Hydraulic port protection plug for shock absorber

Abstract

The hydraulic port protection plug (160 ') is intended to be inserted into a hydraulic port (174') of the shock absorber (24) to prevent contaminants from entering the shock absorber (24) and prevent residual oil from being discharged through the hydraulic port (174 ') during storage, transportation and handling of the shock absorber (24). The hydraulic port (174 ') protection plug (160') includes a tubular body (168 ') and a puncturable seal (162') configured to receive an inboard portion (167 ') of the hydraulic joint (161'). The puncturable seal (162 ') is designed such that an inside portion of the hydraulic joint (161') can pass through the puncturable seal (162 ') of the hydraulic port protection plug (160') and be inserted into the hydraulic port (174 ') of the shock absorber (24) such that the hydraulic port protection plug (160') does not need to be removed in the installed state and the hydraulic joint (161 ') is sealed within the hydraulic port (174') of the shock absorber (24).

Description

Technical Field

[0001] The present disclosure generally relates to shock absorbers used in suspension systems, such as those for motor vehicles. More particularly, the present disclosure relates to protective plugs installed in hydraulic ports of shock absorbers to prevent contamination during transportation, handling, and storage of the shock absorbers before they are installed on a vehicle. Background Art

[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

[0003] Shock absorbers work with the vehicle's suspension system to absorb unwanted vibrations and shocks generated during vehicle movement. To absorb these unwanted vibrations and shocks, shock absorbers are typically connected between the vehicle's elastic mass (body) and inelastic mass (suspension / chassis).

[0004] The most common type of automotive shock absorber is the ram type. A piston is located within a pressure tube, typically connected to the vehicle's spring mass via a piston rod. The pressure tube is typically connected to the vehicle's unsprung mass. The piston divides the pressure tube into upper and lower working chambers. During the compression and rebound strokes, valves restrict the flow of damping fluid from the lower to the upper chamber. Because the compression and rebound valves restrict the flow of damping fluid, the shock absorber generates a damping force, counteracting vibrations that would otherwise be transferred from the unsprung mass to the spring mass.

[0005] Shock absorbers are typically mounted as part of a larger shock absorber assembly, which may also include mounting brackets, an electromechanical valve that controls the damping force, and a spring assembly. Such a spring assembly may include a coil spring that extends helically around a portion of the shock absorber, or an air spring that may include an air bladder that extends annularly around a portion of the shock absorber. Summary of the Invention

[0006] This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

[0007] According to one aspect of the present disclosure, a shock absorber assembly is provided, comprising a shock absorber with a sliding piston that divides the shock absorber into a first working chamber and a second working chamber. A piston rod is mounted on the sliding piston, and the shock absorber assembly has a lower housing opposite the piston rod. One or more hydraulic ports are provided in the lower housing of the shock absorber. During transportation, loading and unloading, and storage before the shock absorber assembly is installed on a vehicle, one or more hydraulic port protection plugs are provided to seal the hydraulic ports in the lower housing. The hydraulic port protection plugs have a tubular body that is geometrically configured to be inserted into the hydraulic ports in the lower housing and prevent contaminants from entering the hydraulic ports of the shock absorber while also preventing any residual oil from leaking from the shock absorber assembly during transportation, loading and unloading, and storage. Furthermore, the hydraulic port protection plugs are designed to remain installed in the hydraulic ports when one or more hydraulic connectors and hydraulic lines are connected to the shock absorber. Therefore, the hydraulic port protection plugs remain installed in the hydraulic ports even after the hydraulic connectors are installed and the shock absorber is mounted on the vehicle.

[0008] Each hydraulic port protection plug includes a pierceable seal configured to receive an inner portion of a hydraulic connector. The pierceable seal is designed so that the inner portion of the hydraulic connector can pass through the pierceable seal of the hydraulic port protection plug and be inserted into the hydraulic port in the lower housing, thereby sealing the hydraulic connector within the hydraulic port of the shock absorber without having to remove the hydraulic port protection plug when installed.

[0009] According to another aspect of the present disclosure, a shock absorber assembly includes a shock absorber having a sliding piston that divides the shock absorber into a first working chamber and a second working chamber, a piston rod mounted on the sliding piston, a lower housing opposite the piston rod, a hydraulic port located in the lower housing of the shock absorber, and a hydraulic coupling configured to cooperate with the hydraulic port in the lower housing of the shock absorber. Similarly, during transportation, loading and unloading, and storage of the shock absorber assembly before it is installed on a vehicle, a hydraulic port protective plug is provided to seal the hydraulic port in the lower housing. The hydraulic port protective plug has a tubular body whose geometric shape is configured to be inserted into the hydraulic port in the lower housing of the shock absorber. The hydraulic port protective plug also includes a pierceable seal that is configured to receive an insertable portion of the hydraulic coupling so that the hydraulic port protective plug seals the hydraulic joint within at least one hydraulic port in the lower housing when in the installed state.

