Method of assembling a bellows accumulator for a suspension damper

Abstract

A method of assembling an accumulator for a suspension damper, wherein the method includes the steps of forming a housing for the accumulator, assembling a bellows assembly by connecting a distal plate and a proximal plate to opposite ends of an annular bellows wall, and inserting the bellows assembly into the housing. The housing is formed such that it includes a distal end having an end wall and an open end opposite the distal end. The bellows assembly is inserted into the open end of the housing in an orientation with the distal plate facing the end wall of the housing. The method continues with coupling the distal plate of the bellows assembly to a stem of a charge port on the end wall of the housing at a fixed axial location using a fixture that engages the stem of the charge port.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to dampers for use in vehicle suspension systems. More particularly, the present disclosure relates to methods of assembling pressurized gas accumulators, including inflatable bellows assemblies within a housing, and mounting them onto dampers. BACKGROUND

[0002] This section provides background information relating to the present disclosure, which is not necessarily prior art.

[0003] Vehicles often include dampers that are used in conjunction with suspension systems to absorb shocks and vibrations that occur while driving the vehicle. To absorb the shocks and vibrations, the dampers are typically connected between the body of the vehicle and the suspension system. A piston is located within the damper. The piston is connected to the body of the vehicle or the suspension through a piston rod. The damper also includes a damper housing. The piston rod and the end of the damper housing opposite the piston rod typically include attachment interfaces that connect the damper to the body and the suspension system. As the damper is compressed or extended, the piston forces damping fluid to flow into and out of a rebound chamber and a compression chamber defined within a pressure tube in the damper housing in order to generate a damping force that counteracts the shocks and vibrations. The dampers also typically include passive mechanical valves or active electro-mechanical valves that operate to restrict the flow of damping fluid between the rebound and compression chambers of the damper to increase the damping force generated by the damper. Many current damper designs utilize externally mounted electro-mechanical valves to control the extension and compression damping.

[0004] Many dampers are also equipped with one or more accumulators. The accumulators are typically divided into a pressurized gas chamber that can supply damping fluid to the damper and an accumulator chamber that receives damping fluid from the damper. Three common types of accumulators are bladder accumulators, piston accumulators, and bellows accumulators. In a bladder accumulator, an elastic balloon-like diaphragm defines the accumulator chamber. A piston accumulator, on the other hand, typically includes a floating piston that separates the pressurized gas chamber from the accumulator chamber. Finally, in a bellows accumulator, a bellows structure defines the pressurized gas chamber. Regardless of the design, the pressurized gas chamber contains pressurized gas that operates to exert a positive pressure within the accumulator that will force damping fluid out of the accumulator when the fluid pressure in the accumulator chamber is less than the gas pressure within the pressurized gas chamber. Typically, the accumulators are pre-assembled and filled with pressurized gas before they are mounted on or otherwise connected to the dampers. SUMMARY

[0005] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0006] According to one aspect of the disclosure, a method of assembling an accumulator for a suspension damper is provided. The method includes the steps of forming a housing of the accumulator, assembling a bellows assembly by connecting a distal plate and a proximal plate to opposite ends of an annular bellows wall, and inserting the bellows assembly into the housing. The housing of the accumulator is formed such that the housing includes a distal end having an end wall and an open end opposite the distal end, and the bellows assembly is inserted into the open end of the housing in an orientation in which the distal plate of the bellows assembly faces the end wall of the housing. The method continues with the step of coupling the distal plate of the bellows assembly to a stem of a charge port on the end wall of the housing of the accumulator at a fixed axial location using a securing member that engages the stem of the charge port.

[0007] According to another aspect of the disclosure, a method of assembling an accumulator for a suspension damper includes the steps of forming a housing of the accumulator, assembling a bellows assembly by connecting a distal plate and a proximal plate to opposite ends of an annular bellows wall, and inserting the bellows assembly into the housing. The housing of the accumulator is formed such that the housing includes a distal end having an end wall and an open end opposite the distal end, and the bellows assembly is inserted into the open end of the housing in an orientation in which the distal plate of the bellows assembly faces the end wall of the housing. The method further includes the step of mounting the accumulator on a damper housing by coupling the open end of the housing of the accumulator to the damper housing and coupling the distal plate of the bellows assembly to a stem of a charge port on the end wall of the housing of the accumulator using a securing member that engages the stem of the charge port. According to this aspect of the disclosure, the method can further include, after the accumulator has been mounted on the damper housing, adding pressurized gas to a pressurized gas chamber within the bellows assembly by supplying pressurized gas to the charge port on the accumulator.

[0008] According to another aspect of the disclosure, a method of assembling an accumulator for a suspension damper includes the steps of forming a housing of the accumulator, assembling a bellows assembly by connecting a distal plate and a proximal plate to opposite ends of an annular bellows wall, and inserting the bellows assembly into the housing. The housing of the accumulator is formed such that the housing includes a distal end having an end wall and an open end opposite the distal end, and the bellows assembly is inserted into the open end of the housing in an orientation in which the distal plate of the bellows assembly faces the end wall of the housing. The method further includes the step of mounting the accumulator on a damper housing by coupling the open end of the housing of the accumulator to the damper housing and coupling the distal plate of the bellows assembly to a stem of a charge port on the end wall of the housing of the accumulator using a securing member that engages the stem of the charge port. According to this aspect of the disclosure, the method can further include, after the accumulator has been mounted on the damper housing, adding pressurized gas to a pressurized gas chamber within the bellows assembly by supplying pressurized gas to the charge port on the accumulator.

