Brake Booster Return Spring Adjustability
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Solution Overview
Problem
Conventional brake boosters experience vibration issues due to the elastic restoring force of the return spring, which affects the operation feeling and is difficult to adjust, especially in limited spaces within the poppet valve.
Innovation Solution
A brake booster design featuring a return spring structure located outside the poppet valve body, with a spring housing and retainer that allows for adjustable elastic force, including a coupling mechanism and air vent hole to prevent noise, enabling easier adjustment and fixing of the return spring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the return spring is disposed inside the poppet valve body with a coupling structure, then the poppet valve can return to initial state using elastic force, but the elastic force cannot be adjusted and vibrations are generated due to limited space
Solution Approach 1:
The return spring is relocated from the internal space of the poppet valve body to the external space around it. Specifically, the return spring is disposed between the diaphragm and the poppet valve body, utilizing the external dimensional space rather than the constrained internal space, thereby enabling adjustability without compromising the return function
Solution Approach 2:
A coupling structure comprising a coupling protrusion and coupling groove is introduced as an intermediary mechanism. This coupling structure mediates between the return spring and the poppet valve body, transmitting the elastic force while allowing for adjustable positioning. The coupling structure enables the return spring to be positioned at different locations to adjust the elastic force magnitude
2Speed
If the return spring directly receives impulsive load when brake pedal is suddenly operated, then the poppet valve returns quickly, but vibrations are generated and transferred to the brake pedal
Solution Approach 1:
The return spring is positioned to engage with the coupling structure in advance, creating a cushioning effect. The coupling structure with its protrusion and groove design provides a controlled engagement mechanism that cushions the impulsive load before it reaches the poppet valve body, reducing vibrations while maintaining return speed
Solution Approach 2:
The coupling structure acts as an intermediary between the return spring and the poppet valve body. It absorbs and dampens the impulsive vibrations generated during sudden brake pedal operation while still transmitting the necessary elastic force for the return motion, preventing direct vibration transfer to the brake pedal
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 allows for customizable operation feeling by adjusting the elastic force, improving driver comfort and reducing vibrations, as the return spring can be easily fixed and adjusted to match individual preferences.
Implementation Method 1
the poppet valve may return to an initial state using an elastic force of the return spring when the input of the brake pedal is released
Implementation Method 2
a brake booster provided to boost a pedal force of the brake pedal using a difference between a negative pressure (a vacuum pressure) and an atmospheric pressure generated from an engine
Data Source
AI summary
A brake booster is provided. The brake booster includes a poppet valve body configured to open a path for atmospheric pressure to be introduced into a variable pressure chamber by an operation rod linked with a brake pedal, and a return spring structure disposed on an outer side of the poppet valve body and configured to adjust an elastic force provided to the poppet valve body when an input of the brake pedal is released.