[0010] According to another aspect of the present disclosure, a method for assembling a shock absorber assembly using the hydraulic port protection plug is provided. The method comprises the following steps: installing a piston and a piston rod within a shock absorber housing; inserting the hydraulic port protection plug into a hydraulic port of the shock absorber housing to place the shock absorber assembly in a shipping and handling configuration; installing the shock absorber assembly in a vehicle; and, while the hydraulic port protection plug is in the hydraulic port, installing a hydraulic connector in the hydraulic port by pressing at least a portion of the hydraulic connector into a pierceable seal in the hydraulic port protection plug.

[0011] More applicable areas will become apparent from the description herein.It should be understood that this description and specific examples are intended for illustration purposes only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

[0013] Figure 1 is a side view of an exemplary shock absorber assembly made in accordance with the present disclosure; Figure 2 yes Figure 1 An enlarged perspective view of the lower housing and rocker arm of an exemplary shock absorber assembly is shown, showing a pair of exemplary hydraulic port protection plugs installed in two hydraulic ports in the lower housing; Figure 3 yes Figure 2 A top perspective view of one of the exemplary hydraulic port protection plugs shown; Figure 4 yes Figure 3 A bottom perspective view of an exemplary hydraulic port protection plug shown in ; Figure 5A and Figure 5B yes Figure 1 an enlarged cross-sectional view of the lower housing of the exemplary shock absorber assembly shown, illustrating the geometry of exemplary hydraulic ports disposed therein; Figure 6A and Figure 6B yes Figure 1 an enlarged cross-sectional view of a lower housing of an exemplary shock absorber assembly, illustrating the geometry of another exemplary hydraulic port disposed therein; Figure 7A and Figure 7B yes Figure 1 an enlarged cross-sectional view of the lower housing of the shock absorber assembly shown, illustrating another exemplary hydraulic port geometry provided therein; Figure 8A yes Figure 1an enlarged cross-sectional view of the lower housing of the exemplary shock absorber assembly shown, illustrating exemplary hydraulic port protection plugs installed in exemplary hydraulic ports of the lower housing; Figure 8B yes Figure 1 an enlarged cross-sectional view of a lower housing of an exemplary shock absorber assembly shown, and illustrating another exemplary hydraulic port protection plug installed in an exemplary hydraulic port of the lower housing; Figure 9A yes Figure 1 an enlarged cross-sectional view of a lower housing of an exemplary shock absorber assembly shown, and illustrating another exemplary hydraulic port protection plug installed in an exemplary hydraulic port of the lower housing; Figure 9B yes Figure 1 an enlarged cross-sectional view of a lower housing of an exemplary shock absorber assembly shown, and illustrating another exemplary hydraulic port protection plug installed in an exemplary hydraulic port of the lower housing; Figure 10 yes Figure 1 an enlarged cross-sectional view of a lower housing of an exemplary shock absorber assembly shown, and illustrating another exemplary hydraulic port protection plug installed in an exemplary hydraulic port of the lower housing; Figure 11A yes Figure 1 an enlarged cross-sectional view of a lower housing of an exemplary shock absorber assembly shown, and illustrating another exemplary hydraulic port protection plug installed in an exemplary hydraulic port of the lower housing; Figure 11B Is for installation in Figure 1 An enlarged cross-sectional view of another exemplary hydraulic port protection plug in a hydraulic port provided in a lower housing of an exemplary shock absorber assembly is shown; Figure 12 Is shown assembled Figure 1 A flow chart of exemplary steps of an exemplary shock absorber assembly method is shown; Figure 13A and Figure 13B yes Figure 1 An enlarged cross-sectional view of the lower housing of the shock absorber assembly is shown, illustrating another exemplary hydraulic port protection plug inserted into the hydraulic port of the lower housing, with an exemplary connector pushed into the hydraulic port protection plug; 14A to 14D yes Figure 13A and Figure 13B a top perspective view of an exemplary hydraulic port protection plug in the illustrated configuration; Figure 15 yes Figure 13A and Figure 13B Another enlarged cross-sectional view of the lower housing of the shock absorber assembly is shown, illustrating the anti-sway performance of the hydraulic joint in the installed state; Figure 16 yes Figure 1 An enlarged cross-sectional view of the lower housing of the shock absorber assembly is shown with another exemplary hydraulic connector inserted into the Figure 13A and Figure 13B In the exemplary hydraulic port protection plug shown; Figure 17 Is for installation in Figure 1 An enlarged cross-sectional view of another exemplary hydraulic port protection plug provided within a hydraulic port provided in a lower housing of an exemplary shock absorber assembly is shown; Figure 18A and Figure 18B yes Figure 1 An enlarged cross-sectional view of the lower housing of the shock absorber assembly is shown, showing Figure 17 The hydraulic port protection plug is inserted into the hydraulic port of the lower housing, wherein the exemplary connector is pushed into the hydraulic port protection plug; Figure 19A and Figure 19B yes Figure 1 an enlarged cross-sectional view of the lower housing of the shock absorber assembly shown, illustrating another exemplary hydraulic port protection plug being inserted into a hydraulic port of the lower housing, with another exemplary connector being pushed through a connector puncture area in the hydraulic port protection plug; 20A to 20C yes Figure 1 an enlarged cross-sectional view of the lower housing of the shock absorber assembly shown, showing another example hydraulic port protection plug inserted into a hydraulic port of the lower housing, with another example connector pushed through a frangible membrane of the hydraulic port protection plug; Figures 21A to 21C yes Figure 1 an enlarged cross-sectional view of the lower housing of the shock absorber assembly shown, showing another exemplary hydraulic port protection plug inserted into the hydraulic port of the lower housing, with another exemplary connector pushed through the frangible membrane and through a sealing rib in the hydraulic port protection plug; and Figure 22 It is assembled Figure 1 A flowchart of the steps of another exemplary method of an exemplary shock absorber assembly is shown. DETAILED DESCRIPTION

