Hydraulic Brake Coupling Valve for Pre-Filled Line Assembly
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Solution Overview
Problem
Existing hydraulic brake systems for handlebar-guided vehicles, such as bicycles, face challenges in delivering pre-filled systems that ensure safe transport, assembly, and automation while minimizing the risk of contamination and operational malfunctions due to incomplete seal removal during assembly.
Innovation Solution
A sensor device with a housing, coupling opening, locking device, and valve closing element that allows for pre-filled hydraulic systems to be delivered and assembled safely, featuring a diaphragm that opens upon insertion of the hydraulic line, ensuring secure sealing and automation through a design that includes a locking mechanism and insert to support the valve closing element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate plug is screwed into the sensor device's hydraulic connection to ensure a secure seal during transport, then the sealing reliability is improved, but the assembly time increases due to the need to remove the plug and attach additional covers
Solution Approach 1:
The patent combines the sealing function and the transport protection function into a single integrated valve closing element that is already mounted on the sensor device. This eliminates the need for separate plugs and covers, reducing assembly steps while maintaining sealing reliability. The valve closing element serves dual purposes: sealing the hydraulic connection during transport and enabling direct connection during assembly.
Solution Approach 2:
The valve closing element is pre-mounted on the sensor device during manufacturing, so that the sealing function is already in place before transport. This preliminary action eliminates the need for additional sealing operations during assembly, reducing assembly time while ensuring sealing reliability from the outset.
2Ease of operation
If the hydraulic brake is delivered pre-filled to the customer, then the filling and bleeding process can be simplified, but the risk of contamination during transport and assembly increases
Solution Approach 1:
The hydraulic system is pre-filled with brake fluid during manufacturing before the valve closing element is installed. The valve closing element is then mounted to seal the hydraulic connection, protecting the pre-filled system from contamination during transport and assembly. This allows the system to be delivered pre-filled while maintaining low contamination risk.
Solution Approach 2:
The valve closing element acts as an intermediary barrier between the pre-filled hydraulic system and the external environment. It seals the hydraulic connection during transport and assembly, preventing contamination while allowing easy connection when the line fitting is installed. This mediator enables pre-filled delivery without increasing contamination risk.
3Reliability
If a check valve is used as a sealing device to avoid contamination, then the sealing reliability is improved, but the device complexity increases
Solution Approach 1:
The patent merges the valve closing element with the sensor device housing, creating an integrated sealing solution. The valve closing element is mounted directly on the sensor device and works in conjunction with the housing structure, eliminating the need for separate check valve components. This integration maintains sealing reliability while reducing device complexity.
Solution Approach 2:
The valve closing element serves multiple functions: it seals the hydraulic connection during transport, prevents contamination, and enables easy connection during assembly. By combining these functions into a single component mounted on the sensor device, the patent avoids the need for multiple separate sealing devices, reducing complexity while maintaining reliability.
Data Source
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AI summary
The invention relates to a sensor device (100), in particular for a hydraulic brake or clutch of steerable vehicles, which has a housing (110) with a coupling opening (115) into which a line fitting (160) for coupling a hydraulic line (170) to the housing (110) can be arranged, and a locking device (140) which is designed and arranged such that the line fitting (160) can be locked in the coupling opening (115) with the locking device (140) as soon as the line fitting (160) is arranged in an operating position in the coupling opening (115) in which the sensor device (100) can be actuated to build up hydraulic pressure, wherein a valve device with a valve closing element (120) is arranged in the housing (110) which is designed and arranged such that the valve closing element (120) in a closed position opens the coupling opening (115). closes,when the pipe fitting (160) is not in the operating position in the coupling opening (115), and the valve closing element (120) opens the coupling opening (115) in an open position when the pipe fitting (160) is in the operating position in the coupling opening (115), wherein the valve closing element (120) is arranged and designed such that the valve closing element (120) surrounds the pipe fitting (160) when the pipe fitting (160) is in the operating position in the coupling opening (115).