Patent Application
20060022516
This invention relates in general to brake systems for vehicles and in particular to a pump assembly with a combination reciprocating high-pressure seal and fluid inlet check valve for use within brake systems.
In conventional vehicular brake systems having anti-lock brake, traction control and/or vehicle stability control, a supply of hydraulic fluid for the vehicle brakes is modulated by a hydraulic control unit. Various hydraulic pumps may be employed to selectively supply hydraulic fluid to the vehicle brakes. Several hydraulic pump designs are known.
U.S. Pat. No. 4,556,261 to Farr, discloses a prior art pump and skid sensing assembly for a vehicle hydraulic anti-skid braking system, as shown in
The seal 19, which is illustrated in detail in
An inlet passageway 41 is formed by the inlet flange 40 and the housing 1. A retaining flange 42 and the housing 1 form an outlet passageway 43 of the check valve assembly. As the plunger 10 is moved towards the ring 12, the seal 19 moves to a second position relative to the plunger 10 so that the face 26 is spaced apart from the adjacent side wall of the groove 25 and the inlet flange 40. In the second position, the seal 19 may abut the retaining flange 41. This allows fluid from the reservoir 35 to be drawn into the increasing volume of the chamber 22 past the seal 19. When the seal 19 is in the second position, the longitudinal passageway 29 is not in direct communication with the outlet passageway 43. When the seal 19 is in the second position, the longitudinal passage 29 is in fluid communication with the inlet passageway 41, and the longitudinal passage 29 is in fluid communication with the radial slot 28. The radial slot 28 is in fluid communication with the outlet passageway 43, such that the check valve assembly is in an open position and the chamber 22 and the reservoir 35 are communicably connected. Therefore, the radial slot 28 allows the longitudinal passageway 29 to be in indirect fluid communication with the outlet passageway 43. The radial slot 28 has an outer radius that extends beyond the outer radius of the longitudinal passage 29 taken about a longitudinal axis of the plunger 10.
As the plunger 10 is moved in the opposite direction, the face 26 of the seal 19 seals against the adjacent face of the groove 25 so that fluid cannot flow between the plunger 10 and the seal 19 or through the slot 28 and the at least one passage 29 within the seal 19. The seal 19 in this condition thus provides a seal between the plunger 10 and the wall of the bore 11, closing the check valve assembly, and allowing the plunger 10 to pump fluid from the secondary chamber 22 into the primary chamber 23.
Although prior hydraulic pumps, such as the one described above, have been effective, it would be desirable to provide a low cost pump assembly having more easily manufactured and more durable components.
The present invention is a pump assembly with a combination reciprocating high-pressure seal and fluid inlet check valve for use within brake systems. The pump assembly comprises a piston for reciprocal movement within a bore in a housing.
The pump assembly includes a housing having a bore formed therethrough and a piston disposed within the bore for reciprocal movement along a longitudinal axis therein. The piston has an inlet flange extending outwardly substantially perpendicular to the longitudinal axis. An annular seal is disposed around the piston for reciprocal movement thereon. The annular seal cooperates with at least one of the piston and the housing to form a longitudinally extending passageway. The passageway, the piston, and the annular seal cooperating to form a check valve assembly. The check valve assembly divides the bore into an inlet chamber and a pumping chamber. The retaining flange and the housing cooperate to form an outlet passageway of the check valve assembly. The annular seal is moveable to a first position relative to the inlet flange in which the at least one longitudinally extending passageway communicates directly with the outlet passageway to the pumping chamber and said check valve assembly is in a flow-through position to fill the pumping chamber with fluid from the inlet chamber during a fluid inlet stroke. The annular seal is moveable to a second position relative to the inlet flange in which the check valve assembly is closed.
