Brake pedal with safety feature

Abstract

A brake booster push rod to pedal interface cage comprising: a plurality of sidewalls; a front surface connected to each of the plurality of side walls at or near a first side of the plurality of side walls, the front surface including a recess for receiving an end of a booster push rod; and at least one weakened portion configured to allow the booster pushrod to move through the front surface with a predetermined force.

Description

Technical Field

[0001] The present disclosure generally relates to the automotive field and, more particularly, to a brake pedal for a vehicle. Background Art

[0002] In a vehicle, a pivotal brake pedal actuable by a driver to brake the vehicle is typically coupled via a booster push rod or the like to an associated brake booster actuator (whether mechanical or electronic). The brake booster actuator is operable to engage the vehicle's brakes with a limited brake pedal stroke, thereby eliminating a "soft" feeling brake pedal and less than ideal brakes.

[0003] Typically, the push rod includes spherical structures at either end configured to securely engage a socket joint of an associated pivotal brake pedal arm or a socket joint of an associated brake booster actuator. Such spherical structures allow the push rod to transfer translational motion between the pivotal brake pedal arm and the brake booster actuator while allowing a degree of pivotal movement. Typically, the spherical joint at the pivotal brake pedal arm is held in the associated socket joint by a plastic or metal clip or bracket, such as Figure 1A-1B the prior art brake booster push rod to pedal interface cage shown. This helps to ensure that the spherical structure is securely held in the associated socket joint but is able to pivot and, in the case of vehicle repair and / or maintenance, is able to be detached and replaced together with the push rod. Summary of the Invention

[0004] The prior art brake booster push rod to pedal interface cage, such as Figure 1A-1BThose shown in [description] provide a good way to ensure that the spherical structure is firmly held in the associated ball and socket joint and can pivot as the brake pedal arm moves. However, in the case of a vehicle collision or other large forces, the driver typically applies a large force on the pedal. Additionally, a collision event may cause the front of the vehicle to be compressed (e.g., pushed closer to the driver or the driver closer to the front of the vehicle), resulting in a large amount of force on the driver's foot on the brake pedal pad. The devices and methods described herein attempt to relieve at least some of this pressure by allowing the push rod to push through the brake booster push rod to the pedal interface cage, thereby allowing the pedal arm and the pad to move further forward when subjected to forces indicative of a collision. Thus, the pedal arm and the pad can have more forward movement, thereby relieving the pressure on the driver's foot and leg because the driver's foot and leg can move forward with the pedal arm and the pad even when there is relative movement between the front of the vehicle and the driver's position. This can help reduce or prevent injuries associated with such situations, particularly in the driver's foot, ankle, and / or leg.

[0005] According to one aspect, a brake booster push rod to pedal interface cage includes: a plurality of side walls; a front surface connected to each of the plurality of side walls at or near a first side of the plurality of side walls, the front surface including a recess for receiving an end of the booster push rod; and at least one weakened portion configured to allow the booster push rod to move through the front surface with a predetermined force. Such a brake booster push rod to pedal interface cage having at least one weakened portion that allows the booster push rod to move through the front surface (e.g., through the recess) with a predetermined force allows further movement of the pedal arm and the pedal pad of the brake pedal in the case of large forces. This can help reduce or prevent injuries to the driver, particularly to the foot or leg, because allowing the pedal arm and the pedal pad to move further forward during a collision event reduces the force on the driver's foot. This is particularly useful when the front of the vehicle is compressed, pushing the brake pedal arm and the pedal pad closer to the driver.

[0006] According to one embodiment, the at least one weakened portion includes one or more slits in the front surface and / or the recess. Such slits can be, for example, slits that extend diagonally across the front surface and the recess to form an X or cross shape; one or more straight or a series of slits that extend through the top, bottom, and / or sides of the front surface, or any other configuration that allows the booster push rod to push through the front surface at a specific force level. Additionally, such slits can allow for an easy way to modify an existing brake booster push rod to pedal interface cage for use in the methods and / or components described herein.

[0007] According to one embodiment, the cage is formed of steel and / or aluminum. This can be formed by cutting and bending metal sheets, by forging, casting, or any other suitable method to form a sturdy and reliable brake booster push rod to pedal interface cage that allows the push rod to move through with a predetermined (e.g., large) force.

