Master Cylinder Gap Flow Path for Residual Pressure Release
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Solution Overview
Problem
Existing master cylinders face challenges in ensuring operational reliability, reducing noise and vibration, maintaining constant piston stroke, preventing medium leakage and foreign substance ingress, and improving durability while promoting assembly and miniaturization.
Innovation Solution
The master cylinder design includes a hydraulic block with a main bore, a first piston connected to a brake pedal, a mounting block with a sub bore, a cap forming a gap flow path with the piston, and elastic members for pedal feel, along with bush members and a damper to guide piston movement and reduce noise and vibration. This configuration allows for efficient pressure release, reduced noise, and enhanced assembly and miniaturization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional master cylinder design is used, then structural simplicity is maintained, but operational reliability is insufficient and residual pressure cannot be quickly released
Solution Approach 1:
The master cylinder is divided into multiple functional blocks: a hydraulic block with main bores, a mounting block with sub bores, and a cap with gap flow paths. This segmentation allows each block to perform specific functions (pressure generation, piston guidance, pressure release) independently, improving operational reliability while managing complexity through modular design
Solution Approach 2:
The cap acts as an intermediary component between the first piston and the reservoir, creating gap flow paths that enable controlled communication between the first liquid pressure chamber and the reservoir. This intermediary structure facilitates quick residual pressure release without requiring direct connection, enhancing reliability while maintaining structural integrity
2Speed
If the piston moves quickly, then braking response is improved, but noise and vibration increase
Solution Approach 1:
The mounting block serves as an intermediary structure that guides piston movement through sub bores and provides mounting positions for dampers. This intermediary guidance system constrains piston motion paths, reducing erratic movements and associated noise/vibration while maintaining quick response capability
Solution Approach 2:
Dampers are pre-installed at mounting positions on the mounting block to cushion piston movement before impact occurs. These dampers absorb shocks and reduce vibrations generated during rapid piston displacement, allowing high-speed operation without excessive noise
3Reliability
If sealing components are added to prevent leakage, then medium leakage is prevented, but assembly complexity increases
Solution Approach 1:
Multiple sealing functions are merged into integrated sealing structures: seals are incorporated at interfaces between the hydraulic block and mounting block, between the mounting block and cap, and within the gap flow paths. This merging approach prevents leakage at multiple points simultaneously without proportionally increasing assembly complexity
Solution Approach 2:
The gap flow paths serve multiple functions: they enable pressure equalization between chambers, allow residual pressure release, and provide sealing surfaces. This multi-functionality reduces the need for separate sealing components, preventing leakage while maintaining assembly simplicity
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 enhances operational reliability by quickly releasing residual pressure, reducing noise and vibration, maintaining a constant piston stroke, preventing medium leakage and foreign substance ingress, and improving durability, while facilitating easier assembly and miniaturization of the product.
Implementation Method 1
a gap flow path formed by a gap between the first piston and the cap so that a first liquid pressure chamber partitioned by the first piston communicates with the connection port on the main bore
Implementation Method 2
an elastic member provided between the first piston and the second piston to provide a pedal feel
Implementation Method 3
bush members and a damper to guide piston movement and reduce noise and vibration
Implementation Method 4
bush members and a damper to guide piston movement and reduce noise and vibration
Data Source
AI summary
Disclosed herein is a master cylinder. The master cylinder according to the present embodiment includes a hydraulic block provided with a main bore formed therein in an axial direction, a first piston having one side inserted into the main bore to be displaceable and the other side exposed to an outside of the hydraulic block and connected to a brake pedal, a mounting block provided with a sub bore formed therein in the axial direction and the sub bore where the first piston is inserted thereinto to be displaceable and passes therethrough and a connection port connecting the sub bore and a reservoir, a cap provided on one side of the first piston, and a gap flow path formed by a gap between the first piston and the cap so that a first liquid pressure chamber partitioned by the first piston communicates with the connection port on the main bore.