Bellows accumulator mounting for suspension dampers

Abstract

An accumulator for a vehicle suspension damper includes a housing having an open end connected to an accumulator port on the damper and a distal end opposite the open end including an end wall extending radially inward to a charge port. A bellows assembly including an annular bellows wall extending between a proximal plate and a distal plate is positioned within the housing to define a pressurized gas chamber within the accumulator arranged in fluid communication with the charge port. The charge port includes a stem extending inward from the end wall of the housing and the distal plate of the bellows assembly has an inner diameter received on the stem. The inner diameter of the distal plate is coupled to the stem of the charge port by a securing member.

Description

Technical Field

[0001] This disclosure relates in its entirety to dampers for use in vehicle suspension systems. More specifically, this disclosure relates to pressurized gas accumulators having an expandable bellows assembly within a housing. Background Technology

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

[0003] Vehicles typically include a damper, which works in conjunction with the suspension system to absorb shocks and vibrations that occur when the vehicle is driven. To absorb shocks and vibrations, the damper is typically connected between the vehicle body and the suspension system. A piston is located within the damper. The piston is connected to the vehicle body or suspension via a piston rod. The damper also includes a damper housing. The ends of the piston rod and damper housing opposite the piston rod typically include attachment interfaces for connecting the damper to the body and suspension system. When the damper is compressed or extended, the piston forces damping fluid into and out of a rebound chamber and a compression chamber defined in a pressure tube within the damper housing to generate a damping force that counteracts shocks and vibrations. The damper typically also includes a passive mechanical valve or an active electromechanical valve that operates 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 electromechanical valves to control the extension and compression of the damping.

[0004] Many dampers also include one or more accumulators. Accumulators are typically divided into a pressurized gas chamber that supplies damping fluid to the damper and an energy storage 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, a flexible, balloon-like diaphragm defines the energy storage chamber. Piston accumulators, on the other hand, typically include a floating piston that separates the pressurized gas chamber from the energy storage 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 apply a positive pressure within the accumulator. This positive pressure forces the damping fluid out of the accumulator when the fluid pressure in the energy storage chamber is lower than the gas pressure inside the pressurized gas chamber. Typically, accumulators are pre-assembled and filled with pressurized gas before they are mounted on or otherwise connected to the damper. Summary of the Invention

[0005] This section provides the general inventive summary of this disclosure, but is not a complete disclosure of its full scope or all its features.

[0006] According to one aspect of the invention, a damper is provided. The damper includes a damper housing, a pressure tube disposed within the damper housing, and a piston slidably disposed within the pressure tube. The piston divides a space within the pressure tube into a rebound chamber and a compression chamber, and is fixedly coupled to a piston rod. An accumulator is connected to an accumulator port on the damper housing. The accumulator includes a housing having an open end coupled to the accumulator port on the damper housing and a distal end including an end wall. The end wall on the distal end of the accumulator extends radially inward to an inflation port. The accumulator includes a bellows assembly. The bellows assembly includes an annular bellows wall extending between a proximal plate and a distal plate to define a pressurized gas chamber within the bellows assembly, the pressurized gas chamber being arranged in fluid communication with the inflation port. The accumulator also includes an accumulator chamber arranged in fluid communication with the compression chamber of the damper and positioned between the distal plate of the bellows assembly and the open end of the accumulator housing. The inflation port on the distal end of the accumulator includes a rod extending inward from the end wall of the housing. The distal plate of the bellows assembly has an inner diameter that receives the rod of the inflation port, and the inner diameter of the distal plate is connected to the rod of the inflation port by a fixing member.

[0007] According to another aspect of this disclosure, the damper includes a pressure tube, a piston slidably disposed within the pressure tube, and a piston rod fixedly connected to the piston. The piston divides a space within the pressure tube into a rebound chamber and a compression chamber, and an accumulator is arranged in fluid communication with at least one of the rebound chamber and the compression chamber. The accumulator includes a housing having a distal end with an end wall. The accumulator also includes a bellows assembly. The bellows assembly includes an annular bellows wall extending between a proximal plate and a distal plate to define a pressurized gas chamber within the accumulator. The accumulator's storage chamber is also located within the housing, and the distal plate of the bellows assembly is located between the pressurized gas chamber and the storage chamber. A charge port is arranged in fluid communication with the pressurized gas chamber. The charge port includes a rod extending from the end wall of the housing into the pressurized gas chamber. The accumulator also has a retaining member that connects the distal plate of the bellows assembly plate to the rod of the charge port.