[0008] According to one embodiment, the recess is at least partially spherical and extends away from the sidewall in the front surface. Such a recess can be configured to receive the spherical end (sometimes with a bearing) of the push rod and allow pivoting movement along with the pivoting movement of the brake pedal arm when the brake is activated or released.

[0009] According to another aspect, a brake pedal booster push rod to pedal interface assembly includes: a pivotable brake pedal arm that includes a foot pad disposed at the distal end of the arm, and a brake booster push rod to pedal interface cage as described above; a brake clip that is connected to the brake booster push rod to pedal interface cage; and an elongate booster push rod that includes a first end adapted to pivotally engage the recess of the brake booster push rod to the pedal interface cage. The brake clip can be made of plastic or any other suitable material and is connected to the brake booster push rod to pedal interface cage to pivotally hold the first end of the push rod in the recess of the brake booster push rod to pedal interface cage. Such an assembly provides an effective brake pedal booster push rod to pedal interface for normal vehicle operation and braking, while allowing the push rod to move through the brake booster push rod to pedal interface cage into the interior of the pedal arm when subjected to a predetermined force level indicating a crash event. Allowing the push rod to move through the brake booster push rod to pedal interface cage into the arm allows the pedal arm and foot pad to move further forward, thereby reducing the force on the driver's foot and leg in the event of a force indicating a collision in the vehicle. This reduction in force can help reduce or prevent injury to the driver.

[0010] According to one embodiment, the pivotable brake pedal arm and the brake booster push rod to pedal interface cage are integrally formed. This can be done by casting or any other suitable method and can ensure that the components remain in proper position relative to each other for proper control of the booster push rod and the braking system.

[0011] According to one embodiment, the at least one weakening portion is located in an interface or connection between the pivotable brake pedal arm and the brake booster push rod to pedal interface cage. In some embodiments, this includes a bracket that fits around the booster push rod to pedal interface cage to secure the cage to the pedal arm. The connection point between the booster push rod to pedal interface cage and the bracket and / or the connection point between the booster push rod to pedal interface cage and the pedal arm can be a weakening point at the interface. Such weakening can be, for example, by a weakened weld or a thinner material or other weakened connection means. This configuration provides a booster push rod to pedal interface cage that does not itself require adjustment (e.g., having a slit in the front face), but allows for pushing through at the weakened interface or connection point with a predetermined force. This can allow for easy adaptation of past booster push rod to pedal interface cages for use in the components discussed herein.

[0012] According to one embodiment, the brake pedal arm is hollow and the at least one weakening portion allows the brake booster push rod to enter the interior of the hollow pedal arm. Optionally, the assembly includes one or more stops that are connected to the pivotable brake pedal arm and are configured to receive the push rod and to prevent further forward and / or sliding movement of the push rod relative to the brake pedal arm after the push rod has moved through the front face of the brake booster push rod to pedal interface cage. Allowing the push rod to move through the hollow pedal arm allows the pedal arm and foot pad to move further forward when subjected to forces indicative of a crash event, thereby reducing the likelihood and / or severity of injury to the driver's foot and / or leg. The one or more stops can be, for example, protrusions on the inner side of the pedal arm that are configured to capture and secure the end of the push rod after the push rod has been pushed through the brake booster push rod to pedal interface cage. Such stops can control and stop further forward and / or sliding movement of the push rod within the pedal arm and, if desired, can additionally allow the driver to further brake by allowing the inner side of the pedal arm to push the brake push rod to actuate the brake booster actuator.

[0013] According to one embodiment, the brake pedal arm includes an opening positioned on the front side of the pedal arm to allow the booster push rod to move through the opening after the booster push rod has moved through the front surface of the brake booster push rod to the front surface of the pedal interface cage. Such an opening can allow the pedal arm to move further forward even in the event of a collision or other event that results in excessive force and thus allow the foot pad to move further forward. This can even further reduce the chance and / or severity of driver injury. Such an opening is particularly useful in compact vehicle configurations and / or assemblies where the pedal arm has a relatively narrow width between the front and rear sides connecting the brake booster push rod to the pedal interface cage. In such compact vehicles and / or assemblies with a narrow pedal arm width, if the pedal arm is caught by a stop within the pedal arm, the pedal arm will not allow greater travel of the push rod and thus the pedal arm and the foot pad. By allowing the push rod to travel through the opening, the pedal arm can move further, thereby reducing the force that may harm the driver.

