TITLE
CLUTCH BOOSTER WITH A TRIGGER OR BALANCING VALVE DESIGN FOR LESSER PEDAL EFFORT FOR AUTOMOTIVE APPLICATION
FIELD OF THE INVENTION
This invention relates to mechanical engineering, specifically automobile engineering and relates to a clutchactuationsystem. This invention relates to a clutch booster with a trigger or balancing valve design for lesser pedal effort for automotive clutch actuation application, also containing a compact in-line air filter, a guide ring in the pneumatic housing, a pneumatic housing with spigot feature, a simple wear indicator& electronic wear indicator.
BACKGROUND OF THE INVENTION
The present invention is directed to new and improvements in pedal feel, wear indicator mechanism, filter, guide ring, spigot design used in clutch booster assy which in turn used for automotive clutch actuation system.
The number of heavy commercial trucks is increasing every year. Many drivers find the effort required to operate a manual clutch on a heavy commercial truck physically difficult. The pedal force required to operate a manual clutch on a heavy commercial truck can be as high as 75 pounds. This pedal force is approximately twice the force required to operate a manual clutch on a light vehicle. Frequent shifting in high density traffic or holding the clutch pedal down during long stops can be fatiguing. Power assistance to reduce the effort required to operate the manual clutch of a heavy commercial truck is thus desirable.
The concept of providing power assistance for manually operated devices is

not new. There are many existing techniques to accomplish power assistance. These devices tend to be complicated which makes them expensive and comprises reliability. Also, these devices frequently have slow response time and they do not provide assistance proportional to the pedal effort.
To provide power assistance for reducing the effort to operate a manual clutch, it is desirable to have a device that provides assistance that is proportional to the effort exerted on the clutch pedal, thereby maintaining the "natural feel" of the operation of the clutch. The response of the device should be quick enough to allow the driver to double clutch when shifting the transmission and the device should be relatively simple to keep manufacturing costs low and reliability high. Several other issues such as a a) compact mechanism to prevent foreign particles from the pneumatic supply, b) prevent excess articulations and mismatch due to split housing arrangement, c) reduce service costs during plunger maintenance,d) better alignment of the hydraulic housing, e) designing an efficient yet simple wear indicator,&f) electronic wear indicator also exist.
Some of the prior art in this field reveal various improvements made over the years in the art, specifically in the above areas in clutch boosters.
Indian Patent Application No: 369/CHE/2009 discloses a booster system of a clutch assembly. In the present invention, the check valve body with air inlet port is arranged in 90 degree from the assembly axis and acts against gravity. This arrangement enables faster positioning of the poppet valve to its original position and enables faster resetting of clutch pedal. The air inlet arrangement also results in decrease of overall height of clutch booster with respect to conventional clutch booster, and facilitates easy installation in the vehicles.
Indian Patent Application No: 562/CHE/2011 claims a hill-assist device (1) for a vehicle comprising: - a clutch booster (2) operatively connected to a clutch pedal and a clutch actuating linkage for aiding in clutch disengagement, said

clutch booster being equipped with a hydraulic cylinder and an air cylinder (11) coupled together, said clutch booster being provided with an adapter (3) for tapping out air from said air cylinder (11), - a solenoid valve (4) having pneumatic connection with the adapter (3) of said clutch booster (2), said solenoid valve (4) is fed with the air tapped out through said adapter (3) upon activation of said clutch booster (2), - a double check valve (5) for selectively receiving air either upon activation of foot brake (6) of the vehicle or upon activation of said solenoid valve (4), - a quick release valve(7) for receiving air delivered through said double check valve (5) and being configured to aid in activating and deactivating the braking device of the vehicle. The present invention also relates to a method of activating a hill-assist device.
With the foregoing in mind, therefore it is the need of the hour is to develop a clutch booster that offers less pedal effort, a compact mechanism to prevent foreign particles from the pneumatic supply, prevent excess articulations and mismatch due to split housing arrangement, reduce service costs during plunger maintenance, offer better alignment of the hydraulic housing, and provide a simple wear indicator.
The primary purposes of the present invention are to create a clutch booster with a trigger or balancing valve design for lesser pedal effort, which reduces the effort required to operate a clutch on a heavy commercial truck. A related purpose is to form a clutch booster of the foregoing characteristics so constructed as to prevent foreign particles from the pneumatic supply, prevent excess articulations and mismatch due to split housing arrangement, reduce service costs during plunger maintenance, offer better alignment of the hydraulic housing, and provide a simple wear indicator. This invention eventually addresses the above and proves to be performance efficient, cost effective and eases the assembly. These and other objects of the invention will become more apparent in the course of the ensuing specification and claims when taken with the accompanying drawings.

