Modular Non-Linear Spring System

Abstract

A modular non-linear spring system capable of simulating traditional brake pedal feel when incorporated into a hydraulic and/or electro-hydraulic vehicle braking system. The system can include a first spacer having a top surface and a bottom surface and an optional second spacer having a top surface and a bottom surface. In one arrangement, a first mechanical spring is in abutting engagement with the top surface of said first spacer, a second mechanical spring is in abutting engagement with the bottom surface of said first spacer and the top surface of said second spacer, and an optional third mechanical spring is in abutting engagement with the bottom surface of said second spacer. The springs are arranged to be progressively compressed using a brake pedal of the braking system.

Claims

1.-29. (canceled)

30. A modular non-linear spring system suitable for use in a vehicle braking system comprising: a first spacer having a top surface and a bottom surface; a first spring having a top and bottom end, said bottom end of said first spring in abutting engagement with said top surface of said first spacer; a second spacer, said second spacer having a top surface and a bottom surface; a second spring having a top and bottom end, said top end of said second spring in abutting engagement with the bottom surface of said first spacer, said bottom end of said second spring in abutting engagement with said top surface of said second spacer, said first and second springs spaced from another by said first spacer; and; a third spring having a top and bottom end, said top end of said third spring in abutting engagement with said bottom surface of said second spacer, said second and third springs spaced from another by said second spacer; wherein said first, second, and third springs are sequentially compressible whereby compression of said first, second, and third springs in said modular non-linear spring system provides a non-linear, progressively increasing mechanical spring force, and, wherein at least two of said first, second, and third springs have different spring sizes, different spring rates, and/or are a different spring type, and, wherein a) said top surface of said second spring is positioned below said bottom surface of said first spring, and/or b) said top surface of said third spring is positioned below said bottom surface of said second spring.

31. The modular non-linear spring system as defined in claim 30, wherein said first, second, and third springs have said different spring sizes, said different spring rate, and/or said different spring type.

32. The modular non-linear spring system as defined in claim 30, wherein at least two of said first, second, and third springs are mechanical springs.

33. The modular non-linear spring system as defined in claim 30, wherein said first spring compresses 5-95% of its full compression length prior to said second spring compressing more than 1-10% of its full compression length.

34. The modular non-linear spring system as defined in claim 33, wherein said first spring compresses 75-95% of its full compression length prior to said second spring compressing more than 1-10% of its full compression length.

35. The modular non-linear spring system as defined in claim 33, wherein said first and second springs compress 5-95% of each of their full compression lengths prior to said third spring compressing more than 1-10% of its full compression length.

36. The modular non-linear spring system as defined in claim 33, wherein said first spring compresses 75-95% of its full compression length prior to said second spring compressing more than 1-10% of its full compression length, said first and second springs compress 75-95% of each of their full compression lengths prior to said third spring compressing more than 1-10% of its full compression length.

37. The modular non-linear spring system as defined in claim 30, wherein said first spring is a clover dome washer or a Belleville washer, said second spring is a coil spring, and said third spring is a clover dome washer or a Belleville washer, said first and third springs having a different spring rate.

38. The modular non-linear spring system as defined in claim 30, wherein said first and second springs are coil springs, and said third spring is a clover dome washer or a Belleville washer, said first and second springs having a different spring rate.

39. The modular non-linear spring system as defined in claim 30, wherein said first spring is a clover dome washer or a Belleville washer or a coil spring, said second spring is a clover dome washer or a Belleville washer or coil spring, and said third spring is a clover dome washer or a Belleville washer or a coil spring.

40. The modular non-linear spring system as defined in claim 30, wherein each of said first, second and third springs has an uncompressed axial length and a compressed axial length, and wherein the uncompressed length of said second spring is greater than the uncompressed length of said first and third springs.

41. A hydraulic brake system comprising a master cylinder having a cavity and a piston supported in the cavity, and a modular non-linear spring system as defined in claim 30 supported in the cavity and engageable with the piston of the master cylinder, and wherein the piston of the master cylinder is configured to compress at least one of said springs.

42. The hydraulic brake system as defined in claim 30, wherein said first, second, and third springs are coaxially aligned along a common axis of the cavity.

