Integrated Brake Secondary Pump Adjustor for Simpler Assembly
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Solution Overview
Problem
Conventional adjusters for secondary pumps in brake systems have complex structures, are difficult and time-consuming to assemble, and are costly, with heavy metal components that complicate manufacturing and reduce production efficiency.
Innovation Solution
A simplified adjustor design featuring a main body with a cylinder and handle, a piston, a blocking member, and a rod, made from lightweight materials like nylon and aluminum, with a focus on integrally formed components for improved sealing and reduced assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional adjuster components are made as independent metal parts, then the adjuster provides reliable function, but the structure becomes complex, assembly becomes difficult and time-consuming, and production cost increases
Solution Approach 1:
The patent merges multiple independent adjuster components into a single integrated body formed by injection molding. The main body incorporates the cylinder, piston, blocking member, and handle as unified structures, eliminating the need for separate metal parts and complex assembly procedures while maintaining the adjuster's functional reliability
Solution Approach 2:
The injection-molded main body performs multiple functions simultaneously: it provides the cylinder chamber for piston movement, incorporates the blocking member mechanism, includes the handle for operation, and integrates sealing elements. This multi-functionality reduces the number of separate components needed
2Strength
If conventional adjuster components are made of metal, then the adjuster achieves sufficient strength, but the overall weight increases, manufacturing becomes difficult, and production efficiency decreases
Solution Approach 1:
The patent changes the material parameter from metal to thermoplastic resin, which enables injection molding manufacturing. This parameter change reduces weight while maintaining sufficient strength for brake adjuster application, and dramatically improves production efficiency through high-speed molding cycles
Solution Approach 2:
The patent uses thermoplastic resin as the primary material for the adjuster body, which can be considered a composite approach combining polymer materials with integrated design. This material selection provides adequate mechanical strength while enabling efficient mass production through molding processes
3Adaptability or versatility
If conventional adjuster has numerous independent components, then the adjuster can be designed with specialized functions, but assembly becomes complex and time-consuming
Solution Approach 1:
The patent combines multiple specialized components (cylinder, piston, blocking member, handle) into a single injection-molded body, eliminating the need for separate assembly operations. This merging maintains the specialized functions of each component while reducing assembly time to virtually zero for the integrated structure
Data Source
AI summary
An adjustor for a secondary pump of a brake is provided, including: a main body, being integrally formed of one piece, including a cylinder and a handle connected to the cylinder, the cylinder having a chamber thereinside, the handle having a passage in communication with the chamber; a piston, movably received in the chamber; a blocking member, connected to the cylinder; and a rod, connected to the piston and extending through the cylinder.