[0009] Advantageously, the assembly methods described herein result in accumulators that are easier to manufacture, install, and fill with pressurized gas, which results in cost savings. Additionally, the way in which the securing member couples the distal plate of the bellows assembly to the stem provides improvements in sealing, durability, corrosion resistance, reduces noise and vibration, and allows the pressurized gas chamber of the accumulator to be filled before or after the accumulator has been installed on the damper. BRIEF DESCRIPTION OF DRAWINGS

[0010] The drawings described herein are for the purposes of illustration only and are not intended to limit the scope of the present disclosure.

[0011] Figure 1 is a side cross-sectional view of an exemplary damper equipped with an exemplary accumulator constructed in accordance with the present disclosure;

[0012] Figure 2 is Figure 1 is a side cross-sectional view of an exemplary accumulator shown in

[0013] Figure 3A is Figure 2 is a partial exploded side cross-sectional view of an exemplary accumulator shown in

[0014] Figure 3B is Figure 2 is a side cross-sectional view of an exemplary accumulator shown in

[0015] Figure 3C is Figure 2 is a side cross-sectional view of an exemplary accumulator shown in

[0016] Figure 3D is Figure 2 is a side cross-sectional view of an exemplary accumulator shown in

[0017] Figure 3E is Figure 2 is a side cross-sectional view of an exemplary accumulator shown in

[0018] Figure 4 is a side cross-sectional view of another exemplary accumulator constructed in accordance with the present disclosure;

[0019] Figure 5Ais Figure 4 a partial exploded side cross-sectional view of an example accumulator shown in FIG. 1, shown with the bellows assembly of the accumulator in a pre-assembly position;

[0020] Figure 5B is Figure 4 a side cross-sectional view of an example accumulator shown in FIG. 1, shown with the bellows assembly inserted into the housing of the accumulator;

[0021] Figure 5C is Figure 4 a side cross-sectional view of an example accumulator shown in FIG. 1, shown with the bellows assembly inserted into the housing of the accumulator;

[0022] Figure 5D is Figure 4 a side cross-sectional view of an example accumulator shown in FIG. 1, shown with the bellows assembly inserted into the housing of the accumulator; DETAILED DESCRIPTION

[0023] A more complete understanding of example embodiments can now be accomplished by reference to the following discussion and the accompanying drawings.

[0024] A more complete understanding of example embodiments can now be accomplished by reference to the following discussion and the accompanying drawings.

[0025] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a," "an," and "the" can be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their

[0026] When an element or layer is referred to as being "on," "engaged to," "connected to," or "coupled to" another element or layer, it can be directly on, engaged, connected, or coupled to the other element or layer, or one or more intervening elements or layers can be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0027] Although the terms first, second, third, etc. can be used herein to describe various elements, components, regions, layers and / or sections, these elements, components, regions, layers and / or sections should not be limited by these terms. These terms can be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms as used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

[0028] Spatially related terms such as “inner,” “outer,” “below,” “below,” “lower,” “above,” and “upper” are used herein to describe the relationship of one element or feature to another, as shown in the figures. In addition to the orientations shown in the figures, spatially related terms may also be intended to cover different orientations of the device during use or operation. For example, if the device in the figures is flipped, then an element described as “below” or “below” other elements or features would be oriented as “above” other elements or features. Thus, the exemplary term “below” can cover both above and below orientations. The device can be oriented in other ways (rotated 90 degrees or otherwise), and the spatially related descriptors used herein are interpreted accordingly.

[0029] Figure 1 An exemplary damper 112 for a vehicle (not shown) is shown. By way of example and not limitation, the damper 112 contains a fluid, such as hydraulic fluid or oil. The damper 112 includes a pressure tube 122 extending longitudinally between a first pressure tube end 156 and a second pressure tube end 157. A piston 124 is slidably disposed within the pressure tube 122. The piston 124 defines a rebound chamber 126 and a compression chamber 128 within the pressure tube 122. Each of the rebound chamber 126 and the compression chamber 128 contains fluid therein. The rebound chamber 126 is longitudinally positioned between the piston 124 and the first pressure tube end 156, while the compression chamber 128 is longitudinally positioned between the piston 124 and the second pressure tube end 157. The volumes of the rebound chamber 126 and the compression chamber 128 vary based on the movement of the piston 124. Piston 124 has a cylindrical surface that seals the interior of pressure tube 122, thus dividing the space inside pressure tube 122 into a springback chamber 126 and a compression chamber 128. In the illustrated example, piston 124 does not have any fluid passages or valve adjustments; however, it should be understood that this disclosure is not limited to this piston design and is equally applicable to dampers with piston designs that include fluid passages and / or valve adjustments. Damper 112 also includes a piston rod 130 extending longitudinally between a first piston rod end 132 and a second piston rod end 134, the first piston rod end being configured to connect to a component of a suspension system or vehicle body (not shown), and the second piston rod end being connected to piston 124.

