Hydraulic Brake Booster Length Reduction and Vibration Isolation
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Solution Overview
Problem
The existing hydraulic brake boosters have a lengthened overall structure due to multiple shafts, leading to degraded brake pedal feeling due to impact and vibration from the contact between the output shaft and control plunger.
Innovation Solution
The hydraulic brake booster design includes a control plunger with a guide having an inner diameter greater than the outer diameter of the output shaft, allowing them to move relative without contact, and incorporates a buffer member to absorb impact and an elastic member to restrict movement, reducing the overall length and improving brake pedal feeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple shafts are used to deliver pedal pressure and hydraulic pressure, then the brake system can achieve reliable pressure transmission, but the overall length of the brake booster is lengthened
Solution Approach 1:
The patent combines the functions of multiple shafts into a single integrated shaft structure. The output shaft integrates both pedal pressure transmission and hydraulic pressure delivery functions, eliminating the need for separate shafts and thereby reducing the overall length of the brake booster while maintaining reliable pressure transmission.
Solution Approach 2:
The output shaft is designed as a multi-functional component that simultaneously performs multiple tasks: transmitting pedal pressure from the input shaft, delivering hydraulic pressure to the wheel cylinder, and providing structural support. This universal design reduces the number of components and shortens the overall length.
2Force
If the output shaft and control plunger are in contact to transmit force, then force transmission is efficient, but impact and vibration are delivered to the brake pedal degrading brake pedal feeling
Solution Approach 1:
The patent introduces a buffer member as an intermediary element between the control plunger and the output shaft. This buffer member mediates the force transmission while absorbing impact and vibration, preventing harmful vibrations from reaching the brake pedal while still maintaining efficient force transmission for normal braking operations.
Solution Approach 2:
The buffer member is pre-installed between the control plunger and output shaft to provide cushioning before impact occurs. This beforehand cushioning absorbs sudden impacts and vibrations during braking, protecting the brake pedal from harmful vibrations while maintaining normal force transmission.
3Manufacturing precision
If the inner diameter of the control plunger guide is equal to the outer diameter of the output shaft for tight fit, then alignment precision is improved, but the control plunger and output shaft make contact causing vibration
Solution Approach 1:
The patent applies local quality by creating a localized gap between the control plunger guide and output shaft. The guide has an inner diameter slightly larger than the output shaft outer diameter, providing a small clearance that prevents contact and vibration while maintaining sufficient alignment precision for proper force transmission.
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 reduces the overall length of the hydraulic brake booster, minimizes vibration and impact transmission to the brake pedal, and enhances brake pedal feeling by preventing pressure variation from the master cylinder from being delivered to the pedal.
Implementation Method 1
the control plunger includes a buffer member provided in the receiving groove to absorb impact occurring due to contact between the control plunger and the output shaft in sudden braking
Implementation Method 2
an elastic member is mounted on the second step surface to restrict a movement range of the control plunger and to absorb impact
Data Source
AI summary
Disclosed is a hydraulic brake booster. A relative movement structure of a control plunger and an output shaft is modified in such a manner that the output shaft operates in the control plunger, thereby reducing the overall length of the booster and the manufacturing cost. An inner circumferential surface of a guide of the control plunger does not make contact with an outer circumferential surface of the output shaft, so that the vibration and the impact caused by the contact between the control plunger and the output shaft are not delivered, thereby improving brake pedal feeling. The control plunger includes a guide having a groove, and an inner diameter of the guide is greater than an outer diameter of the output shaft. The control plunger and the output shaft perform relative movement in the overlap state therebetween, thereby reducing the overall length of the booster and the manufacturing cost.