Further it will be apparent to those skilled in the art that the objects of this invention have been achieved by providing a clutch booster with a trigger or balancing valve design for lesser pedal effort which is unique in nature unlike existing clutch actuation /braking systems as described in the above prior art. Various changes may be made in and without departing from the concept of the invention. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing and modifying other methods and structures for carrying out the same purpose of the present invention. Further, features of some stages disclosed in this application may be employed with features of other stages. Therefore, the scope of the invention is to be determined by the terminology of the following claims and the legal equivalents thereof.
OBJECTIVES OF THE INVENTION
This invention may be summarized, at least in part, with reference to its objects.
The foremost object of the present invention is to present a clutch booster witha trigger or balancing valve design for lesser pedal effortfor automotive clutch actuation application.
Another object of the present invention is to providea clutch booster with a compact inline air filter to prevent foreign particles from the pneumatic supply.
Another object of the present invention isto provide a clutch booster witha guide ring to prevent excessarticulations and mismatch due to split housing arrangement.

A further object of the present invention isto provide a clutch booster thatreduces service costs during plunger maintenance due to having to change only the guide ring and not the entire plunger assembly.
A further object of the present invention isto provide a clutch booster with a spigot diameter that offers better alignment of the pneumatic housing with hydraulic housing during normal installation and servicing.
A further object of the present invention isto provide a clutch booster with a simple wear indicator.
A further object of the present invention isto provide a clutch booster with aelectronic wear indicator.
Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention.
SUMMARY OF THE INVENTION
The present invention embodies a clutch booster witha trigger or balancing valve design for lesser pedal effortfor automotive clutch actuation application.The present invention further contains acompact inline air filter to prevent foreign particles from the pneumatic supply, a guide ring to prevent excessarticulations and mismatch due to split housing arrangement, a spigot diameter that offers better alignment of the hydraulic housing, a simple wear indicator& electronic wear indicator.

The entire assembly comprises of the following parts: hydraulic body
(pneumatic)(1), housing (hydraulic)(2), seal guide(3), seal (pneumatic)(4), seal (hydraulic)(5), sealing ring (6), guide ring (7), piston(8), spacer(9), split bush(10), guide ring(11), seal (pneumatic)(12), spring(13), end cover (14),wire clip (16), dust cover(17), push rod(18), spring(19), spring(20), plunger assy(21), O-ring(22), seal(23), bush(24), cover(25), circlip(26), body (27), pin (28),spring (29), O-ring (30), circlip (31), bolt (32), washer (33), bleed screw(34), dust cap(35), relief valve(36), filter (37), seal (38), retaining ring (39), adaptor (40), seal (face)(41), mounting bolts (42), protective plug (43), and protective plug (44).
DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will be more readily apparent by persons skilled in the art when considered in reference to the following description and when taken in conjunction with the accompanying drawings listed below
Figure 1 is an exploded peripheral view of the present invention components and connector parts.
Figure 2 is across sectional view illustrating the working of the present invention trigger / balancing valve in theclutch booster.
Figure 3 is across sectional view illustrating the present invention in-line filter.
Figure 4 is a cross sectional view illustrating the present invention Guide ring at hydraulic piston.
Figure 5 is across sectional view illustrating the present invention pneumatic housing with spigot feature.