[0030] Damper 112 also includes a damper housing 135. While it should be appreciated that damper housing 135 can be configured in a variety of ways, in the illustrated example, damper housing 135 includes an outer tube 136 extending from a base 138. Outer tube 136 is disposed concentrically around pressure tube 122 and extends longitudinally between a first outer tube end 137 and a second outer tube end 139. Piston rod 130 extends longitudinally outward through first outer tube end 137. Second outer tube end 139 and second pressure tube end 157 are received in base 138 and fixedly coupled thereto. An attachment fitting 143 is mounted to base 138 and is configured to attach to components of a suspension system or vehicle body (not shown). Attachment fitting 143 can be provided in the form of a hole, loop, stud, or other attachment structure.

[0031] One or more control valves 164a, 164b, 164c are externally mounted to base 138. While other types of control valves can be used, in the illustrated implementation, control valves 164a, 164b, 164c are electro-mechanical valves. Operation of control valves 164a, 164b, 164c will be explained in more detail below, but at a high level, control valves 164a, 164b, 164c regulate two fluid flow paths 166a, 166b that can deliver fluid into and out of rebound chamber 126 and compression chamber 128.

[0032] The first fluid flow path 166a allows fluid to flow into and out of the compression chamber 128 through the base 138. The second fluid flow path 166b allows fluid to flow into and out of the rebound chamber 126 through the fluid transfer chamber 168 defined in the annular space between the pressure tube 122 and the outer tube 136. The fluid transfer chamber 168 is arranged in fluid communication with the rebound chamber 126 via one or more open ports 146 in the first pressure tube end 156 and extends to the first control valve 164a. In the open position, the first control valve 164a allows fluid communication between the fluid transfer chamber 168 and a first fluid passage 170a that extends through the base 138 between the first control valve 164a and a second control valve 164b. In the open position, the second control valve 164b allows fluid communication between the first fluid passage 170a and a second fluid passage 170b that extends through the base 138 between the second control valve 164b and a third control valve 164c. In the open position, the third control valve 164c allows fluid flow between the second fluid passage 170b and the compression chamber 128. The first and second fluid passages 170a, 170b include first and second ports 172a, 172b, respectively, in the base 138 that can be connected in fluid communication with other dampers of the vehicle via hydraulic lines (not shown) to provide roll and / or pitch control functions.

[0033] As shown in FIG. 1, when the piston 124 moves away from the base 138 during the rebound stroke, the volume of fluid in the rebound chamber 126 decreases and the volume of fluid in the compression chamber 128 increases. The control valves 164a-164c are opened and regulate the flow of fluid from the rebound chamber 126, through the fluid transfer chamber 168, through the first and second fluid passages 170a, 170b in the base 138, and to the compression chamber 128. The degree and / or timing of the opening of the control valves 164a-164c can be adjusted to adjust the rebound damping characteristics of the damper 112. Figure 1 In other words, during the rebound stroke, fluid from the rebound chamber 126 flows into the fluid transfer chamber 168 via the open ports 146 in the first pressure tube end 156, the fluid in the fluid transfer chamber 168 then passes through the first control valve 164a and into the first fluid passage 170a in the base 138, the fluid in the first fluid passage 170a then passes through the second control valve 164b and into the second fluid passage 170b in the base 138, the fluid in the second fluid passage 170b then passes through the third control valve 164c and out into the compression chamber 128.

[0034]

[0035] ​As the piston 124 moves toward the base 138 during a compression stroke, the volume of fluid in the compression chamber 128 decreases and the volume of fluid in the rebound chamber 126 increases. The control valves 164a-164c are opened and regulate the flow of fluid from the compression chamber 128 through the first and second fluid passages 170a, 170b in the base 138 to the fluid transfer chamber 168, which delivers fluid to the rebound chamber 126. The degree and / or timing of the opening of the control valves 164a-164c can be adjusted to adjust the compression damping characteristics of the damper 112. In other words, during a compression stroke, fluid from the compression chamber 128 flows through the third control valve 164c and into the second fluid passage 170b in the base 138, the fluid in the second fluid passage 170b then passes through the second control valve 164b and into the first fluid passage 170a in the base 138, the fluid in the first fluid passage 170a then passes through the first control valve 164a and flows through the fluid transfer chamber 168 and out into the rebound chamber 126 via the open port 146 in the first pressure tube end 156.