[0008] According to another aspect of this disclosure, an accumulator for a suspension damper is provided. The accumulator includes a housing having an open end configured to be attached to a suspension damper and a distal end opposite the open end. The distal end of the housing has an end wall extending radially inward to an inflation port. The accumulator has a bellows assembly including an annular bellows wall extending between a proximal plate and a distal plate to define a pressurized gas chamber within the accumulator, the pressurized gas chamber being arranged in fluid communication with the inflation port. The accumulator also has an energy storage chamber positioned between the distal plate of the bellows assembly and the open end of the housing. A rod extends from the end wall of the housing into the pressurized gas chamber, and a retaining member connects the distal plate of the bellows assembly to the rod.

[0009] Advantageously, the accumulator design described herein is easier to manufacture, assemble, and fill with pressurized gas, resulting in cost savings. Additionally, the way the fixing components connect the distal plate of the bellows assembly to the rod provides improvements in sealing, durability, and corrosion resistance, reduces noise and vibration, and allows the pressurized gas chamber of the accumulator to be filled before or after it has been mounted on the damper. Attached Figure Description

[0010] The accompanying drawings described herein are for illustrative purposes only for the selected embodiments and not for all possible specific implementations, and are not intended to limit the scope of this disclosure.

[0011] Figure 1 This is a side sectional view of an exemplary damper equipped with an exemplary energy storage device constructed according to the present disclosure;

[0012] Figure 2 yes Figure 1 A side sectional view of an exemplary energy storage device shown;

[0013] Figure 3A yes Figure 2 The figure shows a partially exploded side sectional view of an exemplary energy storage device, which is shown as an energy storage device with its bellows assembly in a pre-assembled position.

[0014] Figure 3B yes Figure 2 The exemplary accumulator shown is a side sectional view, in which a bellows assembly is inserted into the housing of the accumulator and a riveting tool is inserted into the charging port of the accumulator.

[0015] Figure 3C yes Figure 2 The exemplary accumulator shown is a side sectional view illustrating the axial pulling of a riveting tool away from the bellows assembly to create a mechanical deformation on the rod at the inflation port.

[0016] Figure 3D yes Figure 2 The exemplary accumulator shown is a side sectional view of an exemplary accumulator, which is shown after the riveting tool has been removed from the inflation port and before the accumulator has been installed on the damper;

[0017] Figure 3E yes Figure 2 The exemplary accumulator shown is a side sectional view of an exemplary accumulator after it has been installed on the damper.

[0018] Figure 4 This is a side sectional view of another exemplary energy storage device constructed according to this disclosure;

[0019] Figure 5A yes Figure 4 The figure shows a partially exploded side sectional view of an exemplary energy storage device, which is shown as an energy storage device with its bellows assembly in a pre-assembled position.

[0020] Figure 5B yes Figure 4 The exemplary energy storage device shown is a side sectional view of an exemplary energy storage device, which is shown as a bellows assembly inserted into the housing of the energy storage device;

[0021] Figure 5C yes Figure 4 The exemplary accumulator shown is a side sectional view illustrating the filling of the accumulator with pressurized gas through the charging port after the accumulator has been installed on the damper; and

[0022] Figure 5D yes Figure 4 The exemplary accumulator shown is a side sectional view illustrating the axial expansion of the bellows assembly within the accumulator housing as pressurized gas is added through the inflation port, which in turn causes a spring ring on the rod of the inflation port to connect the bellows assembly to the rod. Detailed Implementation

[0023] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. Where possible, the same reference numerals will be used throughout the drawings to refer to the same or similar parts.

[0024] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. Exemplary embodiments are provided so that this disclosure will be thorough and will fully communicate the scope to those skilled in the art. Numerous specific details, such as examples of particular components, apparatus, and methods, are set forth to provide a thorough understanding of embodiments of this disclosure. It will be apparent to those skilled in the art that specific details are not required, that exemplary embodiments may be embodied in many different forms, and should not be construed as limiting the scope of this disclosure. In some exemplary embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.

