Master Cylinder Valve Module for Efficient Brake Fluid Resupply
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Solution Overview
Problem
Conventional tandem master cylinders face a contradiction between sealing and resupply functions, limiting the flow rate necessary for advanced braking systems, particularly in dual-circuit hydraulic systems that require efficient resupply for service and emergency braking.
Innovation Solution
A tandem master cylinder design featuring a piston with a reduced section nose and a valve module that controls communication between the brake fluid reservoir and chamber, allowing direct and efficient resupply without pressure loss, eliminating the need for cups and simplifying manufacturing and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cups are used to provide both sealing and resupply functions, then the sealing function is improved, but the resupply function is limited and slow
Solution Approach 1:
The invention separates the sealing function and resupply function into distinct components: seals provide sealing while a dedicated valve module (with float valve and cam mechanism) provides resupply. This segmentation allows each component to be optimized for its specific function, resolving the contradiction between reliable sealing and efficient resupply.
Solution Approach 2:
The invention extracts the resupply function from the cup component and implements it through a separate valve module. The cup is reduced to providing only sealing, while the valve module (with float valve, cam, and drill hole arrangement) handles resupply, enabling high flow rates without compromising sealing reliability.
2Productivity
If the drill hole issues into the chamber upstream of the piston, then direct communication with the reservoir is enabled, but the piston structure becomes more complex with a reduced section nose
Solution Approach 1:
The invention applies local quality by creating a reduced section nose specifically at the upstream portion of the piston where it interacts with the cam mechanism. This localized structural modification enables the piston to engage the cam for valve control without requiring complete redesign of the entire piston, thus achieving direct resupply communication while minimizing overall structural complexity.
Solution Approach 2:
The invention introduces a cam mechanism as an intermediary between the piston and the float valve. The cam translates piston movement into valve opening/closing action, allowing the drill hole to issue upstream for direct reservoir communication while the cam mediates the control function, reducing the need for complex direct piston-valve integration.
3Ease of manufacture
If the cup is eliminated and replaced with a seal and valve module, then manufacturing and assembly are simplified, but the resupply control mechanism becomes more complex
Solution Approach 1:
The float valve mechanism is designed to be self-regulating: it automatically opens when reservoir pressure exceeds chamber pressure and automatically closes when chamber pressure equals or exceeds reservoir pressure. This self-service capability eliminates the need for complex external control systems, simplifying manufacturing while providing reliable resupply control.
Solution Approach 2:
The cam mechanism serves multiple functions: it controls the float valve timing, guides the piston movement, and enables the reduced section nose to engage properly. This multi-functionality reduces the need for separate control components, simplifying manufacturing and assembly while providing the necessary valve control for the upstream drill hole configuration.
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 design enables instantaneous and efficient resupply of the chamber, reducing the risk of pressure loss and reverse cup positioning, allowing for improved operation without altering the driver's experience and enabling the master cylinder to support advanced braking functions.
Implementation Method 1
a valve module installed in said drill hole to control communication between said reservoir and said chamber as a function of the position of said piston and the pressure in said chamber with respect to the pressure in said reservoir
Implementation Method 2
an elastic connector between said check mechanism and said valve to enable elastic compression of said check mechanism by the pressure applied to it when in its expanded state
Data Source
AI summary
A master cylinder is described. The master cylinder includes a chamber delimited by a piston and supplied from a brake fluid reservoir installed on the top of the master cylinder by an end fitting engaged in a nozzle on the body of the master cylinder. The piston has a nose of reduced section upstream of its skirt guided in the bore hole of the master cylinder and the nozzle is connected to the chamber by a drill hole issuing into the chamber at least partly upstream of the piston in rest position. A valve module is installed in the drill hole to manage communication between the reservoir and the chamber as a function of the position of the piston and the pressure in the chamber with respect to the pressure in the reservoir.