[0036] Further reference is made to Figure 2 The damper 112 also includes at least one accumulator 200 that is attached to the base 138 of the damper housing 135 at an accumulator port 202. As will be explained in greater detail below, the accumulator 200 includes an accumulator chamber 204 that is arranged in fluid communication with at least one of the two fluid flow paths 166a, 166b in the base 138 and thus contains the same fluid that passes through the damper 112. In addition, the accumulator 200 also includes a pressurized gas chamber 206 that is defined by and contained within a bellows assembly 208 positioned within an outer shell 210 of the accumulator 200. The pressurized gas chamber 206 is filled with pressurized gas and sealed and fluidly isolated (i.e., separated) from the accumulator chamber 204. In the illustrated example, the accumulator chamber 204 is positioned longitudinally between the pressurized gas chamber 206 and the base 138. However, it should be appreciated that the damper 112 can be designed with the accumulator chamber 204 in an alternative location, such as, for example, between the pressurized gas chamber 206 and an end wall 216 of the damper housing 135. The bellows assembly 208 is expandable and compressible in an axial direction within the outer shell 210 of the accumulator 200 such that the volumes of both the accumulator chamber 204 and the pressurized gas chamber 206 can increase and decrease with changes in the fluid pressure within the accumulator chamber 204.

[0037] While other configurations are possible, in the illustrated example, the accumulator port 202 is arranged in fluid communication with the third control valve 164c. Pressurized gas within the pressurized gas chamber 206 of the accumulator 200 operates to exert a positive pressure within the accumulator 200 that forces fluid out of the accumulator chamber 204 when the fluid pressure at the accumulator port 202 is less than the gas pressure within the pressurized gas chamber 206. In other words, the volume of the pressurized gas chamber 206 will increase and the volume of the accumulator chamber 204 will decrease until the pressure between the accumulator chamber 204 and the pressurized gas chamber 206 is balanced. Conversely, when the fluid pressure at the accumulator port 202 increases, such as when the third control valve 164c is open, fluid flows into the accumulator chamber 204, causing the volume of the accumulator chamber 204 to increase and the volume of the pressurized gas chamber 206 to decrease until the pressure is balanced. The result is that fluid can be added to or removed from the damper 112 using the combination of the accumulator 200 and the control valves 164a-164c.

[0038] As Figure 2 illustrated, the housing 210 of the accumulator 200 includes an open end 212 that abuts the accumulator port 202 in the damper housing 135 and a distal end 214. An end wall 216 of the damper housing 135 extends radially inward to an air charge port 218 at the distal end 214 of the damper housing 135. The housing 210 of the accumulator 200 is generally cylindrical in shape and extends annularly about an accumulator axis A. While other configurations are possible, the housing 210 of the accumulator 200 can be made of metal and the end wall 216 of the accumulator 200 can be integrally formed with the housing 210 as a single piece, formed as an impact extruded aluminum end cap. The end wall 216 is generally disposed along a transverse plane that is substantially perpendicular to the accumulator axis A. Thus, the end wall 216 of the accumulator 200 generally closes the distal end 214 of the housing 210, except for an opening provided by the air charge port 218 on the distal end 214.

[0039] The bellows assembly 208 of the accumulator 200 is arranged within the housing 210 in a sliding / slipping fit and has an annular bellows wall 220 that extends coaxially about the accumulator axis A and axially between a proximal plate 222 and a distal plate 224 of the bellows assembly 208. Each of the proximal plate 222 and the distal plate 224 of the bellows assembly 208 has a disc shape and is fixed to an outer diameter of the annular bellows wall. The annular bellows wall 220 and the proximal plate 222 and the distal plate 224 of the bellows assembly 208 cooperate together to define the pressurized gas chamber within the accumulator 200. The annular bellows wall 220 has a corrugated shape that allows the bellows assembly 208 to expand and contract in length (i.e., the distance between the proximal plate 222 and the distal plate 224 of the bellows assembly 208 can increase or decrease) depending on the pressure differential between the accumulator chamber 204 and the pressurized gas chamber 206.

[0040] The accumulator chamber 204 is positioned within the accumulator 200 between the distal plate 224 of the bellows assembly 208 and the open end 212 of the housing 210. As noted above, the accumulator chamber 204 is arranged in fluid communication with the compression chamber 128 of the damper 112 and is thus configured to receive hydraulic fluid or oil from the damper 112 through the accumulator port 202. The pressurized gas chamber 206 of the accumulator 200 is arranged in fluid communication with the charge port 218. The charge port 218 includes a stem 226 that extends inwardly from the end wall 216 of the housing 210. The distal plate 224 of the bellows assembly 208 includes an inner diameter 228 that is received on the stem 226 of the charge port 218 and is coupled to the stem by a securing member 230.

