Brake pedal with safety features
A brake booster pushrod to pedal interface cage includes a plurality of side walls; a front face connecting to each of the plurality of side walls at or near a first side of the plurality of side walls, the front face including a recess for receiving an end of a booster pushrod; and at least one weakened portion configured to allow the booster pushrod to move through the front face at a predetermined force.
1 . A brake booster pushrod to pedal interface cage comprising:
a plurality of side walls;
a front face connecting to each of the plurality of side walls at a first side of the plurality of side walls, the front face comprising a recess for receiving an end of a booster pushrod; and
at least one weakened portion configured to allow the booster pushrod to move through the front face at a predetermined force, wherein the at least one weakened portion comprises one or more slits in the front face and/or the recess.
2 . The brake booster pushrod to pedal interface cage of claim 1 , wherein the at least one weakened portion comprises at least one series of slits extending across the front face.
3 . The brake booster pushrod to pedal interface cage of claim 1 , wherein the at least one weakened portion comprises slits extending diagonally across the front face and/or the recess to form an X.
4 . The brake booster pushrod to pedal interface cage of claim 1 , wherein the cage is formed of steel or aluminium.
5 . The brake booster pushrod to pedal interface cage of claim 1 , wherein the recess is a spherical recess in the front face extending away from the side walls.
6 . A brake pedal booster pushrod to pedal interface assembly comprising:
a pivotable brake pedal arm comprising a foot pad disposed at a distal end of the pedal arm, and a brake booster pushrod to pedal interface cage comprising:
a plurality of side walls;
a front face connecting to each of the plurality of side walls at a first side of the plurality of side walls, the front face comprising a recess for receiving an end of an elongate booster pushrod; and
at least one weakened portion configured to allow the booster pushrod to move through the front face at a predetermined force;
a brake clip connecting to the brake booster pushrod to pedal interface cage;
wherein the booster pushrod comprises a first end adapted to pivotably engage the recess of the brake booster pushrod to pedal interface cage; and
one or more stops connected to the pedal arm and configured to receive the booster pushrod and stop further forward and/or sliding movement of the booster pushrod with respect to the pedal arm after the booster pushrod has moved through the front face of the brake booster pushrod to pedal interface cage.
7 . The brake pedal booster pushrod to pedal interface assembly of claim 6 , wherein the pivotable brake pedal arm and the brake booster pushrod to pedal interface cage are integrally formed.
8 . The brake pedal booster pushrod to pedal interface assembly of claim 6 , wherein the at least one weakened portion is in an interface or connection between the pivotable brake pedal arm and the brake booster pushrod to pedal interface cage.
9 . The brake pedal booster pushrod to pedal interface assembly of claim 6 , wherein the pedal arm is hollow and the at least one weakened portion allows the brake booster pushrod to enter an inside of the pedal arm.
10 . The brake pedal booster pushrod to pedal interface assembly of claim 6 , wherein the pedal arm comprises an opening positioned to allow the booster pushrod to move through the opening after the booster pushrod has moved through the front face of the brake booster pushrod to pedal interface cage.
11 . The brake pedal booster pushrod to pedal interface assembly of claim 6 , wherein the predetermined force is calculated based on a maximum force on the foot pad and a pedal ratio of the pedal arm.
12 . A vehicle comprising the brake pedal booster pushrod to pedal interface assembly of claim 7 and/or the brake booster pushrod to pedal interface cage of claim 1 .
13 . A method of forming a brake pedal booster pushrod to pedal interface assembly, the method comprising:
forming or obtaining a brake booster pushrod to pedal interface cage comprising a plurality of side walls and a front face connecting to each of the plurality of side walls, the front face comprising a recess for receiving an end of a booster pushrod and at least one weakened portion configured to allow the booster pushrod to move through the front face at a predetermined force, wherein the at least one weakened portion comprises one or more slits in the front face and/or the recess;
connecting the brake booster pushrod to pedal interface cage to a pivotable brake pedal arm; and
connecting the end of the booster pushrod to pivotably engage the recess of the brake booster pushrod to pedal interface cage.