43. A method of simulating traditional brake pedal feel in a brake pedal of a braking system comprising: providing a modular non-linear spring system as defined in claim 30; and compressing said springs in progression with the brake pedal.

44. A modular non-linear spring system suitable for use in a vehicle braking system comprising: a first spacer having a top surface and a bottom surface; a first spring having a top and bottom end, said bottom end of said first spring in abutting engagement with said top surface of said first spacer; a second spacer, said second spacer having a top surface and a bottom surface; a second spring having a top and bottom end, said top end of said second spring in abutting engagement with the bottom surface of said first spacer, said bottom end of said second spring in abutting engagement with said top surface of said second spacer, said first and second springs spaced from another by said first spacer; and; a third spring having a top and bottom end, said top end of said third spring in abutting engagement with said bottom surface of said second spacer, said second and third springs spaced from another by said second spacer; wherein said first, second, and third springs are sequentially compressible whereby compression of said first, second, and third springs in said modular non-linear spring system provides a non-linear, progressively increasing spring force, and, wherein at least two of said first, second and third springs have different spring sizes, different spring rates, and/or are a different spring type, and, wherein a) said top surface of said second spring is positioned below said bottom surface of said first spring, and/or b) said top surface of said third spring is positioned below said bottom surface of said second spring, wherein said first spring compresses 75-95% of its full compression length prior to said second spring compressing more than 1-10% of its full compression length, said first and second springs compress 75-95% of each of their full compression lengths prior to said third spring compressing more than 1-10% of its full compression length, and, wherein the first spring is a clover dome washer or a Belleville washer or a coil spring, and the third spring is a clover dome washer or a Belleville washer or a coil spring, and, wherein each of the first, second, and third springs has an uncompressed axial length and a compressed axial length, and wherein the uncompressed length of said second spring is greater than the uncompressed length of said first and/or second springs.

45. The modular non-linear spring system as defined in claim 44, wherein said first, second, and third springs are mechanical springs, said first, second, and third springs have different spring size, said different spring rate, and/or said different spring type.

46. The modular non-linear spring system as defined in claim 45, wherein said first spring is a clover dome washer or a Belleville washer, said second spring is a coil spring, and said third spring is a clover dome washer or a Belleville washer, said first and third springs having a different spring rate.

47. The modular non-linear spring system as defined in claim 45, wherein said first and second springs are coil springs, and said third spring is a clover dome washer or a Belleville washer, said first and second springs having a different spring rate.

48. The modular non-linear spring system as defined in claim 45, wherein said first spring is a clover dome washer or a Belleville washer or a coil spring, said second spring is a clover dome washer or a Belleville washer or coil spring, and said third spring is a clover dome washer or a Belleville washer or a coil spring.

49. The hydraulic brake system as defined in claim 44, wherein said first, second, and third springs are coaxially aligned along a common axis of the cavity.

50. A hydraulic brake system comprising a master cylinder having a cavity and a piston supported in the cavity, and a modular non-linear spring system as defined in claim 44 supported in the cavity and engageable with the piston of the master cylinder, and wherein the piston of the master cylinder is configured to compress at least one of said springs.

51. A method of simulating traditional brake pedal feel in a brake pedal of a braking system comprising: providing a modular non-linear spring system as defined in claim 44; and compressing said springs in progression with the brake pedal.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Reference may now be made to the drawings, which illustrate various embodiments that the disclosure may take in physical form and in certain parts and arrangements of parts wherein:

[0051] FIG. 1 illustrates an exemplary brake system including a modular non-linear spring system in accordance with the present disclosure;

[0052] FIG. 2 illustrates a graph showing two load-vs-travel curves for a brake pedal;

[0053] FIG. 3 is a schematic cross-sectional drawing of an exemplary spring system in accordance with the present disclosure;

[0054] FIG. 4 is a perspective view of a first exemplary embodiment of a spring system in accordance with the present disclosure;

[0055] FIG. 5 is a cross-sectional view taken along the line 5-5 in FIG. 4;

[0056] FIG. 6 is a perspective view of another exemplary embodiment of a spring system in accordance with the present disclosure; and

[0057] FIG. 7 is a cross-sectional view taken along the line 7-7 in FIG. 6.

