Nested Piston Component for Hydraulic Brake Master Cylinder
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Solution Overview
Problem
Existing hydraulic brake systems lack a primary piston component that efficiently transfers both brake booster force and driver-applied force to increase internal pressure in the master cylinder, especially in scenarios where the brake booster fails, compromising comfort and ease of operation.
Innovation Solution
A primary piston component with an inner piston body and a hollow cylindrical additional piston component that allows the transfer of brake booster force and driver-applied force into the master cylinder's pressure chamber, enabling operation in both normal and backup modes with reduced production complexity and cost, and a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional single-piston design is used, then the structure is simple and production cost is low, but the braking comfort is poor and the system cannot operate reliably when the brake booster fails
Solution Approach 1:
The piston component is divided into two independent functional parts: an outer piston that interfaces with the brake booster and an inner piston that interfaces with the brake pedal. This segmentation allows each piston to independently perform its function, ensuring that braking can continue even if one system fails, while maintaining a relatively simple overall structure.
Solution Approach 2:
The inner piston is nested within the outer piston, with the inner piston positioned inside the cavity formed by the outer piston. This nested arrangement allows both pistons to coexist in a compact configuration, improving reliability through dual functionality while minimizing the increase in device complexity and maintaining space efficiency.
2Ease of operation
If both brake booster force and driver force are transferred through a complex mechanism, then braking comfort is improved, but the device complexity and production cost increase
Solution Approach 1:
The force transfer mechanisms for the brake booster and the brake pedal are merged into a single integrated piston component assembly. The outer piston receives force from the brake booster while the inner piston receives force from the brake pedal, and both forces are combined to move the primary piston housing into the pressure chamber. This merging eliminates the need for separate complex transmission mechanisms, improving ease of operation while keeping the device complexity low.
3Ease of operation
If a dual-piston component is used to transfer both forces, then braking comfort is improved, but the package size increases
Solution Approach 1:
The inner piston is placed inside the cavity formed by the outer piston, creating a nested configuration. This allows both pistons to occupy the same spatial envelope, effectively doubling the functional capacity while adding minimal volume. The nested design ensures that the package size increase is minimal compared to using two separate piston assemblies.
Solution Approach 2:
The dual-piston design utilizes the radial dimension by placing the inner piston concentrically within the outer piston, rather than stacking them linearly. This dimensional arrangement allows both pistons to function simultaneously while maintaining a compact overall footprint, improving ease of operation without significantly increasing the package size in any single direction.
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 provides enhanced comfort and operational efficiency by allowing increased internal pressure in the master cylinder using both forces, ensuring reliable operation even without the brake booster, while maintaining a simple structure and low production costs.
Implementation Method 1
a brake booster force provided by a brake booster is transferable via an additional piston component on the inner piston body
Implementation Method 2
a driver's braking force applied on a brake actuating element, for instance on a brake pedal, is transferred via the inner piston body on the primary piston housing
Implementation Method 3
both forces can be used to transfer the primary piston component into the pressure chamber of the master cylinder
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The present invention provides a primary piston component for a master cylinder (14) of a hydraulic brake system comprising a primary piston housing (10) and an additional piston component (30), which is configured to be at least partially movable into a cavity (16) of the primary piston housing (10), wherein an inner piston body (26) extends through the cavity (16) along a central line (28) of the primary piston component, wherein a braking force (Fd) applied on a brake actuating element is transferable at least partially on the inner piston body (26), and further on the primary piston housing (10), wherein the additional piston component (30) is at least partially movable into the cavity (16) between the inner piston body (26) and the primary piston housing (10), and wherein a brake booster force (Fb) is transferable at least partially on the additional piston component (30), and via the inner piston body (26) on the primary piston housing (10). The present invention also provides a method of operating a hydraulic brake system.