Brake Booster Reinforcement Plate Fixing Structure
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Solution Overview
Problem
The challenge is to easily fix a reinforcement plate to a front cell in a tie-rod type brake booster, as the conventional caulking method is complicated and increases manufacturing costs due to the reduced thickness and material changes in the front cell, which can lead to deformation issues.
Innovation Solution
A fixing structure is introduced where a reinforcement plate with a through hole is used, and a support member with a bent portion is formed at the penetration point of the front cell, allowing the reinforcement plate to be fixed by a pressing portion that extends perpendicularly from the bent portion, either pressing the rear or front surface of the reinforcement plate, simplifying the installation process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcement plate is installed at the front cell to prevent deformation, then the rigidity of the front cell is improved, but the fixing process becomes complicated and manufacturing costs increase
Solution Approach 1:
The support member is divided into distinct functional segments: a bent portion that fits within the through hole and a pressing portion that extends outward to apply force to the reinforcement plate. This segmentation allows each part to perform its specific function efficiently while simplifying the overall installation process.
Solution Approach 2:
The support member acts as an intermediary component between the front cell and the reinforcement plate. It provides a mechanical connection that simplifies the fixing process by eliminating the need for complex caulking operations, thereby reducing manufacturing complexity while maintaining structural integrity.
2Weight of moving object
If the front cell thickness is reduced to decrease component weight, then the weight of the front cell is reduced, but the front cell becomes prone to deformation
Solution Approach 1:
The solution combines the thin front cell material with a reinforcement plate to create a composite structure. The reinforcement plate provides the necessary structural strength and deformation resistance, while the thin front cell maintains weight reduction benefits. The support member facilitates the connection between these components.
3Reliability
If a reinforcement plate is caulked to the front cell to ensure secure fixing, then the reliability of the connection is improved, but the manufacturing complexity and costs increase
Solution Approach 1:
The pressing function is extracted from the reinforcement plate itself and transferred to a separate support member. This allows the reinforcement plate to maintain its simple flat structure while the support member provides the necessary pressing action, thereby reducing overall structural complexity while maintaining connection reliability.
Solution Approach 2:
The support member is designed to be formed from the front cell material itself (through bending), allowing it to provide self-contained support and fixing functionality without requiring additional complex fastening mechanisms or external components.
Data Source
AI summary
A tie rod-type brake booster including a casing provided with a front cell and a rear cell, the front cell and the rear cell sealingly joining to each other, a tie rod caulked to the rear cell through the casing, a reinforcement plate to closely contact an inner surface of the front cell to enhance rigidity of the casing, the reinforcement plate being provided with a through hole penetrated by the tie rod, and a support member formed at a penetration portion of the front cell penetrated by the tie rod to fix the reinforcement plate, wherein the support member comprises a bent portion bent from the penetration portion of the front cell, and a pressing portion perpendicularly extending from the bent portion with respect to an axial direction of the tie rod.