DETAILED DESCRIPTION OF NON-LIMITING EMBODIMENTS

[0058] Referring now to the drawings, wherein the showings are for the purpose of illustrating non-limiting embodiments of the present disclosure only and not for the purpose of limiting the same, FIGS. 1-7 illustrate various non-limiting embodiments of an improved modular non-linear spring system which is capable of simulating traditional brake pedal feel.

[0059] In FIG. 1, an exemplary brake system 10 generally includes a master cylinder 12 coupled via hydraulic lines 14 to respective brake assemblies 18a-18d associated with respective wheels of a vehicle. The hydraulic lines 14 supply pressurized fluid from the master cylinder 12 to the brake assemblies 18a-18d during braking. The master cylinder 12 in the illustrated exemplary system generates the required pressure to actuate the brake assemblies 18a-18d, either via a foot pedal 20 or other pressure developing component 22 (e.g., mechanical or electric pump, actuator, etc.).

[0060] In a convention hydraulic brake system, all braking pressure is developed by the driver through depression of the foot pedal. In the electro-hydraulic brake system of FIG. 1, the pressure development component 22 generates braking pressure in response to a brake demand signal generated by, for example, depression of the foot pedal 20. To this end, various sensors 24 are typically used to sense displacement of the foot pedal 20 and communicate such information to a brake control device 26, which in turn controls the pressure developing component 22 resulting in the master cylinder 12 generating braking pressure. Typical electro-hydraulic systems can also include a fail-safe function wherein the pedal 20 is used to directly generate braking pressure in the master cylinder 12 in the event of failure or malfunction of the pressure development component 22, related sensors, or brake control unit. It will be appreciated that electro-hydraulic brake systems can include various other components (e.g., actuators, sensors, etc.) for providing suitable system functionality. The specific arrangement of the brake system shown in FIG. 1 is merely for illustrative purposes, and it should be understood that aspects of the present disclosure are applicable to virtually any brake system wherein brake pedal feedback is desired.

[0061] In accordance with the present disclosure, a modular non-linear spring system 30 is designed to provide a non-linear, progressively increasing stroke length versus pedal force characteristic to the pedal 20. In such a configuration, the modular non-linear spring system 30 of the present disclosure behaves similarly to a conventional hydraulic braking system brake pedal in that the traditional brake pedal feel is maintained.

[0062] The modular non-linear spring system 30 of the present disclosure is configured to simulate traditional brake pedal feel. FIG. 2 is a graphical illustration of stroke length (i.e., distance to which the pedal is depressed) versus pedal force. The data values labeled Target Curve provide a stroke length versus pedal force curve for a brake pedal in a traditional hydraulic brake system. As can be seen by the Target curve in FIG. 2, as the stroke length increases, the pedal force increases progressively and non-linearly. The modular non-linear spring system of the present disclosure (labeled Spring 4), when used as part of a hydraulic brake system, is capable of producing a pedal feel substantially similar to that of a traditional brake pedal.

[0063] As illustrated in FIG. 2, the first portion of the curve M1 illustrates the smallest slope wherein as the pedal or piston is initially moved, the load or resistance to the movement of the pedal or piston slowly increases. In this first portion, the Spring 4 line is generally linear, thus representing that essentially only one spring is being compressed in first curve portion M1. As such, if a first spring is configured to first compress and a second and third are configured to later compress, first curve portion M1 illustrates a linear compression first spring being initially compressed and the second and third spring being compressed less than 5-10%. The second portion of the curve M2 illustrates an increased slope (e.g., 20-150%) as compared to the slope in first curve portion M1. The slope of line Spring 4 in the second curve portion M2 is not fully linear. The slight curve of slope of line Spring 4 in the second curve portion M2 is due to two or more springs being compressed and/or one of the spring being a non-linear compression spring. The maximum slope of line Spring 4 in the third curved portion M3 has an increased slope of at least 1.5 times (e.g., 2-20 times, etc.) of the slope of the second curved portion M2. Although the pedal stroke length versus pedal force curve is illustrated in FIG. 2 as comprising substantially straight line segments between various data values (e.g., stroke length values), it can be appreciated that the curve(s) can be substantially continuous between data values.

