Embedded Shim Brake Pad Assembly for Compact Corrosion Resistance
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Solution Overview
Problem
Conventional brake pad assemblies are inefficient due to issues with weight, compactness, fitting accuracy, and resistance to corrosion, necessitating improvements in dimensional and quality aspects.
Innovation Solution
A brake pad assembly with a back plate and shim plate configuration where the shim plate is at least partially embedded in the back plate, utilizing composite materials for the back plate and metallic or polymer materials for the shim plate, reducing corrosion risk and enhancing noise, vibration, and harshness mitigation, while maintaining magnetic handling compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional brake pad assemblies use separate shim plate and back plate components, then assembly flexibility is maintained, but weight increases and compactness decreases
Solution Approach 1:
The shim plate is embedded within the back plate structure, merging two separate components into a single integrated assembly. This reduces the overall volume and weight of the brake pad assembly while maintaining the functional benefits of both the shim plate (noise and vibration reduction) and the back plate (structural support).
2Reliability
If shim plate is separately attached to back plate, then manufacturing is simpler, but corrosion resistance decreases due to exposure and misalignment risk
Solution Approach 1:
The shim plate is nested within a recess or cavity in the back plate, positioning it intermediate the friction pad and the outer surface. This nesting protects the shim plate from direct exposure to corrosive elements and eliminates misalignment issues, while the embedded configuration can be achieved through standard manufacturing processes like casting or molding the back plate with an integrated shim recess.
3Weight of moving object
If brake pad assembly uses traditional materials, then manufacturing compatibility is maintained, but weight reduction and corrosion resistance are limited
Solution Approach 1:
The back plate is formed from composite materials that combine the benefits of metal (strength, magnetic properties for handling) with corrosion-resistant and lightweight characteristics. The shim plate can be formed from metallic, alloy, or polymer materials selected for their specific properties. This composite approach enables weight reduction and improved corrosion resistance while maintaining compatibility with existing manufacturing processes through appropriate material selection and processing methods.
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 solution results in a more compact, lighter brake pad assembly with reduced corrosion risk, improved magnetic handling, and increased battery range in electric vehicles, allowing for additional system components without performance compromise and environmental friendliness.
Implementation Method 1
The shim plate is arranged to reduce noise, vibration and harshness (NVH)
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
The present disclosure relates to a brake pad assembly (1) for a disc brake of a vehicle comprising a back plate (2) comprising an outer surface (2a) and an opposing inner surface (2b). Further, the brake pad assembly (1) comprises a shim plate (3) and a friction pad (4) associated with said inner surface (2b). Furthermore, the shim plate (3) is at least partially embedded in said back plate (2), wherein the shim plate (3) is positioned intermediate the friction pad (4) and the outer surface (2a) of the back plate (2).