[0041] The proximal plate 222 of the bellows assembly 208 is solid and free of holes or passages. In contrast, the inner diameter 228 of the distal plate 224 of the bellows assembly 208 defines a cylindrical bore surface 232 that is slidingly received on the stem 226 of the charge port 218 in a sliding / slip fit. The cylindrical bore surface 232 of the distal plate 224 includes an annular groove 234 that receives a sealing element 236 that seals against the stem 226 of the charge port 218 and prevents gas in the pressurized gas chamber 206 from leaking out of the bellows assembly 208 around the stem 226. While other configurations are possible, the annular bellows wall 220, the proximal plate 222, and the distal plate 224 can all be made of metal, and the proximal plate 222 and the distal plate 224 can be welded to the annular bellows wall 220 at their outer diameters / perimeters. The accumulator 200 also includes a retaining ring 238 that is threadably received (i.e., threaded or screwed) within the open end 212 of the housing 210 to prevent the proximal plate 222 and the annular bellows wall 220 of the bellows assembly 208 from sliding out of the open end 212 of the housing 210. However, it should be appreciated that the retaining ring 238 can alternatively be press fit into the open end 212 of the housing 210 or otherwise secured in a suitable manner. While other connection interfaces are possible, in the illustrated example, the open end 212 of the housing 210 of the accumulator 200 also includes threads 240 that engage the accumulator port 202 of the damper housing 135 such that the open end 212 of the accumulator 200 can be threaded / screwed into the accumulator port 202 on the damper 112.

[0042] In Figure 2 and Figures 3A to 3EIn the illustrated embodiment, the fixed component is a blind rivet nut 230 attached to the terminal end 242 of the stem 226 of the inflation port 218. The blind rivet nut 230 includes a rivet nut bore 244. The distal plate 224 of the bellows assembly 208 includes an annular collar 246 that extends annularly around the stem 226 of the inflation port 218. The annular collar 246 is thus coaxially positioned with the inner diameter 228 of the distal plate 224 and extends axially away from the end wall 216 of the housing 210 from the distal plate 224. Additionally, the annular collar 246 on the distal plate 224 terminates at a collar flange 248 having a diameter 250 that is smaller than the inner diameter 228 of the distal plate 224. The inflation port 218 includes a mechanical deformation 252 at the meeting of the blind rivet nut 230 and the stem 226. The mechanical deformation 252 has an annular shape and a diameter 254 that is larger than the smaller diameter 250 of the collar flange 248. The collar flange 248 is axially positioned between the stem 226 and the mechanical deformation 252 to couple the distal plate 224 of the bellows assembly 208 to the stem 226 of the inflation port 218 at a fixed axial position. Thus, the mechanical deformation 252 on the inflation port 218 prevents the distal plate 224 of the bellows assembly 208 from moving axially within the housing 210. It should be appreciated, however, that depending on the design, the distal plate 224 can or can not be able to rotate within the housing 210 despite the mechanical deformation 252 on the stem 226.

[0043] The rivet nut bore 244 is threaded in the illustrated example and is thus configured such that a riveting tool 256 can be threaded into the rivet nut bore 244. The stem 226 of the inflation port 218 has a tubular wall 258 having a pre-assembly diameter 260a and a pre-assembly length 262a. The tubular wall 258 is configured to be compressed and deformed by the riveting tool 256 to an assembly diameter 260b that is larger than the pre-assembly diameter 260a and an assembly length 262b that is smaller than the pre-assembly length 262a, which operates to couple the distal plate 224 of the bellows assembly 208 to the stem 226 of the inflation port 218 at the aforementioned fixed axial position. It should be appreciated that the tubular wall 258 of the inflation port 218 can be formed by the stem 226, the blind rivet nut 230, both the stem 226 or the blind rivet nut 230, or some other tubular structure or portion of the inflation port 218. Regardless of the specific configuration used, the assembly diameter 260b of the tubular wall 258 of the inflation port 218 is measured across the widest point of the mechanical deformation 252 formed in the inflation port 218 by the riveting tool 256, which can be located at any point on the inflation port 218, including along the stem 226, the blind rivet nut 230, or anywhere in between.

[0044] Accordingly, the charge port 218 of the accumulator 200 is configured to receive both the riveting tool 256 and a gas fitting (not shown) to add gas to the pressurized gas chamber 206 of the bellows assembly 208 in a process sometimes referred to as “filling” the pressurized gas chamber 206. Once this process is complete, a rivet 264, cap, or some other sealing structure can be inserted into the stem 226 of the charge port 218 to seal the pressurized gas chamber 206.

[0045] Referring to Figures 3A to 3E , a method of assembling the accumulator 200 is shown. Prior to, after, or concurrently with the method of assembling the accumulator 200, the damper 112 is assembled by performing the step of installing the piston 124 and piston rod 130 in the damper housing 135, which can also include assembling the pressure tube 122, outer tube 136, and base 138 described above. The method further includes the step of forming the outer shell 210 of the accumulator 200, where the outer shell 210 includes a distal end 214 and an end wall 216, and an open end 212 opposite the distal end 214. As shown in Figure 3A , the method includes the steps of assembling the bellows assembly 208 by connecting the proximal plate 222 and the distal plate 224 to opposite ends of the annular bellows wall 220, and inserting the bellows assembly 208 into the open end 212 of the outer shell 210 with the distal plate 224 of the bellows assembly 208 facing the end wall 216 of the outer shell 210. The method then proceeds with the step of coupling the distal plate 224 of the bellows assembly 208 to the stem 226 of the charge port 218 on the end wall 216 of the outer shell 210 of the accumulator 200 at a fixed axial position using the securing member 230 that engages the stem 226 of the charge port 218. The method further includes the step of inserting the retaining ring 238 into the open end 212 of the outer shell 210 after the step of inserting the bellows assembly 208 into the outer shell 210 so as to prevent the bellows assembly 208 from sliding out through the open end 212 of the outer shell 210, followed by the step of installing the accumulator 200 onto the damper housing 135, which includes coupling the open end 212 of the outer shell 210 of the accumulator 200 onto the damper housing 135. More specifically, the step of installing the accumulator 200 onto the damper housing 135 can include threadably connecting the open end 212 of the outer shell 210 of the accumulator 200 into the accumulator port 202 on the damper housing 135.

