Patent ID: 6062124
Filing Date: 2000-05-16
Classification: B60T,Y10T

Abstract:
A method of forming a motor vehicle brake booster including a front housing; a primary brake actuator rod slidable positioned in the front housing; a rear housing; an emergency spring positioned in the rear housing; an intermediate housing positioned between the front and rear housings and defining a central partition; a front diaphragm having a periphery clamped at the juncture of the front and intermediate housings and acting at a forward face thereof against a rear end of the primary actuator rod; a rear diaphragm having a periphery clamped at the juncture of the rear and intermediate housings; a bearing plate positioned in the rear housing having a rear face receiving a forward end of the emergency spring and a forward face bearing against a rear face of the rear diaphragm; an emergency brake actuator rod having a front end positioned forwardly of the central partition for coaction with a rear face of the front diaphragm, a rear end bearing against a forward face of the rear diaphragm, and an intermediate portion passing slidable through a central aperture in the central partition; and a return spring positioned between the central partition and the rear diaphragm in surrounding relation to the emergency brake actuator rod; the improvement wherein the intermediate housing is formed by the steps of:shaping a first sheet of sheet metal to form a cup shaped rear sheet metal stamping having a rear base portion including a central aperture and a rear rim portion in surrounding relation to the rear base portion;shaping a second piece of sheet metal to form a cup shaped front sheet metal stamping having a front base portion including a central aperture corresponding in size, placement, and configuration to the central aperture in the rear base portion and a front rim portion in surrounding relation to the front base portion;positioning the base portions in confronting relation with the base portion central apertures aligned;securing the base portions together to form the intermediate housing with the base portions coacting to define the central partition of the intermediate housing and the aligned base portion central apertures coacting to define the central aperture of the central partition;providing a bushing sized to slidably receive the intermediate portion of the emergency brake actuator rod; andpositioning the bushing in the aligned central apertures in the base portions of the stampings.