[0014] According to one embodiment, the predetermined force is related to the maximum force on the foot pad. Optionally, the predetermined force is related to a maximum force of 2500 - 3000 N on the foot pad. Generally, outside of a collision event, the maximum force that a driver can apply to the foot pad is approximately 2500 - 3000 N. Thus, applying a force greater than this to the foot pad can indicate that a collision event has occurred. The predetermined force is the force at which the push rod can move through the brake booster push rod to the pedal interface cage. Since the assembly has different configurations (e.g., different pedal arm lengths and widths), the predetermined force level associated with this level of 2500 - 3000 N force on the foot pad will be different for each configuration. For example, in an assembly with a pedal ratio of 4:1, meaning the foot pad is located at a distance from the pivot point of the arm that is four times the distance from the brake booster push rod to the pedal interface cage, the predetermined force allowing the booster push rod to move through the front surface can be calculated as:

[0015] Pedal ratio = L / X = 299.3 / 73 = 4.1

[0016] Force of 2500 N on the foot pad

[0017] Force in the push rod area = Force on the foot pad * Ratio = 2500 N x 4.1 = 10250 N

[0018] Where L is the distance between the pivot point and the foot pad, and X is the distance between the pivot point and the brake booster push rod to the pedal interface cage (in the above example, L = 299.3 mm and X = 73 mm).

[0019] Therefore, the pedal arm size and configuration can be used to calculate the predetermined force to allow the booster push rod to move through the front surface related to the typical maximum force level expected by the driver outside of a collision event.

[0020] According to another aspect, a vehicle includes the previously described components and / or a brake booster push rod to pedal interface cage. Such a vehicle can help reduce or eliminate harm to the driver, particularly harm to the driver's feet and / or legs during a collision event.

[0021] According to another aspect, a method of forming a brake pedal booster push rod to pedal interface assembly includes: forming or obtaining a brake booster push rod to pedal interface cage that includes a plurality of side walls and a front surface connected to each of the plurality of side walls, the front surface including a recess for receiving an end of a booster push rod and at least one weakened portion configured to allow the booster push rod to move through the front surface with a predetermined force; connecting the brake booster push rod to pedal interface cage to a pivotable brake pedal arm; and connecting an end of the booster push rod to pivotally engage the recess of the brake booster push rod to pedal interface cage. Such a method can produce an assembly that provides a safety feature to avoid or reduce harm during a collision.

[0022] Those skilled in the art will understand that the above features can be combined in any manner considered useful. Additionally, modifications and variations described with respect to the system can equally be applied to the method. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1A A front perspective view of a prior art brake booster push rod to pedal interface cage is shown;

[0024] Figure 1B Shows Figure 1A A rear perspective view of the prior art brake booster push rod to pedal interface cage of

[0025] Figure 2A A cross-sectional view of a brake pedal booster push rod to pedal interface assembly connected to a pedal arm with a foot pad is shown;

[0026] Figure 2B A close-up view of a cross-section of the brake pedal booster push rod to pedal interface assembly and its connection to the pedal arm is shown;

[0027] Figure 2C Shows after a collision event Figure 2A A view of the assembly of

[0028] Figure 2D Shows Figure 2C A close-up view of a portion of

[0029] Figure 3A A cross-sectional view of a second embodiment of a brake pedal booster push rod to pedal interface assembly connected to a pedal arm with a foot pad is shown;

[0030] Figure 3B shows a cross-sectional view of components after a collision event; Figure 3A

[0031] Figure 4A-Figure 4B shows perspective front and rear views of a first embodiment of a brake booster push rod to pedal interface cage;

[0032] Figure 5A-Figure 5B shows perspective front and rear views of a second embodiment of a brake booster push rod to pedal interface cage;

[0033] Figure 6A-Figure 6B shows perspective front and rear views of a third embodiment of a brake booster push rod to pedal interface cage; and

[0034] Figure 7 shows a perspective view of an embodiment of a component of a brake pedal arm and a booster push rod to pedal interface cage, having a weakened portion in the interface between the booster push rod to pedal interface cage and the arm. Detailed Description

[0035] Embodiments of the present disclosure will be described below with reference to the accompanying drawings. However, the embodiments of the present disclosure are not limited to specific embodiments and should be construed as including all modifications, variations, equivalent devices and methods, and / or alternative embodiments of the present disclosure.

