Modular Non-Linear Spring System

Abstract

A modular non-linear spring system capable of simulating traditional brake pedal feel when incorporated into a hydraulic and/or electro-hydraulic vehicle braking system. The system can include a first spacer having a top surface and a bottom surface and an optional second spacer having a top surface and a bottom surface. In one arrangement, a first mechanical spring is in abutting engagement with the top surface of said first spacer, a second mechanical spring is in abutting engagement with the bottom surface of said first spacer and the top surface of said second spacer, and an optional third mechanical spring is in abutting engagement with the bottom surface of said second spacer. The springs are arranged to be progressively compressed using a brake pedal of the braking system.

1 .- 29 . (canceled) 
     
     
         30 . A modular non-linear spring system suitable for use in a vehicle braking system comprising:
 a first spacer having a top surface and a bottom surface;   a first spring having a top and bottom end, said bottom end of said first spring in abutting engagement with said top surface of said first spacer;   a second spacer, said second spacer having a top surface and a bottom surface;   a second spring having a top and bottom end, said top end of said second spring in abutting engagement with the bottom surface of said first spacer, said bottom end of said second spring in abutting engagement with said top surface of said second spacer, said first and second springs spaced from another by said first spacer; and;   a third spring having a top and bottom end, said top end of said third spring in abutting engagement with said bottom surface of said second spacer, said second and third springs spaced from another by said second spacer;   wherein said first, second, and third springs are sequentially compressible whereby compression of said first, second, and third springs in said modular non-linear spring system provides a non-linear, progressively increasing mechanical spring force, and,   wherein at least two of said first, second, and third springs have different spring sizes, different spring rates, and/or are a different spring type, and,   wherein a) said top surface of said second spring is positioned below said bottom surface of said first spring, and/or b) said top surface of said third spring is positioned below said bottom surface of said second spring.   
     
     
         31 . The modular non-linear spring system as defined in  claim 30 , wherein said first, second, and third springs have said different spring sizes, said different spring rate, and/or said different spring type. 
     
     
         32 . The modular non-linear spring system as defined in  claim 30 , wherein at least two of said first, second, and third springs are mechanical springs. 
     
     
         33 . The modular non-linear spring system as defined in  claim 30 , wherein said first spring compresses 5-95% of its full compression length prior to said second spring compressing more than 1-10% of its full compression length. 
     
     
         34 . The modular non-linear spring system as defined in  claim 33 , wherein said first spring compresses 75-95% of its full compression length prior to said second spring compressing more than 1-10% of its full compression length. 
     
     
         35 . The modular non-linear spring system as defined in  claim 33 , wherein said first and second springs compress 5-95% of each of their full compression lengths prior to said third spring compressing more than 1-10% of its full compression length. 
     
     
         36 . The modular non-linear spring system as defined in  claim 33 , wherein said first spring compresses 75-95% of its full compression length prior to said second spring compressing more than 1-10% of its full compression length, said first and second springs compress 75-95% of each of their full compression lengths prior to said third spring compressing more than 1-10% of its full compression length. 
     
     
         37 . The modular non-linear spring system as defined in  claim 30 , wherein said first spring is a clover dome washer or a Belleville washer, said second spring is a coil spring, and said third spring is a clover dome washer or a Belleville washer, said first and third springs having a different spring rate. 
     
     
         38 . The modular non-linear spring system as defined in  claim 30 , wherein said first and second springs are coil springs, and said third spring is a clover dome washer or a Belleville washer, said first and second springs having a different spring rate. 
     
     
         39 . The modular non-linear spring system as defined in  claim 30 , wherein said first spring is a clover dome washer or a Belleville washer or a coil spring, said second spring is a clover dome washer or a Belleville washer or coil spring, and said third spring is a clover dome washer or a Belleville washer or a coil spring. 
     
     
         40 . The modular non-linear spring system as defined in  claim 30 , wherein each of said first, second and third springs has an uncompressed axial length and a compressed axial length, and wherein the uncompressed length of said second spring is greater than the uncompressed length of said first and third springs. 
     