[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” may also be intended to include the plural forms unless the context clearly indicates otherwise. The terms “comprising,” “constituting,” “including,” and “having” are inclusive and thus specify the presence of the stated feature, integer, step, operation, element, and / or component, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. Unless there is an explicit order of execution, the method steps, processes, and operations described herein should not be construed as requiring performance in the specific order discussed or described. It should also be understood that additional or alternative steps may be employed.

[0026] When an element or layer is referred to as “on,” “joined to,” “connected to,” or “attached to” another element or layer, the element or layer may be directly on, joined to, connected to, or attached to the other element or layer, or there may be intermediate elements or layers present. Conversely, when an element is referred to as “directly on,” “directly joined to,” “directly connected to,” or “directly attached to” another element or layer, there may be intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the listed items.

[0027] Although the terms first, second, third, etc., are used herein to describe various elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may only be used to distinguish one element, component, region, layer, or segment from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms used herein do not imply sequence or order. Therefore, without departing from the teachings of the exemplary embodiments, the first element, component, region, layer, or segment discussed below may be referred to as a second element, component, region, layer, or segment.

[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] The damper 112 also includes a damper housing 135. While it should be understood that the damper housing 135 can be constructed in various ways, in the illustrated example, the damper housing 135 includes an outer tube 136 extending from a base 138. The outer tube 136 is concentrically arranged around a pressure tube 122 and extends longitudinally between a first outer tube end 137 and a second outer tube end 139. A piston rod 130 extends longitudinally outward through the first outer tube end 137. The second outer tube end 139 and the second pressure tube end 157 are received in the base 138 and are securely coupled to the base. An attachment fitting 143 is mounted to the base 138 and configured to attach to a component of the suspension system or vehicle body (not shown). The attachment fitting 143 may be provided in the form of a hole, ring, stud, or other attachment structure.

[0031] One or more control valves 164a, 164b, 164c are externally mounted to base 138. Although other types of control valves may be used, in the illustrated embodiment, control valves 164a, 164b, 164c are electromechanical valves. The 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, which can deliver fluid to and from the spring chamber 126 and the compression chamber 128.

[0032] A first fluid flow path 166a allows fluid to flow into and out of the compression chamber 128 via the base 138. A second fluid flow path 166b allows fluid to flow into and out of the rebound chamber 126 via a fluid delivery chamber 168 defined in an annular space between the pressure tube 122 and the outer tube 136. The fluid delivery 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 a first control valve 164a. In the open position, the first control valve 164a allows fluid communication between the fluid delivery chamber 168 and a first fluid passage 170a, which 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, which 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 fluid passage 170a and the second fluid passage 170b each include a first port 172a and a second port 172b located in the base 138, which can be fluidly connected to other dampers of the vehicle via hydraulic lines (not shown) to provide roll and / or pitch control functions.

[0033] like Figure 1 As shown, when piston 124 moves away from base 138 during the extension / rebound stroke, the volume of fluid in springback chamber 126 decreases and the volume of fluid in compression chamber 128 increases. Control valves 164a-164c are opened and regulate the flow of fluid from springback chamber 126, through fluid delivery chamber 168, through first fluid passage 170a and second fluid passage 170b in base 138, and to compression chamber 128. The degree and / or timing of the opening of control valves 164a-164c can be adjusted to regulate the extension / rebound damping characteristics of damper 112.

[0034] In other words, during the extension / rebound stroke, fluid from the springback chamber 126 flows into the fluid delivery chamber 168 via the open port 146 in the first pressure tube end 156. The fluid in the fluid delivery chamber 168 then passes through the first control valve 164a and enters 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 enters 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 flows out into the compression chamber 128.

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

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

[0037] While other configurations are possible, in the example shown, accumulator port 202 is arranged in fluid communication with third control valve 164c. Pressurized gas within pressurized gas chamber 206 of accumulator 200 operates to apply a positive pressure within accumulator 200, which forces fluid out of accumulator chamber 204 when the fluid pressure at accumulator port 202 is less than the gas pressure within pressurized gas chamber 206. In other words, the volume of pressurized gas chamber 206 increases, and the volume of accumulator chamber 204 decreases until pressure equilibrium is achieved between accumulator chamber 204 and pressurized gas chamber 206. Conversely, when the fluid pressure at accumulator port 202 increases (such as when third control valve 164c opens), fluid flows into accumulator chamber 204, causing the volume of accumulator chamber 204 to increase and the volume of compressed gas chamber 206 to decrease until pressure equilibrium is achieved. As a result, a combination of accumulator 200 and control valves 164a-164c can be used to add fluid or remove fluid from damper 112.

