Reduced Profile Brake Actuator Diaphragm Compression
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Solution Overview
Problem
Conventional brake actuators have a large profile due to enlarged and outwardly deformed peripheral edges on the diaphragm, which require additional external structures, limiting the space available for brake actuators on vehicles and reducing the functional surface area.
Innovation Solution
The use of a diaphragm with a consistent or slightly enlarged cross-sectional thickness, compressed between opposing points of contact on the base and housing cup, eliminates the need for enlarged peripheral edges and additional flanges, allowing for a reduced overall diameter and profile of the brake actuator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the diaphragm has an enlarged and outwardly deformed peripheral edge to prevent pullout, then the resistance to diaphragm pullout is improved, but the overall profile of the brake actuator increases and the functional surface area is reduced
Solution Approach 1:
The patent moves the diaphragm sealing edge from a radial extension (outwardly deformed) to an axial compression configuration. Instead of enlarging the diaphragm radially to prevent pullout, the sealing edge is compressed axially between the base and housing cup, utilizing the axial dimension for sealing while maintaining a compact radial profile.
Solution Approach 2:
Conventional designs enlarge the diaphragm periphery radially to prevent pullout. This patent inverts the approach by using axial compression force to create the seal and prevent pullout, reversing the traditional direction of the sealing mechanism from radial to axial.
2Reliability
If the diaphragm peripheral edge is enlarged and outwardly deformed, then the diaphragm is prevented from being pulled through the gap, but additional external structures such as flanges, clamps or clips are required which increase the brake actuator profile
Solution Approach 1:
The patent combines the diaphragm sealing function with the housing structure by integrating the sealing mechanism directly into the base and housing cup assembly. The axial compression sealing edge is incorporated into the housing parts themselves, eliminating the need for separate external structures like flanges, clamps, or clips.
Solution Approach 2:
The patent extracts and eliminates the need for additional external structures (flanges, clamps, clips) by implementing a self-contained axial compression sealing system that is integral to the housing design, removing unnecessary components while maintaining sealing effectiveness.
3Force
If the functional surface area of the diaphragm is maximized, then the force and release pressure of the actuator are improved, but the space required for the brake actuator on the vehicle axle increases
Solution Approach 1:
The patent maximizes the functional surface area of the diaphragm by eliminating radial extensions and using axial compression for sealing. This allows the diaphragm to maintain a large active surface area for force generation while keeping the overall radial profile compact, enabling efficient use of limited axial space on the vehicle axle.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances the resistance to diaphragm pullout, maintains the functional surface area, and reduces the overall profile of the brake actuator without compromising its life, enabling smaller structures to hold the housing parts together.
Implementation Method 1
having a peripheral edge compressed between a first rounded point of contact on the first peripheral wall and a second rounded point of contact on the second peripheral wall
Data Source
Figure 1A~2B
Figure 3A~5B
Figure 6
AI summary
A brake actuator can include a first housing part having a first peripheral wall, a second housing part having a second peripheral wall, and a flexible diaphragm located between the first housing part and the second housing part and compressed between a point of contact on the first housing part and a point of contact on the second housing part. At least one of the points of contact may protrude inwardly from the peripheral walls. The diaphragm may have a peripheral edge that does not extend radially beyond at least one of cylindrical profiles defined by the housing parts.