Abstract: A method of forming a stamped metal laminate part from a strip stock with a layer of viscoelastic material laminated between two metal layers, and a laminated abutment clip made by the method. Part carriers are disposed on the sides of the stock. A longitudinal axis extends between the part carriers through the stock. The stock is advanced through a progressive die to a first position where a first form is created, a second position, where a second form is created by modifying the first form, and to a third position where a third form is created. Relative sliding of the metal layers in the stock is prevented between the axis and the form being created, and relative sliding of the metal layers is permitted at a section beyond the particular form being created, preventing delamination of the stock while the first, second and third forms are formed.

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 shim for use in a braking subassembly comprising a metal backing plate comprising a first side surface, wherein the shim comprises at least one flexible tab extending from an edge thereof for assisting in coupling the shim to the backing plate along a backing plate side surface thereof, and wherein the at least one flexible tab comprises an integrally formed and extending finger therefrom, wherein the finger has a leading edge that frictionally engages the backing plate edge surface when the shim is subjected to a separation force, which, relative to the backing plate, has a directional component at least essentially parallel to and in the same direction as the direction in which the finger extends; whereby the shim is resisted from separating from the first side surface of the backing plate at least in part by the frictional resistance of the leading edge of the finger against the backing plate side surface.

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 for use in a brake assembly. The first side surface of the backing plate has a first extending pin and at least a second extending pin spaced apart from the first extending pin and the shim has apertures that align with the extending pins. The shim is coupled against the first side surface of the backing plate and the apertures are aligned with their corresponding pins such that the pins extend through the apertures. Each pin is sufficiently deformed to directly contact and lock down at least a portion of the edge of each respective apertures to secure the shim against the first side surface of the backing plate such that the respective pins do not extend above the top surface of the shim after deformation.

Abstract: A staple for assisting in the coupling of a shim to a first side surface of a backing plate in a brake assembly. In a preferred embodiment, the staple comprises a head section; a body section coupled to the head section, the body section having a concavity so as to form a recessed region therein; and a leg member, shaped for permitting a portion of the material comprising the backing plate to be displaced towards and into the recessed region as the leg member is piercing the first side surface of, and progressing into, the backing plate; and wherein upon insertion of the body section into the backing plate, the concavity of the body section causes the displaced material to fill the recessed region; whereby a shim mounted onto the first side of the backing plate and secured thereto at least in part by the head section is inhibited from movement on and separation from the first surface of the backing plate.

Abstract: A staple for assisting in the coupling of a shim to a first side surface of a backing plate in a brake assembly. In a preferred embodiment, the staple comprises a head section; a body section coupled to the head section, the body section having a concavity so as to form a recessed region therein; and a leg member, shaped for permitting a portion of the material comprising the backing plate to be displaced towards and into the recessed region as the leg member is piercing the first side surface of, and progressing into, the backing plate; and wherein upon insertion of the body section into the backing plate, the concavity of the body section causes the displaced material to fill the recessed region; whereby a shim mounted onto the first side of the backing plate and secured thereto at least in part by the head section is inhibited from movement on and separation from the first surface of the backing plate.

Abstract: A staple for assisting in the coupling of a shim to a first side surface of a backing plate in a brake assembly. In a preferred embodiment, the staple comprises a head section; a body section coupled to the head section, the body section having a concavity so as to form a recessed region therein; and a leg member, shaped for permitting a portion of the material comprising the backing plate to be displaced towards and into the recessed region as the leg member is piercing the first side surface of, and progressing into, the backing plate; and wherein upon insertion of the body section into the backing plate, the concavity of the body section causes the displaced material to fill the recessed region; whereby a shim mounted onto the first side of the backing plate and secured thereto at least in part by the head section is inhibited from movement on and separation from the first surface of the backing plate.