Piston-Side Brake Shim with Lubricant Perforations
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Solution Overview
Problem
Existing shims for disc brake systems, particularly those on the brake piston, are bulky, complex to manufacture, and ineffective in reducing vibrational noise due to inadequate smooth sliding against the brake backing plate, leading to friction, fretting, and damage, while also requiring large and costly inventories for various vehicle models.
Innovation Solution
A piston-side shim with a round or annular plate and bent clips to securely fit on the brake piston, featuring lubricant-retaining surface features and perforations to facilitate smooth sliding and prevent exposure, allowing for even lubricant distribution and reduced friction, and optionally stacked with lubricant-loaded washers for enhanced noise reduction and thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing piston-side shims are used, then the piston edge is secured against exposure, but the shims are bulky and complex to manufacture
Solution Approach 1:
The shim is divided into a plate portion and multiple separate clips. The plate provides the protective surface while the clips independently provide retention, allowing each component to be optimized for its specific function and simplifying manufacturing.
Solution Approach 2:
The retention function is extracted from the main plate body and implemented through separate clips that engage with the piston. This separation allows the plate to be simpler and the clips to be independently manufactured and optimized.
2Reliability
If existing piston-side shims are used, then retention on the piston is achieved, but the shims do not slide smoothly against the brake backing plate, causing friction and noise
Solution Approach 1:
The plate portion is provided with specific surface features including lubricant-retaining features and perforations. These local modifications create areas of reduced friction and improved lubrication exactly where the plate contacts the brake backing plate, while the clips maintain retention without interfering with the sliding surface.
Solution Approach 2:
Lubricant is introduced as an intermediary substance between the plate and brake backing plate. The lubricant-retaining features on the plate hold and distribute lubricant to the contact surface, reducing direct friction and vibrational noise between the solid surfaces.
3Object-generated harmful factors
If shims are designed to fit against the backing plate, then noise reduction is achieved, but large inventories are required for various vehicle models
Solution Approach 1:
The shim design with a standardized plate portion and adjustable clips can accommodate multiple vehicle models and piston configurations. The clips can be positioned or selected to fit different piston geometries while the plate maintains its noise-reducing function, reducing the need for model-specific shim variants.
Solution Approach 2:
The clips are designed to flex and adjust to different piston shapes and sizes. This dynamic adaptability allows a single shim design to fit multiple applications that would otherwise require different fixed designs, reducing inventory requirements.
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 effectively reduces brake squeal and vibrational noise by ensuring smooth sliding and secure retention on the piston, minimizing friction and wear, while accommodating various vehicle models with fewer size and shape variations, thus reducing manufacturing complexity and inventory costs.
Implementation Method 1
The plate has surface features for retaining a lubricant and perforations that allow passage of the lubricant from the piston facing surface toward the plate facing surface
Implementation Method 2
a plurality of piston engaging clips cut from the plate and bent or curved at an angle to the plate, which engage an interior portion of the hollow open end of the brake piston to retain the round plate on the brake piston
Data Source
AI summary
The present invention is a shim or shim assembly that clips onto a brake caliper piston. It is generally a rimmed round (disc or annular) shape to cap the edges of the caliper piston and includes surface features for lubrication, and improved fitting. Reduced noise from frictional fretting is provided along with protection of piston's outer rim. Reduced thermal transfer into the piston is also provided.