Abstract: A subassembly for use in a brake assembly, the subassembly comprising a shim, a backing plate and a friction pad formed of a friction pad material, wherein the friction pad material extends into at least one pass-through hole in the backing plate; and wherein one or more flanges perimetering at least one opening in the shim are encased in the friction material; whereby the shim is resisted from movement at least in part by the one or more flanges being encased in the friction pad material. A preferred methodology of forming the braking subassembly comprises the steps of forming the friction pad on the backing plate and at least partially filling the at least one pass-through hole with said friction pad material such that the one or more flanges perimetering the at least one opening in the shim is encased in the friction pad material.

Abstract: A brake pad assembly is provided. A brake backing plate has a generally planar body with at least one mold hole. A generally planar shim is affixed to a first face of the backing plate. The shim has at least one integral hook that extends into the at least one mold hole in the backing plate. A friction material is molded onto a second opposite face of the backing plate, and fills the at least one mold hole to thereby embed the hook and retain the shim against the backing plate. A method of making a brake pad assembly is also provided.

Abstract: A subassembly for use in a brake assembly, the subassembly comprising a shim, a backing plate and a friction pad formed of a friction pad material, wherein the friction pad material extends into at least one pass-through hole in the backing plate; and wherein one or more flanges perimetering at least one opening in the shim are encased in the friction material; whereby the shim is resisted from movement at least in part by the one or more flanges being encased in the friction pad material. A preferred methodology of forming the braking subassembly comprises the steps of forming the friction pad on the backing plate and at least partially filling the at least one pass-through hole with said friction pad material such that the one or more flanges perimetering the at least one opening in the shim is encased in the friction pad material.

Abstract: A method of securing a shim against a first side surface of a backing plate, wherein the shim and the backing plate together comprise a subassembly for use in a brake assembly, the method comprises the steps of: stamping the first side surface of the backing plate so as to form a first extending pin and at least a second extending pin spaced apart from the first extending pin, each of the pins being integrally connected to the backing plate, and stamping the shim so as to form a first aperture and at least a second aperture spaced apart from the first aperture whereby a respective edge circumscribes each aperture, wherein the position of the at least two extending pins is based at least in part on the position of the first and second apertures or the position of the first and second apertures is based at least in part on the position of the at least two extending pins; coupling the shim against the first side surface of the backing plate and aligning the first aperture with the first pin and aligning the seco

Abstract: A riveted brake assembly comprising a friction pad attached to a metal support plate with rivets. Each rivet comprises a rivet head disposed in a counter bored friction pad hole, a shoulder portion disposed in and filling a small diameter portion of the friction pad hole, a shank portion of lesser diameter than the shoulder portion disposed in the support plate hole, and a tubular tip portion extending beyond said support plate and adapted to be rolled over to secure the friction pad to the support plate. In its preferred form, the rivet is an eyelet of substantially uniform wall thickness, wherein the length and diameter of the rivet shoulder are substantially the same as the length and diameter of the small diameter portion of the friction pad hole.