Pneumatic Brake Booster Return Spring with Integrated Filter Support
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Solution Overview
Problem
Existing pneumatic brake boosters for hydraulic braking systems require additional components like dedicated filter supports, increasing costs and assembly time, while lacking a reliable mechanism to maintain the filter's position during operation.
Innovation Solution
Incorporating a return spring with a dead coil at one end to support the filter, eliminating the need for a dedicated filter support and reducing complexity, the return spring biases the control rod and maintains the filter's position within the booster.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dedicated filter support component is added to maintain filter position, then the filter's positional stability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the filter support function with the return spring by adding a flange to the spring. This flange contacts the filter to maintain its position during operation. By merging two functions (return spring operation and filter support) into a single component, the design eliminates the need for a separate dedicated filter support, thereby reducing device complexity and manufacturing cost while maintaining filter positional stability
Solution Approach 2:
The return spring is designed to perform multiple functions: it provides the return force to reset the valve mechanism and simultaneously supports the filter in its operational position through the flange. This multi-functionality approach allows a single component to address both the operational return mechanism and the filter positioning requirement, reducing the total number of parts needed in the system
2Reliability
If a dedicated filter support component is added, then the filter's positional stability is improved, but the assembly time increases
Solution Approach 1:
By integrating the filter support flange directly onto the return spring, the design eliminates the need for a separate assembly step for installing a dedicated filter support component. The filter can be positioned and supported by the spring-flange combination in a single assembly operation, thereby reducing total assembly time while ensuring reliable filter positioning
3Ease of manufacture
If the return spring is modified to include a flange for filter support, then the overall manufacturing cost is reduced, but the spring's structural complexity increases
Solution Approach 1:
The flange is integrated as part of the return spring structure, allowing the spring to be manufactured as a single piece with the flange attachment. This merging of functions into one component eliminates the need for separate filter support parts and their associated manufacturing and assembly costs, making the overall system more cost-effective despite the slightly increased complexity of the spring itself
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 cost and assembly time of the brake booster by using the return spring to stabilize the filter, ensuring reliable airflow filtration without additional support structures, enhancing the booster's operational reliability.
Implementation Method 1
The return spring is compressed when the valve opens and expands to close the valve when the brake pedal is released
Implementation Method 2
the dead coil is configured to contact the filter and maintain the position of the filter within the booster
Data Source
AI summary
A brake system includes a vacuum booster, a valve positioned within the vacuum booster, the valve including a valve member connected to a rod, the rod configured to move in a linear direction, an air filter positioned within the vacuum booster, and a return spring positioned within the vacuum booster. The return spring includes a first end and a second end with a plurality of coils extending between the first end and the second end. The first end includes a first coil and a second coil positioned radially outward from the first coil, and the first coil is configured to contact the rod and the second coil is configured to support the filter.