Electric Booster Reaction Disc Deformation Control
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Solution Overview
Problem
Conventional electric boosters for vehicles face issues with damage to the reaction disc due to uneven elastic deformation during motor-only or pedal-only operations, requiring additional components and increased device size to prevent damage, which complicates design, manufacturing, and assembly.
Innovation Solution
An electric booster design that includes a reaction disc, a disc holder, a screw nut, a screw bolt, a boosting block, and a pedal rod, with strategically formed gap parts to limit elastic deformation within set widths, preventing excessive stress on the reaction disc and reducing the need for additional components like buffer members or key members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional components such as buffer members or key members are added to prevent damage to the reaction disc, then the reliability of the reaction disc is improved, but the device complexity and size increase
Solution Approach 1:
The patent integrates the reaction disc and block member as a single unified component, eliminating the need for separate buffer members or key members. This merging approach maintains the protective function while reducing the number of parts and simplifying the overall structure, directly resolving the contradiction between reliability and device complexity
2Reliability
If additional components such as buffer members or key members are added to prevent damage to the reaction disc, then the reliability of the reaction disc is improved, but the manufacturing and assembly processes become more complex
Solution Approach 1:
By combining the reaction disc and block member into one integrated component, the patent reduces the number of manufacturing steps and assembly operations required. This eliminates the need to separately manufacture, quality-check, and assemble multiple protective components, thereby improving ease of manufacture while maintaining reliability
3Reliability
If the device size is expanded to accommodate additional protective components, then the reliability of the reaction disc is improved, but the adaptability to limited vehicle space is reduced
Solution Approach 1:
The integrated design of the reaction disc and block member eliminates the need for additional space-consuming components. This merging allows the booster device to maintain enhanced reliability while occupying less space, thereby improving adaptability to the limited space available in vehicle installations
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 solution effectively prevents damage to the reaction disc by limiting elastic deformation, simplifies the booster's structure, improves productivity, and reduces costs, while allowing for miniaturization to fit within limited vehicle space.
Implementation Method 1
a screw nut which is rotated in conjunction with an operation of a motor; a screw bolt which is linearly moved toward the reaction disc in conjunction with a rotation of the screw nut
Implementation Method 2
the amounts of elastic deformation in a portion of the reaction disc corresponding to a screw bolt and a portion thereof corresponding to the pedal rod are different from each other
Data Source
AI summary
An electric booster for a vehicle including: a disc holder accommodating a reaction disc, a screw nut rotated in conjunction with an operation of a motor, a screw bolt linearly moved in conjunction with a rotation of the screw nut, a boosting block disposed between the reaction disc and the screw bolt, and contacting a radially outer portion of the reaction disc when the screw bolt moves, a pedal rod contacting a radially central portion of the reaction disc through the screw bolt and the boosting block, a disc holder pressing hole connected to the screw bolt, and disposed to face the disc holder, and a first breakage prevention gap part formed between the disc holder and the disc holder pressing hole.