Devices and systems for preventing misalignment in vehicle brake assemblies

Abstract

A vehicle brake assembly may include an actuation lever coupled to a brake pedal, and a push rod of a brake booster. The push rod may have a clevis on an end portion thereof. The actuation lever is configured to be pivotally supported between two prongs of the clevis via a clevis pin. The assembly may further include at least one alignment device configured to guide and position the clevis on the push rod into alignment with the actuation lever during construction of the brake assembly.

What is claimed is: 
     
         1 . A vehicle brake assembly, comprising:
 an actuation lever coupled to a brake pedal;   a push rod of a brake booster, the push rod having a clevis on an end portion thereof, wherein the actuation lever is configured to be pivotally supported between two prongs of the clevis via a clevis pin; and   at least one alignment device configured to guide and position the clevis on the push rod into alignment with the actuation lever during construction of the brake assembly.   
     
     
         2 . The assembly of  claim 1 , wherein the actuation lever is a brake pedal arm. 
     
     
         3 . The assembly of  claim 1 , wherein the actuation lever is coupled to a brake pedal arm. 
     
     
         4 . The assembly of  claim 1 , wherein the at least one alignment device is coupled to the actuation lever. 
     
     
         5 . The assembly of  claim 4 , wherein the at least one alignment device comprises a saddle element configured to sit on the actuation lever, the saddle element comprising first and second U-shaped ends configured to receive the actuation lever. 
     
     
         6 . The assembly of  claim 1 , wherein the at least one alignment device is coupled to the clevis on the push rod. 
     
     
         7 . The assembly of  claim 1 , wherein the at least one alignment device comprises a body and at least one sliding surface, the at least one sliding surface extending laterally away from the body to guide and position the clevis on the push rod into alignment with the actuation lever. 
     
     
         8 . The assembly of  claim 7 , wherein the at least one sliding surface has an offset that runs substantially parallel to the body at a predefined distance therefrom. 
     
     
         9 . The assembly of  claim 7 , wherein the at least one sliding surface comprises first and second sliding surfaces running obliquely to one another such that distal ends of each of the sliding surfaces are situated at a greater distance from one another than proximal ends of each of the sliding surfaces. 
     
     
         10 . The assembly of  claim 9 , wherein the first and second sliding surfaces comprise first and second lateral wing elements that form a catchment area therebetween. 
     
     
         11 . An alignment device, comprising:
 a saddle element configured to sit on a pedal arm of a brake assembly, the saddle element comprising first and second U-shaped ends configured to receive the pedal arm,   wherein the first and second U-shaped ends are spaced apart from one another by an opening defined by first and second lateral wing elements; and   wherein the first and second lateral wing elements form a catchment area configured to guide and position a push rod of a brake booster into alignment with the pedal arm.   
     
     
         12 . The device of  claim 11 , wherein at least one sidewall of the saddle element comprises a flange with a circular bore. 
     
     
         13 . The device of  claim 12 , wherein the saddle element is configured to sit on the pedal arm such that the circular bore in the at least one sidewall is aligned with a bushing hole in the pedal arm. 
     
     
         14 . The device of  claim 11 , wherein the opening extends along a longitudinal axis of the saddle element. 
     
     
         15 . The device of  claim 11 , wherein the wings extend outwardly at an angle of about 26 degrees to about 36 degrees. 
     
     
         16 . The device of  claim 11 , wherein the catchment area is configured to guide and position a clevis on an end of the push rod into alignment with the pedal arm. 
     
     
         17 . A vehicle brake pedal assembly, comprising:
 a pedal arm comprising a pair of bushing holes on opposite sides of the arm; and   an alignment device comprising a saddle element comprising first and second U-shaped ends that receive the pedal arm,   wherein the first and second U-shaped ends are spaced apart from one another by an opening defined by first and second lateral wing elements; and   wherein the first and second lateral wing elements form a catchment area configured to guide and position a push rod of a brake booster into alignment with the pedal arm.   
     
     
         18 . The device of  claim 17 , wherein the opening extends along a longitudinal axis of the alignment device. 
     
     
         19 . The device of  claim 17 , wherein the wings extend outwardly at an angle of about 26 degrees to about 36 degrees. 
     
     
         20 . The device of  claim 17 , wherein the catchment area is configured to guide and position a clevis on an end of the push rod into alignment with the pedal arm. 
     
     
         21 . The device of  claim 20 , wherein the clevis comprises two prongs with a hole in each prong, and wherein the catchment area is configured to guide and position the clevis over the pedal arm such that a prong of the clevis is positioned on each side of the pedal arm and the holes of the clevis are in alignment with the bushing holes of the pedal arm. 
     
     
         22 . The device of  claim 17 , wherein the alignment device is integral with the pedal arm. 
     
     
         23 . The device of  claim 17 , wherein the alignment device is affixed to the pedal arm. 
     
     
         24 . The device of  claim 23 , wherein the alignment device is welded to the pedal arm. 
     
     
         25 . A method of constructing a vehicle brake assembly, comprising:
 joining an alignment device with an actuation lever coupled to a brake pedal of the assembly or a push rod of a brake booster of the assembly;   guiding the push rod of the brake booster into alignment with the actuation lever via the alignment device; and   coupling the push rod of the brake booster to the actuation lever.   
     
     
         26 . The method of  claim 25 , wherein joining the alignment device with an actuation lever comprises joining an alignment device with a pedal arm, the alignment device comprising a pair of wings extending outwardly relative to the pedal arm and defining a catchment area between the wings. 
     
     
         27 . The method of  claim 26 , wherein guiding the push rod of the brake booster comprises guiding the push rod into the catchment area to align the push rod with the pedal arm. 
     
     
         28 . The method of  claim 25 , wherein joining the alignment device to the actuation lever or the push rod comprises welding the alignment device to the actuation lever or the push rod. 
     
     
         29 . The method of  claim 25 , wherein joining the alignment device to the actuation lever or the push rod comprises forming the alignment device with the actuation lever or the push rod. 
     
     
         30 . The method of  claim 25 , wherein guiding the push rod of the brake booster into alignment with the actuation lever comprises aligning a clevis at an end of the push rod with the actuation lever. 
     
     
         31 . The method of  claim 30 , wherein aligning the clevis with the actuation lever comprises guiding the clevis over the actuation lever such that a prong on each side of the clevis is positioned on each side of the actuation lever and a hole in each prong is aligned with a bushing hole in each side of the actuation lever. 
     
     
         32 . The method of  claim 31 , wherein coupling the push rod of the brake booster to the actuation lever comprises inserting a pin through the aligned holes of the clevis and the pedal arm.