Dual-Core Brake Master Pump Structure for Low-Friction Sealing
Solution Overview
Problem
Existing brake upper pumps face issues such as increased friction resistance, component wear, oil leakage, and poor braking feel due to enlarged piston seals and springs, leading to high maintenance costs and inconsistent braking performance.
Innovation Solution
A nested brake upper pump with a dynamic and static dual-core structure, featuring a fixed piston cylinder sleeve and movable piston push rod assembly with reduced sealing ring size and independent components, optimized oil circuit, and stable motion trajectory.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the piston seal size is enlarged to increase unit stroke oil push volume, then the braking force is improved, but the friction resistance between the piston seal and inner wall increases
Solution Approach 1:
The piston seal is divided into two independent seals: a front piston seal and a rear piston seal. The front piston seal has a larger diameter to provide sufficient braking force, while the rear piston seal has a smaller diameter to reduce friction resistance. This segmentation allows each seal to be optimized for its specific function without compromising the other.
Solution Approach 2:
Different regions of the piston assembly are given different sealing characteristics. The front piston seal uses a larger diameter rubber seal for high friction and sealing force, while the rear piston seal uses a smaller diameter sealing ring for reduced friction. This local differentiation of sealing properties resolves the contradiction between needing high braking force and minimizing friction resistance.
2Reliability
If a piston spring with greater elasticity is used to enable automatic reset, then the sealing reliability is improved, but the boost hardness and user experience deteriorate
Solution Approach 1:
The spring system is segmented into two independent springs: a front piston spring and a rear piston spring. The rear piston spring provides the necessary elastic force for automatic reset and sealing reliability, while the front piston spring assists with a softer characteristic. This segmentation allows the rear spring to be optimized for reliability without compromising user experience.
Solution Approach 2:
The front piston spring acts as an intermediary that softens the overall boost feel while the rear piston spring maintains sealing reliability. The combination of these two springs with different characteristics mediates between the conflicting requirements of hard reset force and soft user experience.
3Productivity
If the piston push rod moves back and forth constantly, then the braking operation is improved, but the component wear and deformation increase
Solution Approach 1:
The piston push rod is segmented into a front piston push rod and a rear piston push rod that can move independently. This segmentation allows each push rod to have optimized motion characteristics, reducing lateral forces and improving sealing contact, thereby reducing wear and deformation during constant back-and-forth movement.
Solution Approach 2:
The piston push rod assembly is designed with dynamic characteristics that allow it to adapt to braking forces. The independent movement capability of the segmented push rods allows them to self-align and reduce lateral forces during operation, minimizing wear and deformation while maintaining effective braking operation.
4Ease of repair
If the inner wall of the piston cavity is scratched, then the maintenance requirement is triggered, but the replacement cost increases
Solution Approach 1:
The brake pump assembly is segmented into independent replaceable components: piston seals, piston springs, and piston push rods. This segmentation allows for easy replacement of worn components without replacing the entire pump body, reducing maintenance costs and improving ease of repair.
Solution Approach 2:
The design allows for selective replacement of worn components (seals, springs, push rods) while retaining the main pump body. This approach enables recovery of the expensive pump body and only replaces the cheaper wearable parts, significantly reducing replacement costs while maintaining ease of repair.
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
Reduces friction resistance, minimizes wear and leakage, enhances braking feel, and lowers maintenance costs by using a stable dual-core structure with independent components and optimized oil circuit.
Implementation Method 1
a piston spring with greater elasticity is required (for example, the wire diameter of the spring is increased)
Implementation Method 2
the piston oil seal is constantly scraped against the inner wall of the piston cavity
Implementation Method 3
the piston cavity is filled with brake oil
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Provided herein is a nested brake upper pump with a dynamic and static dual-core structure including a brake pump body (1) provided with an oil chamber; a piston push rod assembly (2); a brake handle (3). The piston push rod assembly (2) includes: a fixed piston cylinder sleeve (21) having a cylinder sleeve through hole and forming a large diameter section (11a) and a small diameter section (11b) in the oil chamber; a moving piston push rod movably arranged in the oil chamber. The moving piston push rod includes an oil pushing section and a transmission section at least partially penetrated in the cylinder sleeve through hole; a large diameter piston oil seal located in the large diameter section; a small diameter piston oil seal (23) located in the small diameter section (11b); a fixed sealing ring sleeved on the outer wall of the fixed piston cylinder sleeve (21).