Title of Invention

INTEGRATED BRAKING SYSTEM FOR TWO WHEELERS

Abstract The system comprises master cylinder compartment and caliper compartment being integrated as a single piece.When the master cylinder plunger is pressed by any mechanism,it moves forward and primary seal compresses brake fluid filled in the system and transfer to caliper piston,through a passage,if it is a single pot coliper piston in turn move friction material against rotating disc attached to automotive wheel.After the friction mateial touches the rotating disc,pressure available in the system pushes the integrated body in the opposite direction thus pushing friction material against rotating disc on the side of it.Clamping force is created and the rotating disc is slowed down or stopped depending upon the pressure developed effecting the braking function.
Full Text

Integrated Braking System For Two Wheelers
Field of Invention
The invention pertains to the field of automobile industry. More particularly this invention concerned with hydraulic braking system. Especially this invention is concerned with hydraulic braking system of an automotive using a disc brake.
Background Art
It is well known in the art that in the state of art technology master cylinder and caliper are installed in an automotive as a separate assembly at different locations. In the state of technology For example, in case of a scooter or motor cycle, the master cylinder is installed in the handle bar and caliper is installed in the front fork. These two are connected by means of a flexible hose. The current system involves a separate body for master cylinder and caliper in which the actuating components are assembled.
At the outset of the description which follows it is to be understood that ensuing description only illustrate a particular form of this invention. However, such particular form Is only an exemplary embodiment, and without Intending to imply any limitation on the scope of this invention. Accordingly, the description is to be

understood as an exemplary embodiment and reading of the invention and not intended to be taken restrictively.
it is to be noted that the prior art description gives in detail information of the technology . method, process and system known in the art. It explain the deficiency in the related art and the object of the invention being to overcome or surmount the problem associated with the prior art. This forms the essential feature and the object of the invention.
A search for patents in the relevant area of technology using various data bases was conducted. From the search the following documents were identified . A thorough examination of patents has been done. The results of the finding are summarized as follows.
A cited European patent application having patent no. EP 0434201 A1 dt. 31/10/1990 filed by GM Corporation relates to an invention having integrated anti lock braking and traction control system.
A cited PCT / US patent application WO 91/14605 dt. 19/03/1990 filed by Allied Signal inc. relates to an invention having master cylinder with Integrated adoptive braking and traction control system.

A cited European patent application EP 0 505 224 A1 dt. 20/02/1992 filed by Bendix Europe Service Tech. relates to an invention having Integrated pressure boost and modulate system for hydraulic circuit.
A cited European patent application EP 0 538 920 A1 dt. 22/09/1992 filed by GM Corp. relates to an invention having Integrated antilock braking (ABS) & Traction control (TC) system.
A cited USA patent application US 006456921B1 dt. 19/03/2001 filed by Delphi Tech Inc. relates to an invention having method and system of brake system control.
A cited PCT/US patent application WO 84/02812 dt. 10/03/1983 filed by Towmotor Corpn. relates to an invention having Plugging electrical braking control circuit.
A cited European patent application EP 0 710 199 A1 dt. 01/08/1994 filed by Lucas Ind. Public Ltd. Company relates to an invention having Testing and speed control of electrical motors in vehicles having electronically controlled braking system.

A cited European patent application EP 0 505 532 A1 dt. 26/09/1991 filed by Alfred Teves Gmbh. relates to an invention Anti-lock braking systems.
A cited European patent application EP 0 130 980 A1 dt. 10/03/1983 filed bv Towmotor Corpn. relates to an invention having Plugging electrical braking control circuit.
A cited PCT patent application WO 95/03198 dt. 16/07/1994 filed by ITT Automotive European Gmbh. relates to an invention having Hydraulic braking system with skid and drive slip control.
A cited European patent application EP 0265 761 A3 13/10/1987 filed by Dunlop Limited relates to an invention having Hydraulic systems-Aircarft braking system .
A cited PCT patent application WO 92/06873 dt. 26/09/1991 filed by Alfred Teves Gmbh. relates to an invention having Anti-lock braking system.
A cited PCT patent application WO 95/03201 dt. 16/07/1997 filed by ITT Automotive Europe Gmbh relates to an invention having Hydraulic braking system with skid drive slip control.

