Abstract: A master cylinder assembly (10) and method for manufacturing the same includes a housing 12 for movably receiving a pair of pistons (32, 34) which cooperate with seals (28, 30) to communicate fluid pressure to respective brake circuits during braking. A reservoir 40 is formed by an integrally molded single unit which also extends into the housing bore (11) to define a liner (46) which substantially positions the seals (28, 30) within the bore (11). A sleeve (26) is also positioned in the bore 11 by the liner (46). When the master cylinder assembly (10) is manufactured the reservoir (40) and liner (46) are formed simultaneously.

Abstract: A method of manufacturing a shell (10) for a vacuum brake booster wherein a reinforcing plate (22) is coined to the shape of the end member (16) to provide structural strength for uniformly transmitting forces from a reaction member to the body (16) of the shell. After the reinforcing plate (22) is coined, holes (36, 38) are simultaneously punched through the plate (22) and end member (16) for fastener (40, 42) means through which the brake booster is attached to the reaction member.

Abstract: A connection (40) for joining a front shell (12) to a rear shell (14) to create a housing for a fluid pressure servomotor (10). The peripheral surfaces of the first (12) and second shells (14) have a conical section (46,58) and a radial section (48,60). The conical sections (46,58) are designed to mate prior to the radial sections (48,60) engaging each other to assure that a minimum contact occurs in order to seal the housing.

Abstract: A control valve 44 for use in a fluid pressure operated motor 10 to control the communication of fluid between first and second chambers 34 and 36. The control valve 44 includes a plunger 58, a disc 46 and a retainer 70. The retainer 70 has a cylindrical body 82 with an inwardly projecting lip of which section 84 engages and holds the peripheral surface 48 against shoulder 78 on the hub 26 and an end section 94 which acts as a stop to limit the movement of plunger 58 in bore 38 when the valve 44 is in the released position. Tabs 100, 100'. . . 100.sup.N on sleeve or cylinder 82 are located in groove 102 to lock the retainer 70 in place. In response to an input, push rod 56 moves plunger 58 to allow disc 46 to move and initially interrupt communication of a first fluid between the first and second chamber 34 and 36 and thereafter permit a second fluid to flow into the second chamber 36.

Abstract: A fluid pressurizing device 10 having a master cylinder 12 with a cylindrical projection 52 that extends through the housing of a brake booster 14. The housing of the brake booster 14 has a front shell 56 located on a shoulder 54 of the cylindrical projection 52 and a rear shell 140 located against a shoulder 150. A nut carried by the cylindrical projection 52 engages the rear shell 140 to compress a bead 111 of a diaphragm 110 against a shoulder 57 on the front shell 56. A sleeve 80 connected to a hub member 70 retains a bead 108 of diaphragm 110 and bead 90 of a diaphragm 92 connected to the cylindrical projection 52. In response to an input force, a valve assembly 136 controls the development of a pressure differential across the diaphragms 92 and 110. The pressure differential acts on and moves the diaphragms 92 and 110 toward the first shell 56.

Abstract: A brake actuation assembly (10) wherein a front shell (50) of a booster mechanism (14) is attached to a stationary bulkhead (32) and the housing (58) of a master cylinder (12). On actuation of the booster mechanism (14) an output force is produced to operate the master cylinder (12). The operation of the master cylinder (12) develops a corresponding reaction force which is directly transferred into the stationary bulkhead (22) to substantially eliminate any axial deformation in the rear shell (20) of the booster mechanism (14).

Abstract: A stud for connecting a first housing with a second housing. The stud has a cylindrical body with a head on a first end thereof. The head has a face with an irregular surface that extends from a guide surface to the periphery of the head. The guide surface extends through an opening in the first housing until the irregular surface engages the housing adjacent the opening. An orbital rotating tool engages the guide surface causing the guide surface to flare and engage the housing when a constant pressure is applied to the head. Thereafter, the material adjacent the opening flows into the irregular surface to seal the opening while preventing the stud from rotating when a torque is applied to the cylindrical body.

Abstract: A mechanism for multiplying the travel of a valve as compared with the travel of an input push rod member. The mechanism has a housing with a bore therethrough for retaining an accurate segmented lever. The segmented lever, which is pivotally attached to the housing, axially locates an output push rod member in the bore. A plunger attached to the input push rod has an arcuate projection which engages the segmented lever. The plunger moves in response to an operator input force causing the lever to pivot in said housing and move the output push rod at a different rate of travel than the rate of travel of the input push rod.

Abstract: A lever arrangement for providing a servomotor in a power braking system with a variable operational output force. The servomotor has a wall moved by a pressure differential to create an initial output force. The lever arrangement is attached to the servomotor and modifies the initial output force from the wall to create the variable operational output force which is supplied to a master cylinder.