[0036] Terms such as "first" and "second" used herein may modify various elements, regardless of the order and / or importance of the corresponding elements, and do not limit the corresponding elements. These terms may be used for the purpose of distinguishing one element from another. For example, without departing from the scope of the present invention, a first element may be referred to as a second element, and similarly, a second element may be referred to as a first element.

[0037] The terms used in describing various embodiments of the present disclosure are for the purpose of describing specific embodiments and are not intended to limit the present disclosure. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. All terms used herein, including technical or scientific terms, have the same meaning as commonly understood by one of ordinary skill in the art, unless otherwise defined. Terms defined in commonly used dictionaries should be construed as having the same or similar meaning as the context of the related art and should not be construed as having an ideal or exaggerated meaning, unless clearly defined herein. Depending on the circumstances, even terms defined in the present disclosure should not be construed as excluding embodiments of the present disclosure.

[0038] ​As used herein, the term "vehicle" refers to an object for transporting people or goods. Examples of vehicles include automobiles, cars, trucks, or buses. A vehicle can be an "electric vehicle (EV)" powered by an electric motor that draws current from an on-vehicle energy storage device (such as a battery), which can be charged from an off-vehicle source (such as residential or public power service or an on-vehicle fuel-powered generator). A vehicle can be a two or more wheeled vehicle manufactured for use primarily on public streets and roads.

[0039] Figure 2A A cross-sectional view of a brake pedal booster push rod to pedal interface assembly 10 is shown, where the brake pedal booster push rod to pedal interface assembly 10 is connected to a pedal arm 12 having a foot pad 14; Figure 2B Is shown Figure 2A A close-up view of cross-section B of. The assembly 10 includes a push rod 16, a clip 18, a brake booster push rod to pedal interface cage 20; a ball bearing 22, and a stopper 24.

[0040] The pedal arm 12 extends from a first end 26 about which it can pivot to a second end 28 to which the foot pad 14 is connected. The brake pedal booster push rod to pedal interface assembly 10 is connected between the first end 26 and the second end 28 and can vary which exact point on the pedal arm 12 it is connected to depending on the specific configuration of the vehicle in which it is located. In some embodiments, the brake booster push rod to pedal interface cage 20 and the pedal arm 12 are integrally formed and are not separate components connected (e.g., welded) together. The pedal arm 12 is hollow and includes a front wall 13 and a rear wall 15, the width of which generally varies along the length of the pedal arm 12.

[0041] The push rod 16 extends from a connection portion with a brake booster actuator (not shown) to an end 17 that is connected to the brake booster push rod to pedal interface cage 20, specifically, to a partially spherical recess 30 in the front surface 32 of the brake booster push rod to pedal interface cage 20. The plastic clip 18 is connected around the push rod 16 and connected to the brake booster push rod to pedal interface cage 20 to fix the end 17 of the push rod 16 relative to the brake booster push rod to pedal interface cage 20. The ball bearing 22 is connected around the end 17 of the push rod 16, and when pushed or pulled by the movement of the pedal arm 12, the ball bearing 22 functions to reduce friction and noise in the pivoting and movement of the push rod 16 relative to the brake booster push rod to pedal interface cage 20. The bearing 22 can be, for example, a metal sheet.

[0042] In operation, the driver pushes on the foot pad 14 with his foot, which causes the pedal arm 12 to pivot about the first end 26, thereby moving the push rod 16 to actuate a brake booster (not shown). Then, when the driver removes the force from the foot pad 14, the push rod 16 and the pedal arm 12 move back to their original positions (e.g., by a spring, see Figure 3B ).