[0038] like Figure 2 As shown, the housing 210 of the accumulator 200 includes an open end 212 and a distal end 214 adjacent to the accumulator port 202 in the damper housing 135. An end wall 216 of the damper housing 135 extends radially inward at the distal end 214 of the damper housing 135 to the inflation port 218. The housing 210 of the accumulator 200 is generally cylindrical in shape and extends annularly around the 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 as a single piece with the housing 210, as an impact-extruded aluminum end cap. The end wall 216 is generally arranged along a transverse plane substantially perpendicular to the accumulator axis A. Thus, the end wall 216 of the accumulator 200 substantially closes the distal end 214 of the housing 210, except for the opening provided by the inflation 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 / sliding engagement and has an annular bellows wall 220 that extends coaxially about the accumulator axis A and axially between the proximal plate 222 and the 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 an outer diameter fixed to 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 to define a pressurized gas chamber within the accumulator 200. The annular bellows wall 220 has a corrugated shape, which allows the bellows assembly 208 to expand and contract in length according to the pressure difference between the energy storage chamber 204 and the pressurized gas chamber 206 (i.e., the distance between the proximal plate 222 and the distal plate 224 of the bellows assembly 208 can be increased or decreased).

[0040] An energy storage 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 described above, the energy storage chamber 204 is arranged in fluid communication with the compression chamber 128 of the damper 112 and is therefore 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 inflation port 218. The inflation port 218 includes a rod 226 extending 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 in the rod 226 of the inflation port 218 and connected to the rod by a fastening member 230.

[0041] The proximal plate 222 of the bellows assembly 208 is solid and has no holes or channels. Conversely, the inner diameter 228 of the distal plate 224 of the bellows assembly 208 defines a cylindrical bore surface 232 that is slidably received on the rod 226 of the inflation port 218 with a sliding / slip fit. The cylindrical bore surface 232 of the distal plate 224 includes an annular groove 234 for receiving a sealing element 236 that seals against the rod 226 of the inflation port 218 and prevents gas in the pressurized gas chamber 206 from leaking out of the bellows assembly 208 around the rod 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 diameter / periphery. The accumulator 200 also includes a retaining ring 238 that is threadedly 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 slipping out of the open end 212 of the housing 210. However, it should be understood that the retaining ring 238 may alternatively be press-fitted into the open end 212 of the housing 210 or secured in other suitable ways. While other connection interfaces are possible, in the illustrated example, the open end 212 of the housing 210 of the accumulator 200 also includes a thread 240 that engages the accumulator port 202 of the damper housing 135, allowing the open end 212 of the accumulator 200 to be threaded / screwed into the accumulator port 202 on the damper 112.

[0042] exist Figure 2 and Figures 3A to 3EIn the illustrated embodiment, the securing component is a blind rivet nut 230 attached to the end 242 of the rod 226 of the inflation port 218. The blind rivet nut 230 includes a rivet nut hole 244. The distal plate 224 of the bellows assembly 208 includes an annular collar 246 extending circumferentially around the rod 226 of the inflation port 218. The annular collar 246 is thus coaxially positioned with respect to the inner diameter 228 of the distal plate 224 and extends axially from the end wall 216 of the distal plate 224 away from the housing 210. Additionally, the annular collar 246 on the distal plate 224 terminates at a collar flange 248 having a diameter 250 smaller than the inner diameter 228 of the distal plate 224. The inflation port 218 includes a mechanically deformable portion 252 located where the blind rivet nut 230 and the rod 226 meet. The mechanically deformable portion 252 has an annular shape and a diameter 254 larger than the smaller diameter 250 of the collar flange 248. The collar flange 248 is axially positioned between the rod 226 and the mechanical deformation portion 252 to connect the distal plate 224 of the bellows assembly 208 to the rod 226 of the inflation port 218 in a fixed axial position. Therefore, the mechanical deformation portion 252 on the inflation port 218 prevents axial movement of the distal plate 224 of the bellows assembly 208 within the housing 210. However, it should be understood that, depending on the design, the distal plate 224 may or may not be able to rotate within the housing 210 despite the mechanical deformation portion 252 on the rod 226.

