Patent ID: 7568561

Claim:
A method of forming a braking subassembly for use in a brake assembly, wherein the braking subassembly comprises a shim comprising at least one opening having one or more flanges perimetering therearound wherein the one or more flanges have an inner facing surface and an outer facing surface, a backing plate comprising a first side surface and a second side surface, with at least a first pass-through hole from the first side surface to the second side surface, and wherein the hole is perimetered by a wall, wherein the one or more flanges perimetering the at least one opening in the shim is alignable with and receivable in the at least first pass-though hole when the shim is coupled against the second side surface of the backing plate such that the inner facing surface of the one or more flanges is facing towards a center of the first pass-through hole and the outer facing surface is facing towards the wall of the first pass-through hole, and a friction pad formed of a friction pad material and coupled to the first side surface of the backing plate, wherein the method comprises the steps of: placing the shim against the second side surface of the backing plate and aligning the opening in the shim with the at least first pass-though hole such that the one or more flanges extend into the at least first pass-though hole; and thereafter forming the friction pad on the first side surface of the backing plate and at least partially filling the at least one pass-though hole with said friction pad material such that at least a part of the inner facing surface and at least a part of the outer facing surface of the one or more flanges perimetering the at least one opening in the shim are encased in the friction pad material; whereby the shim is resisted from movement at least in part by at least the part of the inner facing surface and at least the part of the outer facing surface of the flange being encased in the friction pad material.