Dual Master Cylinder Brake Assembly with Quick-Fill Spool
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Solution Overview
Problem
Increased brake running clearances in vehicles require more hydraulic fluid volume, necessitating additional energy for pressurization, which is inefficient and requires a compact brake system that can take up clearances without additional hydraulic power components.
Innovation Solution
A hydraulic brake assembly with a quick-fill function, featuring a dual master cylinder design where a spool directs hydraulic fluid from a quick-fill chamber to the master cylinder chamber upon initial brake application, taking up clearances, and then to a tank when pressure reaches a threshold, allowing continued brake actuation with higher pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If brake running clearances are increased to improve fuel efficiency, then fuel efficiency is improved, but more hydraulic fluid volume is required and additional energy is needed for pressurization
Solution Approach 1:
The master cylinder piston is segmented into two portions with different diameters, creating two distinct chambers (quick-fill chamber and master cylinder chamber) that perform different functions. The larger diameter portion creates the quick-fill chamber for rapid clearance take-up, while the smaller diameter portion creates the master cylinder chamber for sustained brake pressure, allowing the system to handle increased fluid volume requirements without additional energy input.
Solution Approach 2:
The quick-fill chamber is pre-filled with hydraulic fluid and positioned to automatically supply fluid to take up brake clearances upon initial piston movement. This preliminary action of clearance take-up occurs before the main braking phase, eliminating the need for additional energy input during the braking process itself.
2Quantity of substance
If more hydraulic fluid volume is used to take up clearances, then clearance take-up capacity is improved, but additional energy for pressurization is required
Solution Approach 1:
The quick-fill chamber uses the initial movement of the master cylinder piston to automatically pressurize and distribute hydraulic fluid to take up brake clearances. The system serves itself by using the piston's own movement to generate the pressure needed for clearance take-up, eliminating the need for external hydraulic power components or additional energy input.
Solution Approach 2:
The invention uses hydraulic pressure generated by the master cylinder piston's movement to automatically take up clearances. The hydraulic system is designed so that the initial piston movement creates sufficient pressure to force fluid into the brake lines and take up clearances without requiring additional energy input from external sources.
3Device complexity
If a compact brake system is used to avoid additional components, then device complexity is reduced, but the ability to take up clearances without additional hydraulic power may be limited
Solution Approach 1:
The master cylinder piston serves multiple functions: it acts as both the actuating element for brake application and the pump element for clearance take-up. The dual-chamber design allows the same component to handle both rapid clearance elimination and sustained brake pressure generation, eliminating the need for separate hydraulic power components while maintaining full clearance take-up capability.
Solution Approach 2:
The quick-fill chamber is nested within the master cylinder assembly, with the larger diameter portion of the piston creating an internal chamber that is integrated into the overall master cylinder structure. This nested design allows the clearance take-up function to be incorporated within the existing brake system geometry without adding external components.
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
The system efficiently takes up brake clearances with initial brake application, reducing the need for additional hydraulic power components and maintaining effective brake pressure for vehicle retardation or stopping.
Implementation Method 1
direct hydraulic fluid from the quick-fill chamber to the master cylinder chamber and the brakes at a first pressure
Implementation Method 2
The hydraulic fluid from the quick-fill chamber takes up any clearance between the friction elements of the brakes
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A hydraulic brake assembly (12) includes a housing (24) having first and second side-by-side bores (30), each defining a respective master cylinder assembly. Each master cylinder assembly includes a master cylinder piston (32) slidably movable by actuation of a respective brake pedal (18a, 18b) to and between an active position and an inactive position. A spool (74) slidably disposed within a piston bore (70) of the master cylinder piston (32) is operable in a first mode to direct hydraulic fluid from a quick-fill chamber (62) to a master cylinder chamber (50) at a first pressure upon initial movement of the master cylinder piston (32) from the inactive position toward the active position. The spool (74) is operable in a second mode to direct hydraulic fluid from the quick-fill chamber (62) to a tank (20) when pressure in the master cylinder chamber (50) reaches a predefined threshold.