[0064] As best seen in FIG. 3, the exemplary modular non-linear spring system 30 generally comprises upper and lower housing components 32 and 34 (which may be portions of the master cylinder itself, e.g., cavity walls). Supported within the housing components 32 and 34 are a piston 38 and spring seats 40 and 42 (also referred to herein as spacers). A first spring S1 is captured between the piston 38 and spring seat 40. A second spring S2 is captured between the spring seat 40 and the spring seat 42. A third spring S3 is captured between the spring seat 42 and the lower housing 34. The springs are aligned along a common central axis with each other and the spring seats 40 and 42. As will be appreciated, vertical movement of the piston 38 within the upper housing component 32 results in sequential compression of the springs (e.g., S1 then S2 then S3; S2 then S1 then S3; S2 then S3 then S1, etc.).

[0065] It should also be appreciated that the modular non-linear spring system 30 can be adjusted based on a driver-preferred driving and/or braking style. For example, the braking style can be selected from standard braking, performance braking, luxury braking, and/or sport braking. Generally, traditional hydraulic brake systems adopt a standard braking performance, as shown by the two curves in FIG. 2. By adjusting various characteristics of 1) the first mechanical spring S1, 2) the second mechanical spring S2, and/or 3) the third mechanical spring S3 of the modular non-linear spring system of the present disclosure, the braking performance can be adjusted between multiple driving styles. Although aspects of the present disclosure are directed to modular non-linear spring system embodiments for performance, luxury, standard, and sport braking performances, it can be appreciated that the present device can be modified and/or adjusted to fit any other desired driving style.

[0066] As seen in FIG. 2, the pedal stroke length versus pedal force curves are non-linear and have generally progressively increasing slopes, a typical characteristic of brake pedals in conventional hydraulic braking systems. The progressively increasing slope is due partially to 1) the characteristics of each individual mechanical spring, and/or 2) the combined effect of the characteristics of said individual mechanical springs. In one non-limiting configuration, the effect of each spring on pedal force can be amplified when one or more springs are used; however, this is not required. As can be appreciated, at least the shape, size and material characteristics of one or more of the springs can be adjusted to obtain a desired pedal stroke length versus pedal force curve.

[0067] The first and second mechanical springs S1 and S2 can be the same (e.g., coil compression springs) or different types of springs; however, this is not required. The third spring can be a Belleville spring; however, this is not required. As such, the modular non-linear spring system of the present disclosure provides a modularized braking mechanism wherein each mechanical spring compresses sequentially, wherein each spring can be responsible for a separate characteristic of each module. For example, in operation, as the brake pedal is actuated, a piston is caused to descend within the master cylinder, thereby increasingly compressing the first mechanical spring.

[0068] Returning to FIG. 2, the compression of the first mechanical spring S1 is illustrated by a first pedal travel, thereby also defining the first module M1. As the brake pedal is further actuated, the piston is caused to descend further within the master cylinder, now increasingly compressing the second mechanical spring S2 as described above. The compression of the second mechanical spring S2 is illustrated by a second pedal travel distance, thereby also defining a second module M2. As the brake pedal is still further actuated, the piston is caused to descend still further within the master cylinder, now increasingly compressing the third mechanical spring. The compression of the third mechanical spring S3 is illustrated by a third pedal travel distance, thereby defining a third module M3. As can be appreciated, other travel distances can be used. FIG. 2 demonstrates that by changing one or more springs, or one or more characteristics of the one or more springs, different braking performances can be provided. The springs can be configured such that during the compression on one spring, another spring has little or no compression. For example, first spring S1 and second spring S2 can be configured such that when first spring S1 is initially being compressed, second spring S2 will compress less than 5-10% of its full compression while first spring S1 is compressed less than 85-99% of its full compression. Likewise, second spring S2 and third spring S3 can be configured such that third spring S3 will compress less than 5-10% of its full compression while second spring S2 is compressed less than 85-99% of its full compression. As can be appreciated, the springs can be configured to compress at different times relative to the amount of compression of another spring.