[0043] In the illustrated example, the rivet nut hole 244 is threaded and therefore configured such that the riveting tool 256 can be threadedly connected to the rivet nut hole 244. The rod 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 length 262b smaller than the pre-assembly length 262a and an assembly diameter 260b larger than the pre-assembly diameter 260a. This operates to attach the distal plate 224 of the bellows assembly 208 to the rod 226 of the inflation port 218 at the aforementioned fixed axial position. It should be understood that the tubular wall 258 of the inflation port 218 may be formed from the rod 226, the blind rivet nut 230, both the rod 226 and 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 by the riveting tool 256 in the inflation port 218, which can be located at any point on the inflation port 218 (including along the rod 226, the blind rivet nut 230, or any point in between).

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

[0045] refer to Figures 3A to 3E The diagram illustrates a method for assembling the accumulator 200. Before, after, or simultaneously with the method of assembling the accumulator 200, the damper 112 is assembled by performing the step of mounting the piston 124 and piston rod 130 in the damper housing 135. This step may also include assembling the aforementioned pressure tube 122, outer tube 136, and base 138. The method also includes the step of forming a housing 210 of the accumulator 200, wherein the housing 210 includes a distal end 214 and an end wall 216, and an open end 212 opposite to the distal end 214. Figure 3A As shown, the method includes the following steps: 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 housing 210 such that the distal plate 224 of the bellows assembly 208 faces the end wall 216 of the housing 210. The method then continues with the following steps: using a fixing member 230 that engages with the rod 226 of the inflation port 218, the distal plate 224 of the bellows assembly 208 is connected at a fixed axial position to the rod 226 of the inflation port 218 on the end wall 216 of the housing 210 of the accumulator 200. The method further includes the following steps: after inserting the bellows assembly 208 into the housing 210, inserting a retaining ring 238 into the open end 212 of the housing 210 to prevent the bellows assembly 208 from slipping out through the open end 212 of the housing 210; and then mounting the accumulator 200 onto the damper housing 135, which includes connecting the open end 212 of the housing 210 of the accumulator 200 to the damper housing 135. More specifically, mounting the accumulator 200 onto the damper housing 135 may include threading the open end 212 of the housing 210 of the accumulator 200 into an accumulator port 202 on the damper housing 135.

[0046] As mentioned above, Figures 3A to 3E In the embodiment shown, the fixing component 230 is a blind rivet nut 230 positioned at the end 242 of the rod 226 at the inflation port 218. For example... Figure 3BAs shown, the step of connecting the distal plate 224 of the bellows assembly 208 to the rod 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 rod 226 of the inflation port 218 extends through the inner diameter 228 of the distal plate 224 of the bellows assembly 208; and inserting a riveting tool 256 into the inflation port 218 until the riveting tool 256 engages the rivet nut hole 244 in the blind rivet nut 230. 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 nut 230 and form a mechanically deformed portion 252 in the rod 226 and / or the blind rivet nut 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 an assembly diameter 260b (greater than the pre-assembly diameter 260a) and from the pre-assembly length 262a to an assembly length 262b (shorter than the pre-assembly length 262a). Figure 3D As shown, the method then proceeds to the following steps: removing the riveting tool 256 from the inflation port 218 and the rivet nut 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 a rivet 264 into the inflation port 218 to seal the pressurized gas chamber 206.

[0047] exist Figure 4 and Figures 5A to 5D Another exemplary energy storage device 300 is shown in the figure. Many elements of the damper 112 and energy storage device 200 described above are identical or substantially identical between embodiments and will not be described in detail again. Equivalent elements shared between embodiments have corresponding reference numerals, wherein reference numerals beginning with 200 are used for identification. Figure 2 and Figures 3A to 3E The components of the energy storage device 200 shown are identified by reference numerals beginning with 300. Figure 4 and Figures 5A to 5D The same or corresponding elements in the energy storage device 300 shown. For example, reference numeral 210 is used to identify... Figure 2 and Figures 3A to 3E The housing of the energy storage device 200 is shown, while reference numeral 310 is used to identify it. Figure 4 and Figures 5A to 5D The housing of the energy storage device 300 shown.