[0046] As described above, Figures 3A to 3E , the securing member 230 in the embodiment shown in Figure 3BAs shown, the step of coupling the distal plate 224 of the bellows assembly 208 to the stem 226 of the inflation port 218 includes advancing the bellows assembly 208 into the open end 212 of the housing 210 until at least a portion of the stem 226 of the inflation port 218 extends through the inner diameter 228 of the distal plate 224 of the bellows assembly 208; and inserting the riveting tool 256 into the inflation port 218 until the riveting tool 256 engages the rivet hole 244 in the blind rivet 230. As shown, Figure 3C As shown, the method continues with the following steps: pulling the riveting tool 256 away from the distal plate 224 of the bellows assembly 208 in the axial direction 266 to axially compress the blind rivet 230 and form the mechanical deformation 252 in the stem 226 and / or the blind rivet 230. This step of pulling the riveting tool 256 away from the distal plate 224 of the bellows assembly 208 in the axial direction 266 causes the tubular wall 258 of the inflation port 218 to deform from the pre-assembly diameter 260a to the assembly diameter 260b (which is greater than the pre-assembly diameter 260a) and from the pre-assembly length 262a to the assembly length 262b (which is shorter than the pre-assembly length 262a). As shown, Figure 3D As shown, the method then continues with the following steps: removing the riveting tool 256 from the inflation port 218 and the rivet hole 244, attaching a gas fitting (not shown) to the inflation port 218 and filling the pressurized gas chamber 206 with pressurized gas via the gas fitting and the inflation port 218, removing the gas fitting from the inflation port 218, and inserting the rivet 264 into the inflation port 218 to seal the pressurized gas chamber 206.

[0047] In Figure 4 and Figures 5A to 5D another example accumulator 300 is shown. Many of the elements of the previously described damper 112 and accumulator 200 are the same or substantially the same between embodiments and will not be described in detail again. Equivalent elements shared between embodiments have corresponding reference numerals, with reference numerals beginning with 200 being used to identify elements of the accumulator 200 shown in Figure 2 and Figures 3A to 3E , with reference numerals beginning with 300 being used to identify the same or corresponding elements in the accumulator 300 shown in Figure 4 and Figures 5A to 5D . For example, reference numeral 210 is used to identify the housing of the accumulator 200 shown in Figure 2 and Figures 3A to 3E , while reference numeral 310 is used to identify the housing of the accumulator 300 shown in Figure 4 and Figures 5A to 5D .

[0048] In Figure 4 and Figures 5A to 5DIn the illustrated embodiment, the securing component is a split ring 330 that engages both the stem 326 and the distal plate 324 of the bellows assembly 308. The stem 326 of the inflation port 318 has a tubular wall 358 with an outward-facing groove 368. Additionally, the inner diameter 328 of the distal plate 324 of the bellows assembly 308 includes an inward-facing groove 370. Once the accumulator 300 is assembled and filled, the split ring 330 is received within the outward-facing groove 368 on the stem 326 of the inflation port 318 and within the inward-facing groove 370 on the distal plate 324 of the bellows assembly 308 to couple the distal plate 324 of the bellows assembly 308 to the stem 326 of the inflation port 318 at a secured axial position.

[0049] The distal plate 324 of the bellows assembly 308 includes an annular collar 346 positioned coaxially with the inner diameter 328 of the distal plate 324 and extending axially from the distal plate 324 toward the end wall 316 of the housing 310. Similar to the prior design described above, the inner diameter 328 of the distal plate 324 of the bellows assembly 308 defines a cylindrical bore surface 332 that slidingly receives on the stem 326 of the inflation port 318 in a sliding / slip fit. The cylindrical bore surface 332 of the distal plate 324 includes an annular groove 334 that receives a sealing element 336 that seals against the stem 326 of the inflation port 318 and prevents gas in the pressurized gas chamber 306 from leaking around the stem 326 out of the bellows assembly 308.

