Master Cylinder Piston Convex Surface Reduces Free Travel
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Solution Overview
Problem
Current master cylinder designs face challenges in reducing free travel while maintaining a sufficient seal and flow rate to ensure effective braking, as existing solutions either compromise on seal integrity or do not adequately reduce free travel.
Innovation Solution
A master cylinder piston with a convex rounded surface forming an inclined wall, where the orifice is situated wholly on this surface, ensures a sufficient flow rate and perfect seal by preventing separation of the inner lip, even when the orifice is not directly facing the supply duct, thus reducing free travel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the orifice is positioned to face the supply duct in the rest position, then the flow rate of hydraulic fluid is sufficient, but the free travel cannot be reduced
Solution Approach 1:
The piston features a convex rounded surface (incurved convex rounded surface) instead of a flat surface. This curvature allows the orifice to be positioned on the rounded surface such that it is wholly situated there, enabling the orifice to face the supply duct while the sealing lip can contact the rounded surface at multiple points, thus reducing free travel while maintaining sufficient flow rate
2Length of moving object
If the orifice is positioned away from the supply duct to reduce free travel, then the free travel is reduced, but the seal integrity is compromised
Solution Approach 1:
The convex rounded surface provides a continuously curved sealing surface that allows the sealing lip to maintain contact across the rounded surface. This curvature ensures that even when the orifice is positioned to reduce free travel, the sealing lip can still make perfect contact with the rounded surface, maintaining seal integrity while achieving reduced free travel
3Length of moving object
If a frustoconical portion with inclined wall is used, then the free travel is reduced, but the seal separation occurs
Solution Approach 1:
The convex rounded surface replaces the frustoconical inclined wall. The rounded surface provides a continuously curved geometry that prevents the sealing lip from separating, unlike the frustoconical portion which creates a junction zone. The curvature ensures stable contact across the entire sealing surface while maintaining reduced free travel
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 convex rounded surface ensures a perfectly sealed contact between the sealing cup and the piston, maintaining a high flow rate and significantly reducing free travel, thereby enhancing braking responsiveness and reliability.
Implementation Method 1
The convex rounded surface ensures a perfectly sealed contact between the sealing cup and the piston
Implementation Method 2
A master cylinder supplies a hydraulic circuit with hydraulic fluid
Data Source
AI summary
The invention relates to a master cylinder (1) with reduced free travel (23). Current master cylinders have a free travel during the displacement of a piston (6) in a bore (5) of a master cylinder body (3). Such a free travel may be reduced with the aid of a frustoconical portion (24) in the piston, an orifice (14) for communication of hydraulic fluid being situated on said inclined wall, a gap (26) between the inclined wall and an inner wall (12) of the bore allowing a passage for hydraulic fluid capable of filling a pressure chamber (4). However, such inclined walls create a change in the slope of an outer wall (29) of the piston, this change being able to cause a separation of an inner lip (19) of a sealing cup (17). To prevent this separation, the invention provides that the inclined wall forms a convex rounded surface (32).