In a preferred embodiment, the piston includes a retaining flange and an intermediate portion disposed between the retaining flange and the inlet flange. Both the retaining flange and the inlet flange extend substantially perpendicular from the piston. The inlet flange and the housing cooperate to form at least one inlet passageway through the bore. The at least one longitudinally extending passageway and the at least one inlet passageway are communicably connected. The retaining flange and the housing cooperate to form at least one outlet passageway through the bore. The retaining flange may be comprised of a cir-clip disposed around the piston.
A high-pressure seal is disposed around the intermediate portion of the piston. The seal is not as thick as the intermediate portion is long, and, therefore, the seal can reciprocate between the retaining flange and inlet flange. The seal and the inlet flange cooperate to form a first check valve assembly, as will be described below.
The piston, housing, the first check valve assembly, and a second check valve assembly define a pumping chamber. The piston, housing, and the first check valve assembly define an inlet chamber. A fluid inlet supplies fluid to the inlet chamber.
On a fluid inlet stroke, the piston withdraws from the bore and the volume of the pumping chamber increases. As the piston withdraws, the seal is moved into a first position relative to the inlet flange, in which the seal is not seated against the inlet flange. With the seal in the first position, the first check valve assembly is opened, and fluid from the inlet chamber is allowed to flow into the pumping chamber.
On a pumping stroke, the piston moves toward the second check valve assembly, and the seal is moved into a second position relative to the inlet flange, in which the seal is seated against the inlet flange. When the seal is in the second position, the inlet flange and seal cooperate to prevent fluid from exiting the pumping chamber, such that the first check valve assembly is closed. The fluid pressure builds within the pumping chamber until the pressure overcomes the force required to unseat the ball of the second check valve assembly. The second check valve assembly then opens, allowing the pressurized fluid to exit the pumping chamber through a fluid outlet to be delivered to the vehicle brake system.
Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings.
Referring again to the drawings, there is illustrated in
The shaft 51 is generally elongated along longitudinal axis A. The shaft 51 includes a second end portion 56, opposite the first end portion 54. The intermediate portion 55, described above is disposed between the first end portion 54 and the second end portion 56. The second end portion 56 is engaged by a driving mechanism (not shown) for reciprocatingly driving the piston 50. The intermediate portion 55 of the shaft 51 may have a generally circular cross section. The intermediate portion 55 extends outwardly from the axis A to a radius R1, as is shown in
Referring now to
The seal 57 has at least one passageway 58 formed therethrough. In a preferred embodiment, the at least one passageway 58 comprises a plurality of longitudinally extending grooves, preferably with semi-circular cross-section, that have been formed in or machined through the seal 57 around an inner periphery of the seal 57. In a more preferred embodiment, the at least one passageway 58 comprises a plurality of longitudinally extending notches molded in the seal 57, with preferably rectangular or diamond-shaped cross-section. However, it will be appreciated that the at least one passageway 58 may be formed in the seal 57 in any manner, and may have any suitable cross-section. The at least one passageway 58 is formed through the seal 57 such that the at least one passageway 58 does not extend outwardly into the seal 57 any further than a radius R2 from the axis A as shown in
The piston 50 is suitable for use in a pump assembly, such as the first embodiment of a pump assembly, indicated generally at 59, in
Preferably, the seal 57 is formed of a material that is sufficient to sustain operation of the pump assembly 59 under operating conditions within the pump assembly 59 as described herein, such as the relatively high operating pressures of a pump assembly within a vehicle brake system. In a preferred embodiment, the seal 57 is formed of a material that is sufficient to sustain operation of the pump assembly 59 with an operating pressure range of about 0 to about 250 bars absolute pressure within the pump assembly 59, as will be described in more detail below. However, it will be appreciated that operating pressure within the pump assembly 59 may vary, and may be a negative pressure under some operating conditions, as will be described below. In a preferred embodiment, the seal 57 is formed of a material that is sufficient to sustain operation of the pump assembly 59 in a temperature range of about −40 degrees Celsius to about 120 degrees Celsius. Additionally, in a preferred embodiment, the seal 57 is comprised of materials that are compatible with hydraulic brake fluid.
