plate, creating a segmented but coordinated system that reduces squeal while maintaining manageability
Solution Approach 2:
The outside shim plate is positioned to overlap and cover the inside shim plate, with the outside locking pieces engaging with the inside locking pieces. This nested arrangement allows the two plates to work together in a compact configuration, enhancing squeal reduction without excessive complexity
2Reliability
If the inside and outside shim locking pieces are overlapped to prevent separation, then the reliability is improved, but the projection from the pressure plate edge increases causing interference
Solution Approach 1:
The locking mechanism transitions from radial engagement to peripheral engagement. Instead of locking pieces extending radially outward from the pressure plate edge, the inside and outside locking pieces engage with each other in the peripheral direction, allowing separation prevention without increasing radial projection
Solution Approach 2:
The inside shim locking pieces serve as an intermediary between the pressure plate and the outside shim locking pieces. The outside locking pieces engage with the inside locking pieces rather than directly with the pressure plate, creating an intermediate connection that prevents separation while minimizing edge projection
3Reliability
If a complex locking mechanism is used to prevent shim plate separation, then the reliability is improved, but the ease of manufacture decreases
Solution Approach 1:
Both the inside and outside shim plates use the same type of locking piece structure, with bent portions that engage in a similar manner. This homogeneity in locking mechanism design simplifies manufacturing processes and reduces fabrication complexity while ensuring reliable assembly stability
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 shim assembly effectively reduces brake squeal and uneven abrasion while enhancing design freedom and reducing manufacturing costs by allowing independent displacement of shim plates and minimizing edge projections, thus improving the overall performance and usability of disk brakes.
Implementation Method 1
inside shim locking pieces...bent toward the pressure plate so as to be elastically contacted with the peripheral edge of the pressure plate
Data Source
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AI summary
A shim assembly for a disk brake includes inside shim locking pieces (8g-8j) which are provided in an inside shim main body (7b) of the inside shim plate (3b) and bent toward the pressure plate (2b) so that displacement of the inside shim plate (3b) in radial and peripheral directions is restricted and outside shim locking pieces (13g-13i) which are provided in an outside shim main body (12b) of the outside shim plate and bent toward the pressure plate so that displacement of the outside shim plate (4b) in the peripheral direction is allowed and displacement thereof in the radial direction is restricted. Engaging pawls (22a-22c) are provided in the inside shim main body (3b) and projected from a peripheral edge of the pressure plate (2b). The outside shim locking pieces (13g-13j) are respectively engaged with the engaging pawls (22a-22c) so as to cover the engaging pawls, to prevent the outside shim plate (4b) against separation from the inside shim plate.