[0050] The accumulator 300 also includes a biasing ring 372 annularly positioned about the annular collar 346 of the distal plate 324 and axially positioned between the distal plate 324 and the end wall 316 of the housing 310. While other configurations are possible, in the illustrated example, the biasing ring 372 has a similar structure to a push nut washer and includes a plurality of spring fingers 374 that extend radially inward toward the annular collar 346 of the distal plate 324 and are circumferentially spaced apart about the biasing ring 372. The biasing ring 372 is configured to apply a biasing force 376 to the distal plate 324 that urges the distal plate 324 away from the end wall 316 of the housing 310. When the accumulator 300 is filled, the gas pressure within the pressurized gas chamber 306 of the bellows assembly 308 exerts a reaction force 378 on the distal plate 324 that pushes the distal plate 324 toward the end wall 316 of the housing 310. As such, the biasing force 376 of the biasing ring 372 and the reaction force 378 of the pressurized gas chamber 306 of the bellows assembly 308 are in a state of equilibrium that maintains the distal plate 324 in a secured axial position on the stem 326 of the inflation port 318. Figure 5C and Figure 5DAs shown, the addition of gas through the inflation port 318 during the filling process increases the gas pressure within the pressurized gas chamber 306 of the bellows assembly 308, which operates to push the distal plate 324 toward the end wall 316 and cause the distal plate 324 to slide axially on the stem 326 toward the end wall 316 when the reaction force 378 exerted by the gas pressure on the distal plate 324 exceeds the biasing force 376 of the biasing ring 372. This operates to seat the snap ring 330 in the outwardly facing groove 368 on the stem 326 of the inflation port 318 and the inwardly facing groove 370 on the distal plate 324 of the bellows assembly 308 as the accumulator 300 is filled. Finally, the rivet 364 is placed in the inflation port 318 to seal the pressurized gas chamber 306.

[0051] Referring to Figures 5A to 5D , a method of assembling the accumulator 300 is shown. The method includes the steps of forming the housing 310 of the accumulator 300 and assembling the bellows assembly 308 by connecting the distal plate 322 and the proximal plate 324 of the bellows assembly 308 to opposite ends of the annular bellows wall 320. For example, the distal plate 322 and the proximal plate 324 of the bellows assembly 308 can be welded to opposite ends of the annular bellows wall 320. As described above, the housing 310 of the accumulator 300 includes a distal end 314 having an end wall 316 and an open end 312 opposite the distal end 314. As shown, Figure 5A the method includes the step of inserting the bellows assembly 308 into the open end 312 of the housing 310 with the distal plate 324 of the bellows assembly 308 facing the end wall 316 of the housing 310. This step of inserting the bellows assembly 308 into the housing 310 of the accumulator 300 can be performed as part of the assembly process of the damper 112, which can include installing the piston 124 and the piston stem 130 in the damper housing 135. As shown, Figure 5A and Figure 5B the method further includes the step of inserting the retaining ring 338 into the open end 312 of the housing 310 after the step of inserting the bellows assembly 308 into the housing 310 so as to prevent the bellows assembly 308 from sliding out of the open end 312 of the housing 310, followed by the step of installing the accumulator 300 onto the damper housing 135. The step of installing the accumulator 300 on the damper housing 135 involves coupling the open end 312 of the housing 310 of the accumulator 300 to the damper housing 135. More specifically, the step of installing the accumulator 300 on the damper housing can include threading the open end 312 of the housing 310 of the accumulator 300 into the accumulator port 302 on the damper housing 135.

[0052] As Figure 5C and Figure 5DAs shown, the method further includes the step of: using a retaining member (such as a spring ring) 330 that engages with the rod 326 of the inflation port 318, connecting the distal plate 324 of the bellows assembly 308 to the rod 326 of the inflation port 318 on the end wall 316 of the housing 310 of the accumulator 300 at a fixed axial position. The step of connecting the distal plate 324 of the bellows assembly 308 to the rod 326 of the inflation port 318 includes advancing the bellows assembly 308 into the open end 312 of the housing 310 until the rod 326 of the inflation port 318 extends through the inner diameter 328 of the distal plate 324. As the distal plate 324 of the bellows assembly 308 slides on the rod 326 of the inflation port 318 and is pushed closer to the end wall 316 of the accumulator 300, the spring ring 330 is received (i.e. snapped into) the outward-facing groove 368 on the rod 326 of the inflation port 318 and the inward-facing groove 370 on the inner diameter 328 of the distal plate 324 of the bellows assembly 308.

[0053] like Figure 5C and Figure 5D As shown, the step of connecting the distal plate 324 of the bellows assembly 308 to the rod 326 of the inflation port 318 may include supplying gas to the inflation port 318 to increase the gas pressure in the pressurized gas chamber 306 within the bellows assembly 308. This causes the bellows assembly 308 to expand within the housing 310 of the accumulator 300 and push the distal plate 324 of the bellows assembly 308 against the end wall 316 of the accumulator 300 until the spring ring 330 snaps into the outward-facing groove 368 on the rod 326 of the inflation port 318 and the inward-facing groove 370 on the distal plate 324 of the bellows assembly 308.

[0054] Therefore, according to the above method, the step of connecting the distal plate 324 of the bellows assembly 308 to the rod 326 of the inflation port 318 on the end wall 316 of the housing 310 of the accumulator 300 can be performed after the step of mounting the accumulator 300 onto the damper housing 135. However, it should be understood that the step of placing the spring ring 330 in the outward-facing groove 368 on the rod 326 of the inflation port 318 and in the inward-facing groove 370 on the distal plate 324 of the bellows assembly 308 can alternatively occur as a result of or in conjunction with the step of inserting the bellows assembly 308 into the housing 310 of the accumulator 300.