The retaining flange 52 and the housing 60 cooperate to form an outlet passageway 62 through the bore 61. As illustrated, the outlet passageway 62 is generally annular and extends about the periphery of the retaining flange 52, although such is not required. The outlet passageway 62 may have any desired shape and may be disposed about or through any portion of the retaining flange 52. The outlet passageway 62 has an inner radius R3 taken from the axis A. The outlet passageway 62 is formed between retaining flange 52 and the housing 60 such that the outlet passageway 62 does not extend further into the retaining flange 52 any closer than the radius R3 from the axis A, as seen in
The inlet flange 53 and the housing 60 cooperate to form an inlet passageway 63 through the bore 61. As illustrated, the inlet passageway 63 is generally annular and extends about the periphery of the inlet flange 53, although such is not required. The inlet passageway 63 may have any desired shape and may be disposed about or through any portion of the inlet flange 53. The inlet passageway 63 has an inner radius R4 taken from the axis A. The inlet passageway 63 is formed between inlet flange 53 and the housing 60 such that the inlet passageway 63 does not extend further into the inlet flange 53 any closer than the radius R4 from the axis A, as seen in
The seal 57 has a first surface 64 that slidingly engages the walls of the housing 60 that form the bore 61 to form a dynamic seal therebetween. The seal 57 also has a second surface 65 that slidingly engages the outer periphery of the intermediate portion 55 of the piston 50, although such is not required. The seal 57 is able to move relative to the intermediate portion 55 between a first position, in which the seal 57 contacts the retaining flange 52 and a second position, in which the seal 57 contacts the inlet flange 53 as will be described below.
The seal 57 further includes a third surface 66 that engages a surface 68 of the retaining flange 52 when the seal 57 is in the first position thereof. As indicated above, in a preferred embodiment, the at least one passageway 58 is a plurality of similar passageways in the form of grooves that are symmetrically positioned around the seal 57, so that the seal 57 is evenly axially supported by the retaining flange 52 when seated in the first position.
The seal 57 has a fourth surface 67 that may engage a sealing surface 69 of the inlet flange 53 when the seal 57 is in a second position relative to the inlet flange 53, as will be described below. When the seal 57 is in the second position, the fourth surface 67 engages the sealing surface 69. The seal 57 prevents fluid flow through the at least one passageway 59 through the inlet flange 53, because, as is best shown in
Thus, the seal 57 and the inlet flange 53 cooperate to form a first check valve assembly 70, as will be described in more detail below. In a preferred embodiment, the at least one passageway 58 is a plurality of similar passageways that are symmetrically positioned throughout the seal 57, so that the seal 57 is evenly supported by the inlet flange 53 when seated in the second position.
The pump assembly 59 will now be further described. The second end portion 56 of the piston 50 is mounted so that the piston 50 may reciprocate within the bore 61 of the housing 60. The piston 50 slides against the walls of the bore 61 as the piston 50 reciprocates. A seal 71 may be provided or formed by the piston 50 and the walls of the bore 61. The seal 71, the seal 57, and the piston 50 define an inlet chamber 72 within the bore 61. A fluid inlet 73 is communicably connected to the inlet chamber 72 to supply fluid to the pump assembly 59, as will be described below. Alternatively, it will be appreciated that the seal 71 may not be provided, and the inlet chamber 72 may extend such that the fluid of the inlet chamber 72 may be used to lubricate the piston 50 and the walls of the bore 61 to facilitate the reciprocal movement therebetween. In a more preferred embodiment, an o-ring (not shown) may be disposed around the shaft 51 of the piston 50 near the second end portion 56 of the piston 50 instead of the seal 71 such that the inlet chamber 72 extends below the intersection of the walls of the bore 61 and the piston 50.