[0043] As described above, when a collision occurs, this typically causes the driver to apply a large force on the brake pad 14, and thus when the brake pad 14 is pushed as far as possible (limited by the push rod 16), a large force is applied on the driver's foot and / or limb. This is particularly common if the front portion of the vehicle moves towards the driver during a collision (e.g., the front end of the vehicle experiences a crush during a collision). To reduce or prevent injury to the driver in such a situation, the assembly 10 allows the push rod 16 to move through the brake booster push rod to the pedal interface cage 20 with a certain force threshold and into the hollow pedal arm 12, as Figure 2C-Figure 2D shown. Thus, the push rod 16 (with the bearing 22) moves through the brake booster push rod to the pedal interface cage 20, and in this case, is stopped by a stop 24 inside the front wall 13 of the pedal arm 12. As Figure 2C shown, this allows the foot pad 14 to move further forward, thereby relieving some of the force on the driver's foot and leg and reducing or preventing related injuries. Additionally, the stop 24 inside the pedal arm 12 grabs the end 17 of the push rod 16 to prevent further forward and / or sliding movement, and thus allows the push rod 16 to be moved to actuate the brake booster to further brake the vehicle by now using the front wall 13 of the pedal arm 12 with the stop 24. The stop 24 is shown schematically for illustrative purposes only and may take other configurations as long as they are positioned and arranged to stop and guide the end 17 of the push rod 16 when the push rod 16 moves through the brake booster push rod to the pedal interface cage 20 and / or when additional braking is required after moving through the front surface 32.

[0044] Thus, the assembly 10 allows the force on the driver's foot and leg to be reduced in the event of a collision because the assembly 10 is configured to allow the push rod 16 to be pushed through the brake booster push rod to the front surface 32 of the pedal interface cage 20, thereby allowing the pedal arm 12 and the foot pad 14 to move further forward and thus reducing the chance of driver injury in such a situation. The amount of movement allowed through such an assembly 10 will depend on the dimensions of the pedal arm 12 (e.g., length and width), the placement of the assembly 10 relative to the pivot point of the pedal arm, etc. In some embodiments, during a collision, the additional movement in such an assembly 10 can be about 20 mm, thereby reducing the load on the driver's foot due to allowing such movement.

[0045] The force that allows the push rod 16 to move through the brake booster push rod to the pedal interface cage 20 will be related to the expected normal force that the driver can or will apply to the foot mat 14 outside of a crash event. Typically, this force will be up to about 2500 N - 3000 N, although it can vary. Thus, when a force in excess of 2500 - 3000 N is applied to the foot mat 14, the force required to allow the movement of the push rod 16 through the brake booster push rod to the pedal interface cage 20 will be the force experienced at the brake booster push rod to the pedal interface cage 20.

[0046] Figure 3A A cross-sectional view of a second embodiment of the brake pedal booster push rod to pedal interface assembly 10' is shown, the assembly 10' being connected to a pedal arm 12' having a foot mat 14; and Figure 3B A cross-sectional view of the assembly 10' after a crash event is shown. Similar components will be labeled similar to Figure 2A-Figure 2D the components shown therein, and only the differences will generally be discussed.

[0047] The assembly 10' includes a push rod 16 (having an end 17), a clip 18, a brake booster push rod to pedal interface cage 20, and a bearing 22. Instead of Figure 2A-Figure 2D the stop shown in the embodiment of, the assembly 10' includes an opening 40 in the front wall 13 of the pedal arm 12. The opening 40 is located at the point in the pedal arm 12 where the push rod 16 naturally extends and contacts the brake booster push rod to pedal interface cage 20 when the push rod 16 moves through it. The size of the opening 40 is also determined based on the size of the end 17 of the push rod 16 and the bearing 22.

[0048] When the foot mat 14 is subjected to a force that allows the push rod 16 to move through the brake booster push rod to the pedal interface cage 20, as Figure 3B shown, the push rod 16 is then also able to move through the opening 40 in the front wall 13 of the pedal arm 12. This configuration allows for more movement of the pedal arm 12 and thus the foot mat 14 in the forward direction during a crash event, thereby allowing for a reduction in the forces on the driver's foot and / or leg that could cause damage or injury.

[0049] Figure 4A-Figure 6B An exemplary embodiment of the configuration of the brake booster push rod to pedal interface cage is shown that allows the push rod 16 to move through the cage when the push rod 16 is subjected to a specific force level (e.g., a force level associated with more than 2500 N - 3000 N on the foot mat 14).

[0050] Figure 4A-Figure 4BShows perspective front and rear views of a first embodiment of a brake booster push rod to pedal interface cage 20, the brake booster push rod to pedal interface cage 20 including a side wall 42 and a front surface 32 connected at (or near) a first side of the side wall 42. The front surface 32 includes a recess 30 that is configured to receive an end 17 of the push rod 16 and is thus partially spherically shaped in this case to receive the spherical end 17 of the push rod 16.