[0069] Referring now to FIGS. 4 and 5, another exemplary embodiment of the modular non-linear spring system is illustrated and identified generally by reference numeral 30. FIG. 4 illustrates the spring system 30 alone, while FIG. 5 illustrates the modular non-linear spring system 30 in cross-section installed within a cavity of a master cylinder 12. The modular non-linear spring system 30 includes a first spring S1, a second spring S2 and a third spring S3. First and second spacers 40 and 42 (also referred to as upper and lower spring seats, respectively) confine the second spring S2 therebetween. The first spring S1 is confined between the first spacer 40 and a piston 60 of the master cylinder 12. The third spring S3 is confined between the second spacer 42 and the master cylinder 12.

[0070] In the embodiment of FIGS. 4 and 5, the second spring S2 is a helical coil mechanical spring, while the first and second springs S1 and S2 are spring washers. For example, the first spring S1 can be a disc washer (e.g., a clover dome washer) while the third spring S3 can be, for example, a Belleville spring washer. The first spring S1 and at least portions of the spacer 40 are received within a recess 62 of the piston 60.

[0071] The modular non-linear spring system 30 of the present disclosure can comprise many shapes and sizes; however, it is still capable of being inserted into the interior cavity of a master cylinder. In one non-limiting embodiment, the first mechanical spring can be recessed so as to seat securely within the piston recess (pocket). Similarly, the second mechanical spring can be seated within the first and second spring seats (i.e., spacers 40 and 42). The third mechanical spring can be seated within the pocket of the master cylinder 12 below the lower spring seat (i.e., spacer 42). As can be appreciated, the size of the first, second, and third mechanical springs S1, S2 and S3 can be selected to optimize braking performance and brake pedal feel.

[0072] Referring now to FIGS. 6 and 7, another exemplary embodiment of the modular non-linear spring system is illustrated and identified generally by reference numeral 30. The modular non-linear spring system 30 is similar to the embodiment of FIGS. 4 and 5 and has similar components as indicated by the double prime notation, except that the first spring S1 is a linear compression spring, and the second spring S2 is a multi-rate compression spring. S2 is a multi-rate spring in that the coil thickness vary along a length of the spring. As can be appreciated, S2 could be formed of two or more nested springs having different free lengths, coil materials, etc. to create a multi-rate spring.

[0073] In operation, when the modular non-linear spring system 30/30 and the piston 60/60 of the master cylinder 12/12 are in a non-actuated position, the first spring S1/S1 is negligibly compressed between the piston 60/60 and the first spacer 40/40. As the brakes are actuated, the piston 60/60 is caused to move downwardly, thereby partially or fully compressing the first spring S1/S1 against said first spacer 40/40. When the piston 60/60 continues to move downwardly, the first spacer 40/40 is also caused to move downwardly, thereby partially or fully compressing the second spring S2/S2 between the first spacer 40/40 and second spacer 42/42, and continued compression of the first spring S1/S1 between the piston 60/60 and the first spacer 40/40. When the piston 60/60 continues to move further downwardly, the second spacer 42/42 is also caused to move downwardly, thereby exerting a force on the third spring S3/S3. As such, the third spring S3/S3 can become partially or fully compressed between the second spacer 42/42 and a surface (inner wall) of the master cylinder 12/12, the second spring S2/S2 remains partially or fully compressed between the first spacer 40/40 and the second spacer 42/42, and the first spring S1/S1 remains partially or fully compressed between the piston 60/60 and the first spacer 40/40. The partial and/or full compression of the first, second, and third springs provides a combination of non-linear, progressively increasing spring forces to match that of a conventional brake pedal.

[0074] In the illustrated embodiments, the first, second and third mechanical springs have an uncompressed axial length and a compressed axial length. The uncompressed length of the second mechanical spring is greater than the uncompressed lengths of the first and third mechanical springs. Further, the difference in the axial length of the second spring between its uncompressed state and compressed state may be greater than the difference in length between the uncompressed and compressed states of the first and second springs. As such, module M2 may have the greatest travel as compared to module M1 and module M3.

[0075] While considerable emphasis has been placed herein on the structures and configurations of the preferred embodiments of the disclosure, it will be appreciated that other embodiments, as well as modifications of the embodiments disclosed herein, can be made without departing from the principles of the disclosure. These and other modifications of the preferred embodiments, as well as other embodiments of the disclosure, will be obvious and suggested to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the present disclosure and not as a limitation thereof.