Angled Master Cylinder Insert Deflects Engine Thrust
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Solution Overview
Problem
In vehicle collisions, engine components compress against the master cylinder, causing the brake pedal to rise in the passenger compartment and potentially injuring the driver, as existing solutions either delay pressure evacuation or fail to prevent the pedal's recoil due to significant mechanical thrust.
Innovation Solution
A master cylinder end piece with a contact surface angled or perforated to deflect or limit the forces applied by engine elements during an impact, featuring an insert with a non-perpendicular contact surface and optional perforation device, allowing for adjustable orientation and secure attachment to the master cylinder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a device is added to evacuate pressure from the braking circuit during impact, then the immediate recoil of the braking device is prevented, but the brake pedal still rises in the passenger compartment due to direct mechanical thrust from engine components
Solution Approach 1:
The patent introduces an intermediary element (the angled contact surface or perforation device) between the engine components and the master cylinder. This intermediary either deflects the thrust force away from the master cylinder axis or limits the force transmission through perforation, thereby preventing brake pedal rise without requiring complex active control systems
Solution Approach 2:
The patent changes the geometric parameter of the contact surface (angling it relative to the master cylinder axis) to alter the direction of force transmission. By modifying the angle of contact, the thrust from engine components is redirected away from the braking circuit, preventing pedal rise while maintaining a simple device structure
2Object-affected harmful factors
If the master cylinder end is given a particular shape (curved or inclined contact surface) to deflect forces, then the brake pedal rise is prevented, but the production complexity and manufacturing difficulty increase significantly
Solution Approach 1:
The patent segments the master cylinder into a standard cylindrical body and a separate end piece (protective cap). The angled contact surface is incorporated into this detachable end piece, which can be manufactured separately using standard machining processes and then attached to the master cylinder. This segmentation allows the complex angled surface to be produced independently without requiring the entire master cylinder to be custom-manufactured
Solution Approach 2:
The protective end piece is designed to fit over and attach to the existing master cylinder body, creating a nested structure. This allows the master cylinder to maintain its standard manufacturing process while the protective cap with the angled surface provides the force-deflection function, combining simplicity of production with effective protection
3Object-affected harmful factors
If a protective device with angled contact surface is integrated into the master cylinder, then force deflection is achieved, but specific manufacture is required for each vehicle configuration
Solution Approach 1:
The patent makes the end piece detachable and replaceable, allowing the configuration of the angled contact surface to be adjusted dynamically based on the specific vehicle layout and engine component positions. Different end pieces with different angles can be installed on the same master cylinder to accommodate various vehicle configurations, eliminating the need for completely different master cylinders for each application
Data Source
Figure 1
Figure 2~4A
Figure 4B~4D
AI summary
The cylinder (1) has an end (3) arranged opposite to an element e.g. battery, of an engine and another end (4) integrated with a brake system. An insert (7) is assembled on the former end of the cylinder, where the insert comprises a contact surface (10) e.g. round surface, at an end (9) of the insert opposite the cylinder. The contact surface is arranged opposite the element and not perpendicular to a development axis (6) of the cylinder. The contact surface of the insert is developed in a plane inclined with respect to the development axis.