Cup-Shaped Spring Retainer for Brake Master Cylinder Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing master cylinder brake systems face issues with structural rigidity and debris generation during assembly, particularly due to the design of spring retainers with short slots and snap-in motion, which can lead to misalignment and increased debris production.
Innovation Solution
A cup-shaped spring retainer with recesses on its side wall for structural rigidity and a method of assembling the spring and retainer into a piston, involving radial force application to deflect fingers, gradual release, and axial engagement to reduce debris and ensure proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the spring retainer uses short slots with snap-in motion for assembly, then the assembly process is simpler, but structural rigidity is reduced and misalignment occurs
Solution Approach 1:
The side wall is segmented into multiple regions by introducing recesses that divide the wall into distinct sections. This segmentation allows the side wall to maintain structural rigidity while accommodating longer slots, as each segment between recesses acts as a rigid support element preventing excessive deformation during assembly.
Solution Approach 2:
The recesses are positioned at specific locations along the side wall to provide dimensional support. By strategically placing these recesses, the design adds structural support in the radial dimension while allowing the slots to extend further axially, thus maintaining rigidity without compromising assembly simplicity.
2Ease of manufacture
If the parting line is located on the rubbing surface during molding, then manufacturing is easier, but debris is generated during assembly
Solution Approach 1:
The parting line is extracted from the rubbing surface and relocated to a non-critical area. By positioning the parting line within the recesses rather than on the rubbing surfaces, the design separates the molding ejection path from the friction contact zones, eliminating debris generation while maintaining manufacturing feasibility.
Solution Approach 2:
The recesses serve as intermediary zones that accommodate the parting line. These recesses act as a buffer region where the mold separation occurs, shielding the rubbing surfaces from direct contact with the parting line and preventing debris generation in the friction zones.
3Manufacturing precision
If longer slots are used in the spring retainer, then alignment is improved, but structural rigidity is reduced
Solution Approach 1:
The side wall is divided into rigid segments by the recesses, with each segment providing structural support. This segmentation allows the slots to extend longer for improved alignment while the recesses prevent the side wall from becoming too flexible, maintaining sufficient rigidity despite the increased slot length.
Solution Approach 2:
The side wall structure functions as a composite design where the solid material between recesses provides rigidity while the recesses and longer slots provide alignment tolerance. This composite approach combines the benefits of both rigid support and alignment precision.
Data Source
AI summary
A cup shaped spring retainer is slidably disposed within a cup shaped piston, encapsulating a spring therebetween. The side wall of the spring retainer presents a plurality of recesses and a plurality of slots defining a plurality of fingers. A tang, projects radially outward at the distal end of each of the fingers to engage a retaining ring within the piston in a latch position. The combination of the spring retainer and the piston provide an arrangement whereby all of the fingers may be compressed with the spring retainer outside of the piston to an insert position with the tangs disposed in gripping engagement with the spring. After inserting the compressed spring retainer into the piston, the radial compression the of the fingers may be released to allow the fingers to expand from the insert position to the latch position at which point the deflection of the fingers is discontinued.