Master Cylinder Separator for Brake Gas Inhibition
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Solution Overview
Problem
Hydraulic systems in vehicles, such as motorcycles and ATVs, face reduced performance due to the presence of air bubbles and gases that can pass through compensating and intake ports, leading to latency and decreased responsiveness, especially during high-speed operations and competitive events.
Innovation Solution
A master cylinder assembly design that includes a separator aligned with the compensating port to prevent air bubbles from entering the pressure side of the system, while maintaining an open intake port without a separator to allow free fluid movement and gas venting, thereby enhancing system responsiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separator is placed over the compensating port to prevent air bubbles from entering the pressure side, then system responsiveness is improved, but fluid flow between the reservoir and cylinder is restricted
Solution Approach 1:
The separator is divided into an upper portion and a lower portion with a gap between them, allowing the separator to block air bubbles at the compensating port while still permitting fluid flow through the gap. This segmentation resolves the contradiction by creating distinct zones: the upper portion prevents air entry (improving reliability) while the gap maintains fluid communication (preserving quantity of substance).
Solution Approach 2:
The separator is positioned specifically at the compensating port location rather than covering the entire reservoir opening, and the gap between upper and lower portions is strategically placed to allow fluid flow. This localized approach ensures that air prevention function is achieved at the critical port area while fluid flow paths remain open through the gap.
2Quantity of substance
If the intake port is kept open without a separator to allow free fluid movement, then fluid flow is improved, but air bubbles can enter the system and reduce responsiveness
Solution Approach 1:
The separator structure with upper and lower portions creates a segmented barrier at the compensating port that selectively blocks air while permitting fluid passage through the gap, resolving the contradiction between fluid flow and air prevention.
Solution Approach 2:
The separator acts as an intermediary element at the compensating port that mediates between the need for fluid communication and the need to prevent air entry. The gap in the separator serves as an intermediate pathway that allows fluid to pass while the upper and lower portions intercept air bubbles.
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 reduces the flow of air bubbles into the hydraulic lines, improving the responsiveness and performance of the hydraulic system by isolating gases from the pressure side, especially during high-speed operations.
Implementation Method 1
A master cylinder assembly design that includes a separator aligned with the compensating port to prevent air bubbles from entering the pressure side of the system
Implementation Method 2
Hydraulic systems generally use an incompressible fluid to generate leverage and perform work (e.g., squeezing a brake pad or operating a clutch). In a hydraulic brake system, for example, when a brake lever is squeezed by a force, a push rod moves a piston in a master cylinder. Movement of the piston traps fluid within the master cylinder and increases the pressure within one or more hydraulic lines. The force is transmitted through the fluid in the hydraulic lines and acts on one or more caliper pistons to engage the brake pads against the rotors.
Implementation Method 3
Release of the brake lever allows the push rod and the piston in the master cylinder assembly to return back into its rest position, which may be assisted by a spring. The return action relieves the pressure within the hydraulic lines and allows the caliper pistons to disengage from the brake pads and thereby releasing the rotors.
Data Source
AI summary
Master cylinder assemblies, particularly for operation of the brake or clutch of motorcycles or other ATVs, are susceptible to a reduction in pressure due to the introduction of unwanted gases within the hydraulic lines. As a result, the brake or clutch system may not operate as designed. The present disclosure describes master cylinder assemblies that include one or more fluid separators, with a separator at least at the compensating port of the fluid reservoir to inhibit or prevent air or other gases from entering the piston channel through the compensating or inlet ports.