Figure 6 is across sectional view illustrating the present invention simple wear indicator.
Figure 7 is a cross sectional view illustrating the present invention electronic wear indicator.
DETAILED DESCRIPTION
The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of particular applications of the invention and their requirements. The present invention can be configured as follows:
The present invention is a clutch booster with a trigger or balancing valve design for lesser pedal effortfor more durability, significant weight reduction and less wear and tear of parts.
Construction
As shown in Figures 1 to 6, the present clutch booster invention components are as follows:
According to a preferred embodiment of the present invention, as depicted in Figure 1,the entire assembly of the present invention comprises of the following parts: hydraulic body (pneumatic) (1), housing (hydraulic) (2), seal guide (3), seal (pneumatic) (4), seal (hydraulic) (5), sealing ring (6), guide ring (7), piston (8), spacer (9), split bush (10), guide ring (11), seal (pneumatic) (12), spring (13), end cover (14),wire clip (16), dust cover (17), push rod (18), spring (19), spring (20), plunger assy (21), O-ring (22), seal (23), bush (24), cover (25), circlip (26), body (27), pin (28),spring (29), O-ring (30), circlip (31), bolt (32), washer (33), bleed screw (34), dust cap (35), relief valve (36), filter (37), seal

(38), retaining ring (39), adaptor (40), seal (face) (41), mounting bolts (42), protective plug (43), and protective plug (44).
Unique trigger / balancing valve design for lesser pedal effort
According to a preferred embodiment of the present invention, as depicted in Figure 2 featuring the plunger assy (21, 22, 23), cover assy (22, 25), bush assy (22, 24), air inlet pressure(Pp),annular area (Aa), Force(Fa),housing (hydraulic) (2).The present invention has a unique trigger / balancing valve for less clutch pedal effort with progressive feel during clutch operation than the conventional models. The present invention threshold pressure (i.e.) hydraulic pressure required to open air inlet (Pp)port is less because of additional force acting in annular area (Aa)of housing (hydraulic) (2) which leads to reduction in pipe line pressuregiving less pedal effort with progressive feel to the user.
In-line filter
According to a preferred embodiment of the present invention, as depicted in Figure 3, the present invention has a compact air filter (36) which prevents the foreign particles from the pneumatic supply. Due to the compact design, this filter can be directly accommodated into the pneumatic inlet port (PIP)and no separate port is required.
Guide ring at hydraulic piston
According to a preferred embodiment of the present invention, as depicted in Figure 4, the present invention has a guide ring (7) in the pneumatic housing (1) which guides the piston (Ø 25.4mm) and takes up the articulations and mismatch due to split housing arrangement.Also in field service, the customer can change only guide ring and need not change the entire plunger assembly. This results in less service cost to customer.

Pneumatic Housing with spigot feature
According to a preferred embodiment of the present invention, as depicted in Figure 5, the present invention has a spigot diameter (Ds) on the pneumatic housing (1) which enters the housing (hydraulic) (2) bore for better alignment (concentricity) during assembly & service. This ensures concentricity of housing (Pneumatic) (1) & housing (hydraulic) (2) always.
Simple Wear Indicator
According to a preferred embodiment of the present invention, as depicted in Figure 6, the present invention has a simple wear indicator that consists of Body (27), pin (28), spring (29), O-ring (30) & circlip (31). Conventional models use pin, O-ring, spring, Body, Screw and Washer in their wear indicator which includes additional thread operation in hydraulic housing for Bolt assembly (M4x0.7 – 2Nos).
Electronic wear indicator
According to a preferred embodiment of the present invention, as depicted in Figure 7, the present invention has a electronic wear indicator that consists of pin with reed switch (45), O-ring (30), spring (29), Body (27), circlip (31), magnet (46). Conventional models use same construction except magnet (46)&pin with reed switch (45) arrangement in their wear indicator. With conventional wear indicator, User has to manually measure the projecting length of the pin to identify the clutch lining wear. According to a preferred embodiment of the present invention, the wear indicator has additional parts like magnet (46) and pin with reed switch (45). The magnet (46) is placed inside pneumatic housing (1)and the positive and negative terminal in the pin with reed switch (45)will be connected to the dash board. When the reed switch is away from the magnet (46), the light in the dashboard will be in off condition