A Cited Japan patent application P 2001-289271 A dt. 19/10/2001 relates to an invention having Mechanical Caliper twin pot type.
A cited US Patent application US 6,336,328 dt. Jan 08, 2002 filed by Honda Giken Kogyo Kabushiki, Kalsha, Tokyo (JP) relates to an invention having a master cylinder and tank combination as per claim No.l and relates to a rear brake with an independent caliper, whereby the rear brake and the master cylinder are connected by an extended hose as per claim No. 10 and not an integration of master cylinder and caliper.
The invention is unique and radically different from all the cited patent specifications. The novel feature of the invention is in the integration of master cylinder and the caliper so as to form integrated braking system specially adopted for two wheelers.
Summary of the invention
Therefore it is the principal object of the invention to provide an improved integrated braking system which is unique as compared to state of the art technology.
In accordance with one aspect of present invention there is provided an improved braking system by integrating the master cylinder and caliper of a braking system so as to form an integrated single assembly using a conventional casting method such that the integrated assembly being installed on to the fork where caliper is installed in the existing system.

In accordance with another aspect of invention there is provided one bleed screw which is adequate to bleed the integral system.
In accordance with another aspect of invention one single die or mould can be designed and one pour of metal is enough to get an integrated casting and one machining line and one assembly line is adequate to produce the integrated braking component.
Further objects of the invention will be apparent from the ensuing description .
The above and other objects features and disadvantages will be clear from the following description of preferred embodiment taken in conjunction with accompanying drawings.
The foregoing description of outlined rather broadly preferred and alternative feature of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing and modifying other structures for carrying out the same purposes of the present invention. Those skilled in the art should realize such equivalent

conception do not depart from the spirit and scope of the invention in its broadest form.
Brief description of Drawings
The accompanying drawings are intended to provide further understanding of the invention and are incorporated in and constitute a part of invention. The drawings illustrate an embodiment of the invention and together in the description illustrate salient feature and principle of the invention.
The drawing are given by way of non-limitative example to explain the nature of the invention.
For a more complete understanding of the instant invention reference is now made to the following description taken in conjunction with accompanying drawings.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
Figure 1 of the drawings shows in elevation the current practice of Installation of hydraulic bral
Figure 2 of the drawings shows in elevation the master cylinder assy.
Figure 3 of the drawings shows in elevation the caliper assembly and
Figure 4 of the drawings shows in elevation an embodiment of the invention of integral braking system according to the invention.
The Integrated Braking System concept is explained taking motorcycle / scooter (any two wheeler, powered or unpowered like motor cycle or scooter or mountain bicycle) as an example.
Following are the shortcomings of the existing installation.
1. Normally, no bleed screw is provided in the master cylinder, in the example of two wheeler hydraulic braking system.
2. Bleed screw Is provided in the caliper. The head difference between master cylinder and the caliper is such that bleeding the system to remove air completely is very difficult and time consuming.

3. It is possible to bleed the system completely in the production line using evacuate and fill concepts. It is very costly. The service centers cannot afford to install / invest on the evacuate and fill component
4. A flexible hose connects the master cylinder and caliper. It consumes certain volume of brake fluid displaced from the master cylinder to cater for its expansion under pressure. This results in additional lever travel.
5. In the Foundry aspect, for one vehicle set. it needs two dies and pours twice to get one caliper casting and one master cylinder casting.
6. In the manufacturing aspect, it needs a separate machining line and assembly line for caliper and master cylinder.
7. Though hydraulic braking system is advantageous over mechanical drum brake system, it is expensive compared to a drum brake system.
Figure (1) shows the current practice of installation of the hydraulic brake system, for example, the front brake system in a motor cycle.
Hydraulic braking system consists of the following: -
A master cylinder assembly (A) installed in the handle bar.

A caliper assembly (C) installed in the fork (F).
A hose assembly (B) connecting the master cylinder assembly (A) and
caliper assembly (C), using banjo bolts (E) and gasket (G)
A rotor assembly (D) installed in the wheel, which rotates when the
vehicle is moving.
Figure (2) shows the master cylinder assembly. As illustrated in figure(2) the master cylinder assembly (A) is installed in the handle bar on the right hand side. The master cylinder consists of body (1), spring (2), primary seal (3), plunger (4), secondary seal (5), circlip (6), boot (7). hand lever (8), diaphram (9), reservoir cap (10).
As illustrated in figure (3) which shows the caliper assembly, consists of body (11). pistons (12)(13) (example is taken from a twin pot caliper), piston seal (14)(15), wiper seal (16)(17), friction pads (18)(19), sliding pin (20)(21). dust preventing boots (22) (23), carrier (24) and bleed screw. The caliper is installed in the fork tube. Both master cylinder and the caliper are connected by means of flexible hose (B). The brake rotor (D) is installed in the wheel that rotates along with wheel.

