Manual braking system with hydraulic brake booster

An apparatus for use with a vehicle braking system having a brake pedal adapted to be used by an operator, a pushrod having one end connected to the brake pedal, a master cylinder having a mechanical input connected to an opposite end of the pushrod, and at least one wheel cylinder, the braking system further including a booster connected to a vacuum system, the apparatus comprising:

• a hydraulic pressure intensifier comprising
• an intensifier inlet adapted to be fluidly connected to an output of the master cylinder,
• an intensifier outlet adapted to be fluidly connected to an input of the wheel cylinder,
• an intensifier cylinder having a stepped internal bore with a larger end having an interior surface receiving the intensifier inlet and a smaller end adjacent the intensifier outlet,
• an intensifier piston having a larger end disposed in the larger end of the intensifier cylinder and a smaller end disposed in the smaller end of the intensifier cylinder, the larger end having
• a larger end face, and
• a seal contacting the larger end face when the larger end face is positioned immediately adjacent the interior surface, the seal forming an enclosed volume intersecting the intensifier inlet, the enclosed volume being bounded by the larger end face and the interior surface of the intensifier cylinder and having a cross-sectional area substantially equal to a cross-sectional area of the smaller end of the piston,
• a biasing element disposed between the smaller end of the piston and the smaller end of the cylinder for biasing the intensifier piston toward the larger end of the cylinder,
• a sealing ring disposed on the smaller end of piston to fluidly separate the smaller and larger ends of the intensifier cylinder, and
• a vent path having one end intersecting an annular volume between the smaller end of the intensifier piston and the larger end of the intensifier cylinder, and the vent path having an opposite end extending through a wall of the intensifier cylinder;
• a pressure sensor connected to the vacuum system and having an output providing
• a first state in response to a normal pressure in the vacuum system, and
• a second state in response to an abnormal pressure in the vacuum system;
• and
• a bypass valve operatively connected to the pressure sensor, the bypass valve having an input fluidly connected to an output of the master cylinder and the intensifier inlet and an output fluidly connected to the wheel cylinder and the intensifier outlet, the bypass valve having
• an open state for fluidly connecting the master cylinder to the wheel cylinder via the bypass valve in response to the first state of the output of the pressure sensor, and
• a closed state fluidly connecting the hydraulic pressure intensifier between the master cylinder and the wheel cylinder in response to the second state of the output of the pressure sensor, whereby a fluid pressure from the master cylinder applied to the inlet of the intensifier cylinder is multiplied to a greater fluid pressure at the outlet of the intensifier cylinder and applied to the wheel cylinder.