as the circuit is open. When the clutch lining wears off, the pin comes back closer to magnet and the circuit gets closed. Due to which the light in the dash board glows and gives the indication of clutch lining wear. In general, the light starts glowing at 75% clutch lining wear condition.
While there has been shown and described what is considered to be preferred embodiments of the invention, it will, of course, be understood that various modifications and changes in form or detail could readily be made without departing from the spirit of the invention. It is therefore intended that the invention be not limited to the exact forms described and illustrated, but should be constructed to cover all modifications that may fall within the scope of the appended claims.
It will be apparent to those skilled in the art that the objects of this invention have been achieved by providing the above invention. However various changes may be made in the structure of the invention without departing from the concept of the invention. Therefore, the scope of the invention is to be determined by the terminology of the following claims and the legal equivalents thereof.

1. A clutch booster with a trigger or balancing valve design for lesser pedal effort comprising of:
hydraulic body (pneumatic) (1),
housing (hydraulic) (2),
seal guide (3),
seal (pneumatic) (4),
seal (hydraulic) (5),
sealing ring (6),
guide ring (7),
piston (8),
Spacer (9)
split bush (10),
guide ring (11),
seal (pneumatic) (12),
spring (13),
end cover (14),
wire clip (16),
dust cover (17),
push rod (18),

spring (19),
spring(20),
plunger assy(21),
o-ring(22),
seal(23),
bush(24),
cover(25),
circlip(26),
body(27),
pin(28),
spring(29),
o-ring(30),
circlip(31),
bolt(32),
washer(33),
bleed screw(34),
dust cap(35),
relief valve(36),
filter (37),
seal(38),
retaining ring (39),
adaptor (40),

seal (face) (41),
Mounting bolts (42
protective plug (43)
protective plug (44)
reed switch (45) and
Magnet (46)
Characterized in that the clutch booster contains a trigger or balancing valve consists of and a spigot diameter (Ds)on the hydraulic housing (2).
The clutch booster as claimed in Claim 1 and working thereof wherein the trigger or balancing valve consists of plunger assy (21, 22, 23), cover assy (22, 25), bush assy (22, 24), air inlet pressure(Pp),annular area (Aa), Force(Fa),housing (hydraulic) (2).The present invention has a unique trigger / balancing valve for less clutch pedal effort with progressive feel during clutch operation than the conventional models. The present invention threshold pressure (i.e.) hydraulic pressure required to open air inlet (Pp) port is less because of additional force acting in annular area (Aa)of housing (hydraulic) (2) which leads to reduction in pipe line pressure giving less pedal effort with progressive feel to the user.
The clutch booster as claimed in Claim 1 and working thereof wherein, the clutch booster contains an inline air filter (37) directly accommodated into the pneumatic inlet port (PIP) with no requirement of a separate port and prevents the foreign particles from entering the pneumatic supply
The clutch booster as claimed in Claim 1 and working thereof wherein the guide ring (11) in the housing (pneumatic) (1) guides the piston (8)

and takes up the excess articulations and mismatch due to split housing arrangement.
The clutch booster as claimed in Claim 1 and working thereof wherein the spigot diameter (Ds) on the hydraulic housing (2) enters the housing (hydraulic) (2) bore for better alignment and concentricity during assembly & service.
The clutch booster as claimed in Claim 1 wherein the simple wear indicator comprises of Body (27), pin (28), spring (29), O-ring (30), and circlip (31).
The clutch booster as claimed in Claim 1 wherein the electronic wear indicator comprises of Body (27), pin with reed switch (45), spring (29), O-ring (30), circlip (31), Magnet (46)