To address the above shortcomings retaining the advantage of a hydraulic brake system, the integral brake system idea is invented.
As illustrated in figure (4) the master cylinder body (1) and caliper body (11) is integrated as a single piece using conventional casting technique. A rotor assembly (D) is installed in the wheel. The integrated braking assembly is installed in the appropriate location. The integrated braking assembly is connected to the hand lever* by means of cable and suitable lever. When the hand lever is actuated during brake application the cable connected to the hand lever is actuated which in turn actuates the suitable lever provided in the integrating braking assembly. The levers provided in the integrated brake assembly in turn moves the plunger(4) forward compressing the spring (2) and the primary seal(3) compresses the brake fluid in the system and transfers to the caliper area under pressure through passage (25). The secondary seal (5) prevents the fluid leak through the master cylinder mouth. The plunger (4) is retained by means of the circlip (6) and covered using a boot (7) to prevent from dust entry inside the master cylinder. This pressure developed in the caliper area actuate the caliper piston(12)(13) or pistons. The seal (14) (15) assist the caliper piston to return to the home position after pressure release. The seal (16) (17) prevents the dust entry into the caliper. If it is twin pot caliper, both the pots are connected through the passage (26) and so on for multiple pot caliper. The caliper pistons (12)(13)

in turn moves the friction material (18) against the rotating disc(D) attached to the automotive wheel . After the friction material (18) touches the rotating disc (D), the pressure available in the system pushes the integral body (1 & 11) in the opposite direction tnus pusning the triction material (19) against the rotating disc (D) on the other side of the disc (D). Thus a clamping force is created and the rotating disc (D) is slowed down or stopped depending upon the pressure developed effecting the braking ftinction.
By using this Integral Braking System design, the brake hose which connects the master cylinder, and the caliper (as in conventional system) is eliminated . The bleeding of this system is more effective. Replacing the existing drum brake with IBS is very simple and inexpensive.
The master cylinder is used to displace the brake fluid into the caliper and generate pressure to result in clamping force on to the rotor. The salient feature of the invention is that both the master cylinder and the caliper are integrated into an single assembly that is installed on to the fork where caliper is installed in the existing system.
The function of the hydraulic braking system in existing vehicle is as follows :-

The lever (8) is pressed to apply the brake. This displaces the brake fluid in the system to the caliper assembly.
As volume of brake fluid is displaced into the caliper, the pads (18 & 19) are moved and the pressure developed in the system is transmitted as a clamping force on to the rotor (D).
This function result in either stopping the vehicle completely or slowing down the vehicle depending upon the load applied on the hand lever of the master cylinder.
It is herein explained the function of a hydraulic brake system in accordance with state of art technology and the current practice of installation.
As explained the master cylinder is used to displace the brake fluid into the caliper and generates pressure to result in clamping force on to the rotor. The innovation claimed is that both the master cylinder (A) and the caliper(C) are integrated into single assembly that is installed on to the fork where caliper (C) is Installed in the existing system.

Advantages of the invention
a) By this arrangement, the short coming enumerated herein is eliminated in such a way, that one bleed screw is provided which is adequate to bleed the integral system.
b) By integrating the master cylinder with the caliper, the short coming enumerated herein is elijninated since there is no head difference.
c) Hence bleeding the brake system to remove the air becomes very simple, effective and consumes minimum most time. No evacuate and fill equipment is required for bleeding the system.
d) By this innovation, the flexible hose is eliminated to connect the master cylinder and the caliper This eliminates the short coming enumerated herein. No additional lever travel is required to cater for hose expansion.
e) It is also ensured that no joints provided between master cylinder and caliper thus leak free brake system.
f) One single die can be designed and one pour of metal is enough to get an integrated casting. This innovation thus eliminates the short coming

enumerated herein, that is, two dies and two pours of the casting resulting in saving of metal and cost.
g) One machining line and one assembly line are adequate to produce the integrated braking component. Thus, this innovation eliminates the short coming enumerated herein and thereby simplifying the manufacture and saving cost.
h) By this innovation, the flexible hose (B), the banjo bolts (E) and Gaskets
(G) both at master cylinder and caliper ends, the mounting holder and the
bolts for the master cylinder are eliminated. This eliminates the short
coming enumerated herein and makes the hydraulic brake system less
expensive.
i) Suitable levers mounted on to the Integral Braking System can operate the master cylinder piston. These levers can be operated by the conventional cable system used in drum brake installation.
j) This facilitates the vehicle manufacturer to make use of the components used for drum brake installation, like, hand lever, hand lever mounting brackets, stop light switch and the cables.

k) The rider will see no difference in the handle bar but feel good and stable when applies the brake.
I) The vehicle manufacturer need not invest on new lever development when they offer hydraulic brake system on the same model as an option to the end user.
m) The existing braking function is retained in the Integral Braking System (IBS).