At the end of the bore 61 opposite the piston 50, a second check valve assembly 74 is provided. The second check valve assembly 74 includes a ball 75 and a seat 76. Preferably, the second check valve assembly 74 is formed of a material that is sufficient to sustain operation of the pump assembly 59 under operating conditions within the pump assembly 59 as described herein, such as the relatively high operating pressures of a pump assembly within a vehicle brake system. Additionally, in a preferred embodiment, second check valve assembly 74 is comprised of materials that are compatible with hydraulic brake fluid. A pumping chamber 77 is defined within the bore 61 between the second check valve assembly 74 and the combination of the piston 50 and the seal 57. As is evident from the structure of the pump 59 and as will be evident from the operation of the pump 59 described below, the pump 59 is highly efficient due to the relatively small unswept volume of the piston 50.
The operation of the pump assembly 59 will now be described. At the end of a pumping stroke, when the piston 50 is closest to the second check valve assembly 74, the seal 57 is in the second position, thereby seated against the sealing surface 69 of the inlet flange 53 (the first check valve assembly 70 is shut). During a fluid inlet stroke, the piston 50 moves in a direction I away from the second check valve assembly 74. The seal 57 is disposed between the retaining flange 52 and the inlet flange 53, and, as the piston 50 moves away from the second check valve assembly 74, pressure in the pumping chamber 77 drops below the pressure in the inlet chamber 72 as the pumping chamber 77 expands. The differential pressure unseats the seal 57 from the inlet flange 53, opening the first check valve assembly 70 and allowing fluid to flow from the inlet chamber 72 through the passageways 63, 58, and 62, into the pumping chamber 77. The seal 57 will generally have greater friction to the wall of the bore 61 than to the piston 50, and will tend to remain stationary as the piston 50 moves. However, as the piston 50 continues to move away from the second check valve assembly 74, the retaining flange 52 will eventually intercept the seal 57, and the seal 57 will be urged away from the second check valve assembly 74 by the retaining flange 52 of the piston 50, so that the seal 57 is now in the first position thereof. Once the seal 57 has been intercepted by the retaining flange 52, the seal 57 will remain seated against the retaining flange 52 as long as the piston 50 continues to move in the same direction, e.g., away from the second check valve assembly 74.
During a pumping stroke, the piston 50 moves in a direction P, back toward the second check valve assembly 74. As the piston 50 moves, the seal 57 again tends to remain stationary due to friction with the wall of the bore. Additionally, as the pumping chamber gets smaller as the piston 50 moves toward the second check valve assembly 74, pressure starts to rise, even with the first check valve assembly 70 still open, due to head losses in the passageways. Thus, the seal 57 moves out of the second position thereof. As the piston 50 continues to move toward the second check valve assembly 74, the inlet flange 53 will eventually intercept the seal 57, and the seal 57 will be urged toward the second check valve assembly 74 by the inlet flange 53 of the piston 50. Once the seal 57 has been intercepted by the inlet flange 53, the seal 57 will remain in the second position thereof, i.e. seated against the inlet flange 53, as long as the piston 50 continues to move in the same direction, e.g., toward the second check valve assembly 74. When the seal 57 is in the second position thereof, the first check valve assembly 70 is in the closed position, as illustrated in
As the piston 50 continues to move toward the second check valve assembly 74, the fluid pressure within the chamber 77 continues to build until the fluid pressure within the chamber 77 is greater than the resistance required to unseat the ball 75 from the seat 76 of the second check valve assembly 74. When the ball 75 is unseated, the second check valve assembly 74 opens and pressurized fluid is discharged from the pump 59 via an outlet 78.
