Brake Master Cylinder Piston Stop with Deep Slots
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Solution Overview
Problem
Existing brake master cylinder assemblies are structurally complex, leading to high manufacturing and assembly costs, and can suffer from hydraulic leakage and sealing issues due to tight contact between the piston stop and piston, which causes debris and compromises the sealing effect.
Innovation Solution
A master cylinder assembly with a piston stop that snaps into the piston, featuring deep slots on its circumferential wall and an 'R'-shaped lead for easy assembly, along with radially extending grooves and a flange for improved brake fluid circulation, reduces parts and assembly stress, enhancing the sealing performance and manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the piston stop is assembled by threaded connection or riveting, then the connection is secure, but the structure becomes complicated and manufacturing cost increases
Solution Approach 1:
The piston stop is integrated directly with the piston body, eliminating separate fastening components (screws, pins, spring seats) and reducing the number of parts from 4-5 to fewer components. The piston stop forms an integral part of the piston structure, achieving secure connection without additional fastening elements.
Solution Approach 2:
The piston stop structure serves multiple functions: it provides mechanical support, acts as a mounting surface for the spring, and integrates with the piston body. This multi-functional design eliminates the need for separate components and simplifies the overall assembly.
2Volume of moving object
If the spring is enclosed in the piston stop, then the structure is compact, but the clearance is too small causing contact between spring and piston stop
Solution Approach 1:
The spring is extracted from the enclosed space within the piston stop and repositioned in the cavity of the piston body. This extraction provides sufficient clearance between the spring and piston stop, preventing contact and avoiding plastic debris generation that would compromise sealing.
Solution Approach 2:
The spring positioning is changed from a radial enclosure (within piston stop bore) to an axial arrangement (in piston cavity). This dimensional repositioning creates adequate clearance while maintaining the compact overall structure.
3Productivity
If the piston stop is forced assembled onto the piston, then the assembly is complete, but debris is produced and sealing effect is compromised
Solution Approach 1:
Deep slots are pre-formed on the circumferential wall of the piston stop before assembly. These slots create elastic deformation zones that allow the piston stop to flex during assembly, enabling smooth insertion without forced contact that would generate debris and compromise sealing.
Solution Approach 2:
The rigidity of the piston stop is locally modified by introducing deep slots, which create elastic deformation capability. This parameter change allows the piston stop to adapt during assembly, preventing tight contact and debris generation while maintaining structural integrity.
4Strength
If extra parts are used for piston stop assembly, then the connection is secure, but the manufacturing and assembling cost increases
Solution Approach 1:
Multiple functions previously requiring separate parts (fastening, spring mounting, structural support) are merged into the integrated piston stop structure. This eliminates the need for screws, pins, spring seats, and other extra parts, reducing both manufacturing complexity and cost.
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
The simplified assembly and design of the piston stop reduce debris production and improve sealing efficiency, facilitating quicker brake fluid circulation and lower production costs while maintaining reliable performance.
Implementation Method 1
a spring acting between the piston and the piston stop
Implementation Method 2
the piston stop snaps into the piston... deep slots extending axially and running through the thickness of the circumferential wall... elasticity of the piston stop can be improved
Data Source
AI summary
The present invention relates to a master cylinder assembly in a brake system and a piston stop. The master cylinder assembly comprises one or more piston assemblies. At least one of the piston assemblies comprises a piston (1), a piston stop (2) and a spring (3), wherein the piston stop (2) snaps into the piston (1), and the spring is retained between the piston (1) and the piston stop (2) and placed outside the piston stop (2). According to the present invention, on a circumferential wall of the piston stop (2) are provided deep slots (4) extending axially and running through the thickness of the circumferential wall, and these deep slots open towards one side of the piston stop where it snaps into the piston (1).