Salient feature of the Invention
1. Integrating the master cylinder and the caliner of a braking system as a single assembly using a conventional casting method such that the single assembly being installed to the fork where the caliper is presently installed in the existing system.
2. The elimination of head difference between master cylinder and the caliper for effective and simple bleeding.
3. Elimination of flexible hose connection between master cylinder and caliper saving additional fluid volume consumption due to hose expansion.
4. Elimination of leak joints between master cylinder & hose and caliper & hose.
5. Elimination of flexible hose and related fittings, elimination of clamping provisions in the master cylinder resulting in cost effective braking system.



6. Simple and cost effective retrofitment hydraulic brake system replacing the drum brake in existing vehicles running in the field,



The invention will be explained in relation to specific embodiment. It is inferred that the forgoing description is only illustrative of the present invention and it is not intended that the invention be limited or restrictive thereto. Many other specific embodiments of the present invention will be apparent to one skilled in the art from the foregoing disclosure. All substitution, alterations and modification of the present invention which come within the scope of the claims are to which the present invention is readily susceptible without departing from the spirit of the invention.
The scope of the invention should thereof be determined not with reference to the above description but should be determined with reference to appended claims along with full scope of equivalents to which such claims are entitled.



CLAIMS
(1) Integrated Braking System for two wheelers comprising of integrated
assembly of master cylinder and the caliper using a conventional casting
method, the said assembly being installed on the appropriate location where the
caliper is presently installed in the existing system.
(2) Integrated Braking System for two wheelers as claimed in claim 1
comprising a master cylinder compartment and caliper compartment assembled
to form a single body that forms the integrated braking assembly and a rotor
assembly installed in the wheel, the integrated braking assembly being installed
in the appropriate location, the integrated braking assembly is connected to the
hand lever or foot pedal by means of cable and suitable lever, such that when
the hand lever or foot pedal is actuated during brake application, the cable
connected to the hand lever or foot pedal is activated which in turn activates the
suitable levers provided in the integrated braking assembly, the levers provided
in the integrated braking assembly in turn moves the plunger forward and the
primary seal compresses the brake fluid in the system and transfers to the
caliper area under pressure through a passage, this pressure developed in the
caliper area actuate the caliper piston or pistons, through a passage, the said
caliper pistons in tunn move the friction material against the rotating disc being
attached to the wheel such that after the friction material touches the rotating
disc the pressure available in the system pushes the integral body in the
opposite direction thus pushing the friction material against the rotating disc on
the other side of the disc such that a clamping force is created and the rotating
disc being either slowed down or stopped depending upon the pressure
developed effecting the braking function.

(3) Integrated braking system for two wheelers as claimed in claim 1 wherein
the said pot caliper is a single pot caliper.
(4) Integrated braking system for two wheelers as claimed in claim 1 wherein
the said pot caliper is a two pot caliper wherein both the pots are connected
through a passage.
(5) Integrated braking system for two wheelers as claimed in claim 1 wherein
the said pot caliper is a multiple pot caliper.
(6) Integrated braking system for two wheelers as claimed in claim 1 wherein
one bleed screw being provided which is adequate to bleed the entire braking
system.
(7) Integrated braking system for two wheelers as claimed in claim 1 wherein
one single die being designed and one pour of metal being enough to get an
integrated casting.
(8) Integrated braking system for two wheelers as claimed in claim 1 wherein
one machining line and one assembly line being adequate to produce the
integrated braking component.
(9) Integrated braking system for two wheelers as claimed in claim 1 wherein
suitable levers being mounted on the integral braking system that can operate
the master cylinder piston.
(10) Integrated braking system for two wheelers as claimed in claim 1 wherein
the system retains the existing braking function.
(11) Integrated braking system for two wheelers as described in the
specification as illustrated by way of drawings accompanying the description.


Documents:

135-mas-2002-abstract.pdf

135-mas-2002-claims filed.pdf

135-mas-2002-claims granted.pdf

135-mas-2002-correspondnece-others.pdf

135-mas-2002-correspondnece-po.pdf

135-mas-2002-description(complete)filed.pdf

135-mas-2002-description(complete)granted.pdf

135-mas-2002-drawings.pdf

135-mas-2002-form 1.pdf

135-mas-2002-form 19.pdf


Patent Number 210194
Indian Patent Application Number 135/MAS/2002
PG Journal Number 50/2007
Publication Date 14-Dec-2007
Grant Date 25-Sep-2007
Date of Filing 20-Feb-2002
Name of Patentee M/S. BRAKES INDIA LIMITED
Applicant Address PADI, CHENNAI - 600 050,
Inventors:
# Inventor's Name Inventor's Address
1 H. RAMASUBRAMANIAN BRAKES INDIA LIMITED PADI, CHENNAI - 600 050,
PCT International Classification Number F16D 55/00
PCT International Application Number N/A
PCT International Filing date
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 NA