     
         41 . A hydraulic brake system comprising a master cylinder having a cavity and a piston supported in the cavity, and a modular non-linear spring system as defined in  claim 30  supported in the cavity and engageable with the piston of the master cylinder, and wherein the piston of the master cylinder is configured to compress at least one of said springs. 
     
     
         42 . The hydraulic brake system as defined in  claim 30 , wherein said first, second, and third springs are coaxially aligned along a common axis of the cavity. 
     
     
         43 . A method of simulating traditional brake pedal feel in a brake pedal of a braking system comprising:
 providing a modular non-linear spring system as defined in  claim 30 ; and   compressing said springs in progression with the brake pedal.   
     
     
         44 . A modular non-linear spring system suitable for use in a vehicle braking system comprising:
 a first spacer having a top surface and a bottom surface;   a first spring having a top and bottom end, said bottom end of said first spring in abutting engagement with said top surface of said first spacer;   a second spacer, said second spacer having a top surface and a bottom surface;   a second spring having a top and bottom end, said top end of said second spring in abutting engagement with the bottom surface of said first spacer, said bottom end of said second spring in abutting engagement with said top surface of said second spacer, said first and second springs spaced from another by said first spacer; and;   a third spring having a top and bottom end, said top end of said third spring in abutting engagement with said bottom surface of said second spacer, said second and third springs spaced from another by said second spacer;   wherein said first, second, and third springs are sequentially compressible whereby compression of said first, second, and third springs in said modular non-linear spring system provides a non-linear, progressively increasing spring force, and,   wherein at least two of said first, second and third springs have different spring sizes, different spring rates, and/or are a different spring type, and,   wherein a) said top surface of said second spring is positioned below said bottom surface of said first spring, and/or b) said top surface of said third spring is positioned below said bottom surface of said second spring,   wherein said first spring compresses 75-95% of its full compression length prior to said second spring compressing more than 1-10% of its full compression length, said first and second springs compress 75-95% of each of their full compression lengths prior to said third spring compressing more than 1-10% of its full compression length, and,
 wherein the first spring is a clover dome washer or a Belleville washer or a coil spring, and the third spring is a clover dome washer or a Belleville washer or a coil spring, and, 
 wherein each of the first, second, and third springs has an uncompressed axial length and a compressed axial length, and wherein the uncompressed length of said second spring is greater than the uncompressed length of said first and/or second springs. 
   
     
     
         45 . The modular non-linear spring system as defined in  claim 44 , wherein said first, second, and third springs are mechanical springs, said first, second, and third springs have different spring size, said different spring rate, and/or said different spring type. 
     
     
         46 . The modular non-linear spring system as defined in  claim 45 , wherein said first spring is a clover dome washer or a Belleville washer, said second spring is a coil spring, and said third spring is a clover dome washer or a Belleville washer, said first and third springs having a different spring rate. 
     
     
         47 . The modular non-linear spring system as defined in  claim 45 , wherein said first and second springs are coil springs, and said third spring is a clover dome washer or a Belleville washer, said first and second springs having a different spring rate. 
     
     
         48 . The modular non-linear spring system as defined in  claim 45 , wherein said first spring is a clover dome washer or a Belleville washer or a coil spring, said second spring is a clover dome washer or a Belleville washer or coil spring, and said third spring is a clover dome washer or a Belleville washer or a coil spring. 
     
     
         49 . The hydraulic brake system as defined in  claim 44 , wherein said first, second, and third springs are coaxially aligned along a common axis of the cavity. 
     
     
         50 . A hydraulic brake system comprising a master cylinder having a cavity and a piston supported in the cavity, and a modular non-linear spring system as defined in  claim 44  supported in the cavity and engageable with the piston of the master cylinder, and wherein the piston of the master cylinder is configured to compress at least one of said springs. 
     
     
         51 . A method of simulating traditional brake pedal feel in a brake pedal of a braking system comprising:
 providing a modular non-linear spring system as defined in  claim 44 ; and
 compressing said springs in progression with the brake pedal.