[0055] Advantageously, the design of the accumulators 200 and 300 allows the assembly and filling of the accumulators 200 and 300 to be combined with (i.e., simultaneously) the assembly of the damper 112. This can result in manufacturing efficiency and associated cost reduction.

[0056] While aspects of the disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments can be conceived by modification of the disclosed dampers without departing from the spirit and scope of the disclosure. Such embodiments should be understood to fall within the scope of the disclosure as determined based on the claims, and any equivalents thereof.

Claims

1. A method for assembling an energy storage device for a suspension damper, the method comprising the following steps: A housing is formed for an energy storage device, wherein the housing includes a distal end having an end wall and an open end opposite to the distal end; The bellows assembly is assembled by connecting the distal and proximal plates to opposite ends of the annular bellows wall. The bellows assembly is inserted into the open end of the housing with the distal plate of the bellows assembly facing the end wall of the housing. Using a fixing component that engages with the rod of the inflation port, the distal plate of the bellows assembly is connected to the rod of the inflation port on the end wall of the housing of the accumulator at a fixed axial position. as well as The accumulator is mounted on the damper housing by connecting the open end of the accumulator's housing to the damper housing.

2. The method of claim 1, wherein the retaining member is a spring ring and the step of connecting the distal plate of the bellows assembly to the rod of the inflation port comprises advancing the bellows assembly into the open end of the housing until the rod of the inflation port extends through the inner diameter of the distal plate and the spring ring is received in an outwardly facing groove on the rod of the inflation port and an inwardly facing groove on the inner diameter of the distal plate of the bellows assembly.

3. The method of claim 2, wherein the step of connecting the distal plate of the bellows assembly to the rod of the inflation port comprises supplying gas to the inflation port to increase the gas pressure in the pressurized gas chamber within the bellows assembly, thereby causing the bellows assembly to expand within the housing of the accumulator and push the distal plate of the bellows assembly against the end wall until the reed snaps into the outwardly facing groove on the rod of the inflation port and the inwardly facing groove on the distal plate of the bellows assembly.

4. The method of claim 3, wherein after the step of mounting the accumulator on the damper housing, the following step is performed: supplying gas to the inflation port to increase the gas pressure in the pressurized gas chamber within the bellows assembly to place the spring ring in the outward-facing groove in the rod of the inflation portion.

5. The method of claim 1, wherein after the step of mounting the accumulator on the damper housing, the step of connecting the distal plate of the bellows assembly to a rod on the end wall of the housing of the accumulator is performed.

6. The method according to claim 1, further comprising the following step: Prior to the step of mounting the accumulator on the damper housing, gas is supplied to the inflation port to increase the gas pressure in the pressurized gas chamber within the bellows assembly.

7. The method of claim 1, wherein the step of mounting the accumulator on the damper housing comprises threading the open end of the housing of the accumulator into an accumulator port on the damper housing.

8. The method according to claim 1, further comprising the following step: After the step of inserting the bellows assembly into the housing and before the step of mounting the accumulator onto the damper housing, a retaining ring is inserted into the open end of the housing to prevent the bellows assembly from slipping out of the open end of the housing.

9. A method for assembling an energy storage device for a suspension damper, the method comprising the following steps: A housing is formed for an energy storage device, wherein the housing includes a distal end having an end wall and an open end opposite to the distal end; The bellows assembly is assembled by connecting the distal and proximal plates to opposite ends of the annular bellows wall. The bellows assembly is inserted into the open end of the housing with the distal plate of the bellows assembly facing the end wall of the housing. Using a fixing component that engages with the rod of the inflation port, the distal plate of the bellows assembly is connected to the rod of the inflation port on the end wall of the housing of the accumulator at a fixed axial position. The accumulator is mounted on the damper housing by connecting the open end of the accumulator's housing to the damper housing; and The fixing component is a blind rivet nut located at the end of the rod at the inflation port.

10. The method of claim 9, wherein the step of connecting the distal plate of the bellows assembly to the rod of the inflation port comprises advancing the bellows assembly into the open end of the housing until at least a portion of the rod of the inflation port extends through the inner diameter of the distal plate of the bellows assembly.

11. The method of claim 10, further comprising the step of: Insert the riveting tool into the inflation port and the rivet nut hole in the blind rivet nut.

12. The method of claim 11, further comprising the step of: The riveting tool is pulled axially away from the distal plate of the bellows assembly to axially compress the blind rivet nut and form a mechanically deformed portion in the blind rivet nut, the mechanically deformed portion having a diameter larger than the inner diameter of the distal plate of the bellows assembly.

13. The method of claim 12, wherein the step of pulling the riveting tool away from the distal plate of the bellows assembly in the axial direction causes the blind rivet nut to deform from a pre-assembly diameter to an assembly diameter greater than the pre-assembly diameter, and from a pre-assembly length to an assembly length less than the pre-assembly length.

14. The method of claim 12, further comprising the step of: Remove the riveting tool from the inflation port and the rivet nut hole.

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