Modular Vacuum Brake Booster Conical Rolling Section
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Solution Overview
Problem
Existing pneumatic brake boosters face inefficiencies and increased costs due to the need for multiple membrane versions to accommodate different stroke ranges, leading to reduced boosting force and response, as well as higher production and logistics costs.
Innovation Solution
A modular brake booster design featuring a booster housing with a conical section in the rolling area and an annular gap, allowing a single standardized diaphragm to be used across various stroke ranges, reducing material deformation, production costs, and preventing membrane damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple membrane versions are used to accommodate different stroke ranges, then the brake booster can be adapted to different vehicle applications, but the device complexity and production costs increase
Solution Approach 1:
The patent implements a universal diaphragm design that functions across multiple stroke ranges by introducing a conical section in the rolling area of the amplifier housing. This conical geometry allows a single standardized diaphragm to accommodate varying stroke requirements through controlled deformation patterns, eliminating the need for multiple specialized membrane versions while maintaining adaptability to different vehicle applications.
Solution Approach 2:
The invention changes the geometric parameters of the housing rather than the diaphragm itself. By providing a conical section with specific angle ranges (5°-15°) in the rolling area, the system allows the same diaphragm to adapt to different stroke ranges through parameter variation in the housing structure, thereby reducing component variety while maintaining versatility.
2Area of stationary object
If the radial distance between the diaphragm plate and booster housing is minimized, then the pneumatically effective surface area is maximized, but the membrane may suffer from excessive deformation and damage
Solution Approach 1:
The patent applies local quality by creating a conical section specifically in the rolling area where the diaphragm deformations occur most intensely. This localized geometric feature with controlled angle (5°-15°) provides structural support precisely where needed, allowing the radial distance to be minimized for maximum effective area while preventing excessive deformation and membrane damage through the reinforced conical geometry.
3Ease of manufacture
If a standardized diaphragm is used across all stroke ranges, then production costs and part variety are reduced, but the diaphragm may not maintain full contact with the plate at maximum stroke
Solution Approach 1:
The invention introduces dynamics by creating a conical rolling area that adapts to different stroke ranges. The conical geometry (5°-15° angle) allows the rolling fold to dynamically adjust its position and deformation pattern based on the specific stroke requirement, ensuring that a standardized diaphragm maintains full contact with the plate at maximum stroke across all applications while simplifying production.
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 maintains efficiency and reduces part variety and production costs, while ensuring the membrane remains in full contact with the plate, enhancing the boosting force and response without increasing logistics costs.
Implementation Method 1
the rolling fold (7) rolls down on a rolling area (8) on the inner wall of the amplifier housing (2)
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a pneumatic brake booster (1), having a negative pressure chamber (3) and a working chamber (4) in a booster housing (2), which are separated from each other by an elastic diaphragm (5), wherein in some regions the diaphragm lies against a diaphragm plate (6), which can be slid axially between a zero position (N) and a maximum stroke (M), wherein an axial distance between the zero position and the maximum stroke defines a stroke range (H) of the brake booster, wherein the diaphragm has a rolling fold (7), which rolls on a rolling region (8) on an inner wall of the booster housing during the sliding of the diaphragm plate. The aim of the invention is to provide a solution in which a modular system should be made more efficient for a plurality of stroke ranges and the loss of efficiency should be minimized or avoided. This aim is achieved, according to the invention, in that the booster housing has, in the rolling region, an inclined, conical section (9) having a cone angle (ɑ) greater than or equal to 8° and an axial extent (A) > 1/3 * stroke range (H).