As the piston 50 continues to move toward the second check valve assembly 74, the volume of the inlet chamber 72 increases. The increase in volume of the inlet chamber 72 may create negative pressure or a vacuum pressure within the inlet chamber 72. This vacuum pressure within the inlet chamber 72 pulls fluid from the fluid inlet 73 into the inlet chamber 72. Thus, the pump assembly 59 may be a self-priming or pre-charging pump, and the pump assembly 59 may operate with negative pressure conditions within the inlet chamber 72. At the end of a pumping stroke, the first end portion 54 of the piston 50 is relatively close to the second check valve assembly 74. With the piston 50 in this position, the first check valve assembly 70 and the second check valve assembly 74 are in relatively close proximity to one another, such that the pumping chamber 77 is relatively small, as compared to the pumping chambers of conventional pumps. The axial distance between the first check valve assembly 70 and the second check valve assembly 74 is minimized so that the pump assembly 59 has a relatively small unswept volume.
It will be appreciated that the size and design of the seal 57, the at least one passageway 58, the passageway 62, and the passageway 63, must be coordinated so that the seal 57 and piston 50 cooperate such that the pump 59 operates as described above. Conversely, it will be appreciated that the seal 57, the at least one passageway 58, the passageway 62, and the passageway 63 could be any size or shape capable of performing as described above.
Referring now to
In the above-described embodiment, the retaining flange 52 is integral to the piston 50. The retaining flange 52 and the piston 50 may be formed as an integral unit, or the retaining flange 52 may be formed separately and permanently fixed to the piston 50 by any suitable means, such as welding or permanent adhesive, etc.. However, it is also contemplated that the retaining flange may be formed separately and non-permanently affixed to the piston 50. The retaining flange may be pressed on, affixed with a snap fit, affixed with threading or any other non-permanent method. Such an arrangement may be advantageous in facilitating the positioning of an original or replacement seal onto the piston. In the example illustrated in
Preferably, the seal 157 differs from the seal 57 in that the seal 157 does not have a passageway formed therethrough. Instead, the seal 157, the piston 150, and the housing 160 cooperate the form at least one passageway 158 between the seal 157 and the piston 150 about an inner periphery of the seal 157. Preferably, the at least one passageway 158 formed between the seal 157 and the piston 150 is generally annular, although such is not required. It will be appreciated that the seal 157 may include various passageways formed therein, such as the at least one passageway 58 described in the prior embodiment. The at least one passageway 158 has an outer radius R2 from the axis A. The outer radius R2 is smaller than an inner radius R4 of a passageway 163 formed by the inlet flange 153 and the housing 160. The at least one passageway 158 has an inner radius R1 from the axis A. The inner radius R1 is larger than the inner radius R3 of a passageway 162 formed by the retaining flange 152 and the housing 160. The inner radius R1 may also be larger than an outer radius of the passageway 162, although such is not required. If the inner radius R1 is larger than an outer radius of the passageway 162, as shown in
The seal 157 and the inlet flange 153 form a check valve assembly 170. However, the structure of the check valve assembly 170 varies from structure of the check valve assembly 70. The at least one passageway 158 is communicably connected to the passageway 162 formed by the cir-clip 152, the piston 150, and the housing 160. In a preferred embodiment, the at least one passageway 158 is shaped such that no matter how the seal 157 is rotated relative to the cir-clip 152, the at least one passageway 158 is communicably connected to the passageway 162.
When the seal 157 is in a first position relative to the inlet flange 153, the seal 157 is unseated from the sealing surface 169 of the inlet flange 153, and may be seated against the surface 168 of the cir-clip 152, as described in the previous embodiment and as shown in
The pistons 50, 150, seals 57, 157 and pump assemblies, 59, 159 have been described for use in a vehicle braking system, including, but not limited to, vehicle braking systems having anti-lock braking systems, and/or integrated or stand alone traction control and vehicle stability control systems. However, it will be appreciated that the pistons 50, 150, the seals 57, 157 and pump assemblies 59, 159 may be used in any vehicle component or in any other device requiring a piston, seal, or pump assembly. It will further be appreciated that the components of the various embodiments described herein may be used in any combination in accordance with the present invention.
In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.