[0051] The brake booster push rod to pedal interface cage 20 is typically formed of metal (such as steel or aluminum) and can be cut and bent into Figure 4A-Figure 6B the shape shown in, or can be cast or formed by any other suitable method. The side wall 42 forms a housing into which a clip 18 extends and secures the push rod 16 relative to the brake booster push rod to pedal interface cage 20, and in particular secures the end 17 relative to the recess 30. This configuration is capable of holding the end 17 in the recess 30 and also allows pivotal movement when the pedal arm 12 pushes the push rod 16 in one direction and the brake booster push rod 16 is pushed back in the other direction, for example by a spring 41 as Figure 3B shown.

[0052] In this embodiment, the brake booster push rod to pedal interface cage 20 includes two slits 50 that form an X - shape in the front surface 32 and the recess 30. Such slits can be machined into the front surface 32 and the recess 30, for example, or formed by any other means. Such slits 50 are configured to allow the end 17 of the push rod 16 to push through the front surface 32 of the brake booster push rod to pedal interface cage 20 when subjected to a large crash event force, as described with respect to Figure 2A-Figure 3B This configuration with the opening 40 that allows for more movement of the pedal arm 12 and the foot pad 14 relative to the end 17 of the push rod 16 can be particularly advantageous in vehicles with a compact configuration, i.e., in the compact configuration of the vehicle where the pedal arm 14 has a smaller width and there is not much additional movement between the normal positioning of the end 17 of the push rod 16 in the brake booster push rod to pedal interface cage 20 and the stop of the end 17 using a stop within the arm 14 as Figure 2A-Figure 2D shown. Thus, even in vehicles where the pedal arm 14 has a compact size and / or a smaller width, extending the push rod 16 through the opening 40 outside of the pedal arm 12 can provide a reduced force on the driver during a crash event.

[0053] Figure 5A-Figure 5BPerspective front and rear views of a second embodiment of a brake booster push rod to pedal interface cage 20 are shown. In this embodiment, the front surface 32 includes a string of two rows of slits extending across the top and bottom sides of the front surface 32. The line of slits 52 provides a weakened portion of the brake booster push rod to pedal interface cage 20 that allows the push rod 16 to move through the front surface 32 of the brake booster push rod to pedal interface cage 20 in the event of sufficient force caused by a collision.

[0054] Such a series of slits 52 is shown for example purposes and may be formed by more or fewer slits, more or fewer lines, slits of different sizes, on the sides of the front surface 32 rather than the top and bottom, etc.

[0055] Figure 6A-Figure 6B Perspective front and rear views of a third embodiment of a brake booster push rod to pedal interface cage 20 are shown. In this embodiment, the recess 30 in the front surface 32 includes a single slit 50 extending through the center of the recess 30.

[0056] Figure 7 A perspective view of an embodiment of an assembly of a brake pedal arm 12 and a booster push rod to pedal interface cage 20 is shown, having a weakened portion in the interface between the booster push rod to pedal interface cage 20 and the arm 12. In this embodiment, the booster push rod to pedal interface cage 20 can be at least partially held in connection with the arm 12 by a bracket 60 (e.g., by welding). One or more of the connection points 70, 72, 74, and 76 can be weakened to allow the push rod 16 to push through the front surface 32 with a predetermined force. For example, the regions 72 and 74 can be weakened to allow disconnection between the booster push rod to pedal interface cage 20 and the arm 12 and the bracket 60, respectively; and / or the regions 76 and 70 can be weakened to allow disconnection between the bracket 60 and the arm 12. Such weakened connections can be, for example, by a weak weld or thinner connection material, or any other means that allows deformation at a specific predetermined force.

[0057] Therefore, Figure 4A-Figure 7 Each brake booster push rod to pedal interface cage 20 shown in shows a different embodiment of a brake booster push rod to pedal interface cage and / or assembly that has been constructed to allow the booster push rod 16 to move through the recess 30 with a predetermined force (e.g., a force indicative of a collision event). This can allow for a reduction in the forces on the driver's foot and leg, thereby reducing or preventing as regarding Figure 2A-Figure 3BAny relevant injuries discussed. Although these specific embodiments are shown as examples, the brake booster push rod to pedal interface cage 20 can have other configurations that allow the push rod 16 to be pushed through the front surface 32, for example, a weakened connection of the front surface 32 and the side wall 42 or other configurations of the brake booster push rod to pedal interface cage 20 that remains robust to fix the push rod 16 under normal driving conditions but allows the push rod to move through the front surface 32 under collision forces.

