Power brake booster system

In a power brake assembly having a housing, an input member, a pair of movable power walls in said housing, a control valve mechanism for selectively controlling differential air pressure acting on said power walls to operate said assembly in accordance with movement of said input member, an output member for transmitting actuating force to a master cylinder, and reaction means for transmitting a portion of the actuating force reaction to said input member:

• a unitary, generally cylindrical, power piston having formed therein a control valve chamber containing said control valve mechanism and a reaction means chamber containing said reaction means, and including as integral portions thereof mounting means for said power walls and support and guide sections for supporting and guiding said piston in axial movements in said housing;
• said piston having one of said mounting means for one of said power walls at one end thereof, the other mounting means for the other of said power walls being at an intermediate position axially between said support and guide sections, and one of said support and guide sections being at the other end of said piston, said piston having a maximum outer diameter defined by said one mounting means and a minimum outer diameter defined by said one support and guide section, all portions of said piston located axially between and including said one mounting means and said one support and guide section having maximum and intermediate outer diameters with no such outer diameter over which either of said power walls slide during assembly being larger than any other diameter which is axially closer to said one mounting means so that power walls may be sequentially slidably received onto said piston axially from said other end of said piston toward said one mounting means during assembly;
• said reaction means having a reaction body mounted in said reaction means chamber, said reaction means being of the rubber-like disc type.

In a power brake assembly having a housing, an input member, a pair of movable power walls in said housing, a control valve mechanism for selectively controlling differential air pressure acting on said power walls to operate said assembly in accordance with movement of said input member, an output member for transmitting actuating force to a master cylinder, and reaction means for transmitting a portion of the actuating force reaction to said input member:

• a unitary, generally cylindrical, power piston having formed therein a control valve chamber containing said control valve mechanism and a reaction means chamber containing said reaction means, and including as integral portions thereof mounting means for said power walls and support and guide sections for supporting and guiding said piston in axial movements in said housing;
• said piston having one of said mounting means for one of said power walls at one end thereof, the other mounting means for the other of said power walls being at an intermediate position axially between said support and guide sections, and one of said support and guide sections being at the other end of said piston, said piston having a maximum outer diameter defined by said one mounting means and a minimum outer diameter defined by said one support and guide section, all portions of said piston located axially between and including said one mounting means and said one support and guide section having maximum and intermediate outer diameters with no such outer diameter over which either of said power walls move during assembly being larger than any other outer diameter which is axially closer to said one mounting means so that said power walls may be sequentially and slippably received onto said pattern axially and in proper order from said piston other end toward said one mounting means during assembly.

For use in a power brake assembly having a housing with a rear wall, an input member, a pair of movable power walls in said housing with a fixed divider wall therebetween, a control valve mechanism for selectively controlling pressures acting on said power walls to operate said assembly in accordance with movements of said input member, reaction means, and an output member for transmitting actuating force to a master cylinder, the invention comprising:

• a subassembly of said power brake assembly including said control valve mechanism, said reaction means and a unitary, generally tubular, power piston having as integral portions thereof a pair of mounting means for said pair of power walls and a pair of support and guide sections for supporting and guiding said piston in axial movements with respect to said housing rear wall and said divider wall, and wherein the piston has one mounting means for one of said power walls at one end thereof and another mounting means for the other of said power walls at an axially intermediate position between said support and guide sections with one of said support and guide sections being at the other piston end, said piston having a largest outer dimension defined by said one mounting means, a smallest outer dimension defined by said one support and guide section and all portions of said piston located axially between said one mounting means and said one support and guide section and over which said one power wall must pass during assembly having intermediate outer dimensions no larger than any other dimension which is axially closer to said one mounting means so that said walls may be slippingly received onto said piston sequentially in proper order and axially from said other end of said piston toward said one mounting means,
• said control valve mechanism including a movable valve installed in said other piston end and adapted to be connected to said input member upon final assembly of the power brake assembly,
• said reaction means being mounted in said piston adjacent said piston one end and adapted to be connected to said output member upon final assembly of the power brake assembly.