[0048] exist Figure 4 and Figures 5A to 5DIn the illustrated embodiment, the retaining element is a spring ring 330 that engages with both the rod 326 and the distal plate 324 of the bellows assembly 308. The rod 326 of the inflation port 318 has a tubular wall 358 with an outwardly facing groove 368. Additionally, the inner diameter 328 of the distal plate 324 of the bellows assembly 308 includes an inwardly facing groove 370. Once the accumulator 300 is assembled and filled, the spring ring 330 is received within the outwardly facing groove 368 on the rod 326 of the inflation port 318 and within the inwardly facing groove 370 on the distal plate 324 of the bellows assembly 308 to attach the distal plate 324 of the bellows assembly 308 to the rod 326 of the inflation port 318 in a fixed 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 previous design described above, the inner diameter 328 of the distal plate 324 of the bellows assembly 308 defines a cylindrical bore surface 332 that is slidably received on the rod 326 of the inflation port 318 with a sliding / sliding engagement. The cylindrical bore surface 332 of the distal plate 324 includes an annular groove 334 for receiving a sealing element 336 that seals against the rod 326 of the inflation port 318 and prevents gas in the pressurized gas chamber 306 from leaking out of the bellows assembly 308 around the rod 326.

[0050] The accumulator 300 also includes a bias ring 372, which is circumferentially positioned around 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 bias ring 372 has a structure similar to a push nut washer and includes a plurality of resilient spring fingers 374 that extend radially inward toward the annular collar 346 of the distal plate 324 and are circumferentially spaced around the bias ring 372. The bias ring 372 is configured to apply a bias force 376 to the distal plate 324, which pushes 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 applies a reaction force 378 to the distal plate 324, which pushes the distal plate 324 toward the end wall 316 of the housing 310. like Figure 5C and Figure 5DAs shown, during the filling process, gas is added through the inflation port 318, increasing the gas pressure within the pressurized gas chamber 306 of the bellows assembly 308. 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 gas pressure operates to push the distal plate 324 toward the end wall 316 and cause the distal plate 324 to slide axially toward the end wall 316 on the rod 326. When the accumulator 300 is filled, this operation causes the spring ring 330 to be positioned in 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. Finally, a rivet 364 is placed in the inflation port 318 to seal the pressurized gas chamber 306.

[0051] refer to Figures 5A to 5D This illustrates a method for assembling an energy storage device 300. The method includes the steps of: forming a housing 310 of the energy storage device 300; and assembling the bellows assembly 308 by connecting the distal plate 322 and proximal plate 324 of the bellows assembly 308 to opposite ends of the annular bellows wall 320. For example, the distal plate 322 and proximal plate 324 of the bellows assembly 308 may be welded to opposite ends of the annular bellows wall 320. As described above, the housing 310 of the energy storage device 300 includes a distal end 314 having an end wall 316 and an open end 312 opposite to the distal end 314. Figure 5A As shown, the method includes the following steps: inserting a bellows assembly 308 into the open end 312 of the housing 310, wherein the distal plate 324 of the bellows assembly 308 faces 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 may include mounting the piston 124 and piston rod 130 in the damper housing 135. Figure 5A and Figure 5B As shown, the method further includes the following steps: after inserting the bellows assembly 308 into the housing 310, inserting a retaining ring 338 into the open end 312 of the housing 310 to prevent the bellows assembly 308 from slipping out of the open end 312 of the housing 310, followed by mounting the accumulator 300 onto the damper housing 135. Mounting the accumulator 300 onto the damper housing 135 involves connecting the open end 312 of the housing 310 of the accumulator 300 to the damper housing 135. More specifically, mounting the accumulator 300 onto the damper housing may include threading the open end 312 of the housing 310 of the accumulator 300 into an accumulator port 302 on the damper housing 135.

[0052] like 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 various aspects of this disclosure have been specifically shown and described with reference to the above embodiments, those skilled in the art will understand that various additional embodiments can be conceived by modifying the disclosed damper without departing from the spirit and scope of the disclosure. Such embodiments should be understood to fall within the scope of this disclosure as defined by the claims and any equivalents.