[0058] Although the invention has been described with reference to exemplary embodiments, those skilled in the art will understand that various changes can be made and elements thereof can be replaced with equivalents without departing from the scope of the invention. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the invention without departing from the basic scope thereof. Therefore, the invention is not limited to the specific embodiments disclosed, but the invention will include all embodiments falling within the scope of the appended claims.

Claims

1. A brake booster push rod to pedal interface cage (20), comprising: a plurality of side walls (42); a front surface (32) connected to each of the plurality of side walls (42) at or near a first side of the plurality of side walls, the front surface (32) including a recess (30) for receiving an end (17) of a booster push rod (16); and At least one weakened portion is configured to allow the booster push rod to move through the front surface with a predetermined force.

2. The brake booster push rod to pedal interface cage (20) according to claim 1, wherein: The at least one weakened portion comprises one or more slits (50) in the front surface (32) and / or the recess (30).

3. A brake booster push rod to pedal interface cage according to any one of the preceding claims, wherein: The at least one weakened portion includes at least one series (52) of slits extending across the front surface (32).

4. A brake booster push rod to pedal interface cage (20) according to any one of the preceding claims, wherein: The at least one weakened portion includes a slit (50) extending diagonally across the front surface (32) and / or recess (30) to form an X.

5. A brake booster push rod to pedal interface cage (20) according to any one of the preceding claims, wherein: The cage (20) is formed from steel or aluminum.

6. A brake booster push rod to pedal interface cage (20) according to any one of the preceding claims, wherein: The recess (30) is a spherical recess in the front surface extending away from the side wall (42).

7. A brake pedal booster push rod to pedal interface assembly (10), comprising: a pivotable brake pedal arm (12) comprising a foot pad (12) disposed at a distal end of the pedal arm (12), and a brake booster push rod to pedal interface cage (20) according to any one of the preceding claims; a brake clip (18) connected to the brake booster push rod to pedal interface cage (20); and An elongated booster push rod (16) includes a first end (17) adapted to pivotally engage the brake booster push rod to a recess (30) of a pedal interface cage (20).

8. Assembly (10) according to claim 7, wherein The pivotable brake pedal arm (14) and the brake booster push rod to pedal interface cage (20) are integrally formed.

9. Assembly (10) according to any one of claims 7-8, wherein The at least one weakened portion is located in the interface or connection between the pivotable brake pedal arm and the brake booster push rod to pedal interface cage (20).

10. The assembly (10) according to any one of claims 7 to 9, wherein: The pedal arm (12) is hollow, and the at least one weakened portion allows the brake booster push rod (16) to enter the interior of the pedal arm (12).

11. The assembly (10) according to any one of claims 7 to 10, further comprising: One or more stops (24) connected to the pedal arm (12) and configured to receive the booster push rod (16) and prevent further forward and / or sliding movement of the booster push rod (16) relative to the pedal arm (12) after the booster push rod (16) has moved through a front surface (32) of the brake booster push rod to pedal interface cage (20).

12. Assembly (10) according to any one of claims 7 to 11, wherein: The pedal arm (12) includes an opening (40) positioned to allow the booster push rod (16) to move through the opening (40) after the booster push rod (16) has moved through the front surface (32) of the brake booster push rod to pedal interface cage (20).

13. An assembly according to any one of claims 7 to 12, wherein: The predetermined force is related to the maximum force on the foot pad (14), preferably, wherein the predetermined force is related to the maximum force of 2500-3000N on the foot pad (14).

14. A vehicle comprising an assembly (10) according to any one of claims 6-13 and / or a brake booster push rod to pedal interface cage (20) according to any one of claims 1-5.

15. A method of forming a brake pedal booster push rod to pedal interface assembly (10), the method comprising: forming or obtaining a brake booster push rod to pedal interface cage (20) comprising a plurality of side walls (42) and a front surface (32) connected to each of the plurality of side walls (42), the front surface (32) comprising a recess (30) for receiving an end (17) of a booster push rod (16) and at least one weakened portion configured to allow the booster push rod to move through the front surface with a predetermined force; Connecting the brake booster push rod to pedal interface cage (20) to a pivotable brake pedal arm (14); and An end (17) of a booster push rod (16) is connected to pivotally engage the brake booster push rod to a recess (30) of a pedal interface cage (20).

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