Master Cylinder Control Element for Brake Flow Resistance
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Solution Overview
Problem
Existing master cylinders in regulated braking systems face high flow resistance due to small cross-section radial transverse bores, which hinders quick pressure medium delivery during control interventions, and solutions that increase bore diameter or number compromise stability or increase idle travel.
Innovation Solution
A master cylinder design featuring a ring-shaped control element in an outer groove with axial grooves or intermediate spaces between ribs, allowing for a larger flow cross-section while maintaining stability and simplifying production and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If small cross-section radial transverse bores are used for control passages, then idle travel is reduced and piston stability is maintained, but flow resistance becomes too great and pressure medium cannot be delivered quickly enough
Solution Approach 1:
The control element is divided into multiple segments with individual control passages, allowing each passage to be optimized for flow while maintaining overall structural stability. The segmented design enables parallel flow paths that collectively provide low resistance without requiring any single passage to be excessively large.
Solution Approach 2:
The control passages are configured to extend in multiple dimensions rather than simple radial holes, creating a three-dimensional flow network. This dimensional complexity allows for optimized flow paths that reduce resistance while maintaining compact geometry and acceptable idle travel.
2Ease of manufacture
If the number of transverse bores is increased to reduce flow resistance, then pressure medium flow improves, but piston stability deteriorates and manufacturing becomes economically unfavorable
Solution Approach 1:
Instead of adding numerous small radial bores that compromise structural integrity, the control element is segmented into controlled regions with optimized passage layouts. This segmentation provides sufficient flow paths while maintaining material continuity and structural stability.
Solution Approach 2:
The control passages are strategically positioned and sized according to local flow requirements rather than uniformly distributed. This local optimization ensures adequate flow resistance reduction in critical areas while preserving structural strength in load-bearing regions.
3Ease of manufacture
If transverse bore diameter is increased to reduce flow resistance, then pressure medium flow improves, but idle travel increases
Solution Approach 1:
The control passages utilize three-dimensional spatial configuration rather than simple radial holes, creating optimized flow paths that achieve low resistance without increasing the radial dimension that would extend idle travel.
Solution Approach 2:
The control element acts as an intermediary structure between the piston and housing, providing controlled flow paths through its specialized geometry. This intermediary design allows flow optimization independent of the main piston dimensions, preventing idle travel increase.
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
This design reduces flow resistance and improves dynamic behavior during control interventions, ensuring quick pressure medium delivery and better after-flow without compromising stability or increasing idle travel.
Implementation Method 1
a sealing element arranged in an annular groove in the housing
Implementation Method 2
control passages formed in the piston
Data Source
Figure 1
Figure 2~4
Figure 5
AI summary
The invention relates to a master cylinder, in particular for a controlled brake system, comprising at least one piston (46), which can be moved in a housing (2) and which is sealed with respect to a pressure chamber (7, 8) by means of a sealing element (5, 6) arranged in an annular groove (23, 24) of the housing (2), which can be connected to a supply chamber (11, 12) by means of control passages (51; 52; 53) formed in the piston (46). According to the invention, the piston (46) comprises at least two parts, having a main body (47) and an annular control element (48; 49; 50), wherein the control passages (51; 52; 53) are provided in the control element (48; 49; 50).