Claims

1. A damper, the damper comprising: Damper housing; A pressure tube, which is disposed within the damper housing; A piston, which is slidably disposed within the pressure tube, thereby defining a springback chamber and a compression chamber; A piston rod, which is fixedly connected to the piston; and An energy storage device, the energy storage device being connected to an energy storage port on the damper housing, The accumulator includes: a housing having an open end connected to the accumulator port on the damper housing and a distal end having an end wall extending radially inward to the inflation port; A bellows assembly having an annular bellows wall extending between a proximal and a distal plate to define a pressurized gas chamber within the bellows assembly, the pressurized gas chamber being arranged in fluid communication with the inflation port; and an energy storage chamber positioned within the housing between the distal plate of the bellows assembly and the open end of the housing. The inflation port includes a rod extending inward from the end wall of the housing, and the inner diameter of the distal plate of the bellows assembly is received on the rod of the inflation port and connected to the rod of the inflation port by a fastening member. The fixing component is a spring ring that engages with both the rod and the distal plate of the bellows assembly; The rod of the inflation port has a tubular wall with an outwardly facing groove, the inner diameter of the distal plate of the bellows assembly includes an inwardly facing groove, and the spring ring is received in the outwardly facing groove on the rod of the inflation port and in the inwardly facing groove on the distal plate of the bellows assembly to connect the distal plate of the bellows assembly to the rod of the inflation port at a fixed axial position.

2. The damper of claim 1, wherein the distal plate of the bellows assembly includes an annular collar positioned coaxially with the inner diameter of the distal plate and extending axially from the distal plate toward the end wall of the housing, and wherein the accumulator includes a biasing ring extending circumferentially around the annular collar of the distal plate and extending axially between the distal plate and the end wall of the housing.

3. The damper of claim 2, wherein the biasing ring is configured to apply a biasing force to the distal plate, the biasing force pushing the distal plate away from the end wall of the housing, wherein the gas pressure in the pressurized gas chamber of the bellows assembly applies a reaction force to the distal plate, the reaction force pushing the distal plate toward the end wall of the housing, and wherein the gas pressure in the pressurized gas chamber of the bellows assembly is increased by adding gas to the pressurized gas chamber via the inflation port, thereby operating to slide the distal plate toward the end wall when the reaction force applied to the distal plate by the gas pressure exceeds the biasing force of the biasing ring, and operating to cause the spring ring to move from the outward-facing groove on the rod disposed at the inflation port and the inward-facing groove on the distal plate of the bellows assembly.

4. The damper according to any one of the preceding claims, wherein the cylindrical bore surface extends around the inner diameter of the distal plate, and wherein the cylindrical bore surface includes an annular groove for receiving a sealing element.

5. A damper, said damper comprising: Damper housing; A pressure tube, which is disposed within the damper housing; A piston, which is slidably disposed within the pressure tube, thereby defining a springback chamber and a compression chamber; A piston rod, which is fixedly connected to the piston; and An energy storage device, the energy storage device being connected to an energy storage port on the damper housing, The accumulator includes: a housing having an open end connected to the accumulator port on the damper housing and a distal end having an end wall extending radially inward to the inflation port; A bellows assembly having an annular bellows wall extending between a proximal and a distal plate to define a pressurized gas chamber within the bellows assembly, the pressurized gas chamber being arranged in fluid communication with the inflation port; and an energy storage chamber positioned within the housing between the distal plate of the bellows assembly and the open end of the housing. The inflation port includes a rod extending inward from the end wall of the housing, and the inner diameter of the distal plate of the bellows assembly is received on the rod of the inflation port and connected to the rod of the inflation port by a fastening member. The fixing component is a blind rivet nut, which is attached to the end of the rod and includes a rivet nut hole.

6. The damper of claim 5, wherein the distal plate of the bellows assembly includes an annular collar extending circumferentially around the rod of the inflation port and terminating at a collar flange having a diameter smaller than the inner diameter of the distal plate.

7. The damper of claim 6, wherein the inflation port includes a mechanically deformable portion at the point where the blind rivet nut and the rod meet, the mechanically deformable portion having a diameter larger than the diameter of the collar flange, and the collar flange being axially positioned between the rod and the mechanically deformable portion to connect the distal plate of the bellows assembly to the rod of the inflation port at a fixed axial position.

8. The damper of claim 5, wherein the inflation port has a tubular wall having a pre-assembly diameter and a pre-assembly length, and wherein the tubular wall is configured to deform to an assembly diameter greater than the pre-assembly diameter and an assembly length less than the pre-assembly length when the tubular wall is compressed by a riveting tool to attach the distal plate of the bellows assembly to the rod of the inflation port at a fixed axial position.

9. The damper according to any one of claims 5-8, wherein the cylindrical bore surface extends around the inner diameter of the distal plate, and wherein the cylindrical bore surface includes an annular groove for receiving a sealing element.

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