[0014] The following description is merely exemplary and is not intended to limit the present disclosure, application, or uses.

[0015] Example embodiments will now be described more fully with reference to the accompanying drawings. Exemplary embodiments are provided to make the present disclosure more comprehensive and to fully convey the scope of the present disclosure to those skilled in the art. In order to provide a comprehensive understanding of the embodiments of the present disclosure, many specific details are listed, such as examples of specific components, devices, and methods. It will be apparent to those skilled in the art that the example embodiments can be embodied in a variety of different forms without resorting to specific details, and neither form should be construed as limiting the scope of the present disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0016] The terms used herein are intended only to describe specific example embodiments and are not intended to be limiting. As used herein, the singular forms "a," "an," and "the" also include the plural forms, unless the context clearly indicates otherwise. The words "comprise," "include," "encompass," and "have" are inclusive and therefore specify the presence of the features, integers, steps, operations, elements, and / or components, but do not exclude 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 should not be understood as necessarily requiring execution in the specific order discussed or described, unless an order of execution is specifically indicated. It should also be understood that additional or alternative steps may be employed.

[0017] 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 to, connected to, or coupled to the other element or layer, or intervening elements or layers may be present. Conversely, 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 may be no intervening elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (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.

[0018] Although the words first, second, third, etc. may be used herein to describe various elements, components, regions, layers and / or parts, these elements, components, regions, layers and / or parts should not be limited by these words. These words may only be used to distinguish one element, component, region, layer or part from another region, layer or part. Unless the context clearly indicates otherwise, the "first", "second" and other numerical terms used herein do not imply an order or sequence. Therefore, the first element, component, region, layer or part discussed below may be referred to as the second element, component, region, layer or part without departing from the teachings of the exemplary embodiments.

[0019] For ease of description, spatially relative terms such as "inside," "outside," "below," "beneath," "lower," "above," and "upper" may be used herein to describe the relationship of one element or feature to another element or feature shown in the figures. In addition to the orientations depicted in the figures, spatially relative terms may be used to describe different orientations of the device during use or operation. For example, if the shock absorber assembly 20 shown in the figures were turned over, the element described as the "lower housing" would be located "above" the other elements or features. Thus, the example term "lower" may include both lower and upper orientations, depending on the orientation of the shock absorber assembly 20, which may be different from the orientation shown in the figures (e.g., rotated 90 or 180 degrees or other orientations), and the spatially relative descriptors used herein should be interpreted accordingly.

[0020] Figure 1 An exemplary pre-installed shock absorber assembly 20 is shown, which includes a spring 22 that extends annularly around a shock absorber 24 to form the entire shock absorber assembly 20. It should be understood that the shock absorber assembly 20 is configured to be installed in a vehicle as part of a suspension system. It should also be understood that Figure 1 The shock absorber assembly 20 shown in FIG is shown in a pre-installed configuration, state, or condition and, therefore, is shown prior to installation on a vehicle. It should also be understood that the shock absorber assembly 20 is typically shipped, handled, and stored in this pre-installed configuration, state, or condition, wherein the shock absorber 24 has not yet been filled with a working volume of hydraulic fluid or oil, although some residual fluid or oil may remain in the shock absorber 24 during assembly and / or testing.

[0021] The shock absorber assembly 20 includes a lower housing 26 and an upper assembly 28. The lower housing 26 is formed by the pressure tube 30 of the shock absorber 24 and a mounting fixture 32. In the illustrated embodiment, the mounting fixture 32 is provided in the form of a yoke; however, it should be understood that the mounting fixture 32 can be provided in the form of other types / styles of connection structures. Regardless of the type, the mounting fixture 32 is configured to be connected to an inelastic component of the vehicle, such as an axle, wheel knuckle, or lower control arm. The upper assembly 28 is composed of the spring 22, a lower spring seat 34, an upper spring seat 36, and a top mount 38. The top mount 38 comprises a unitary molded and rigid member, typically made of stamped steel. Thus, the top mount 38 is configured to be mounted to an elastic component of the vehicle, such as a shock tower in the vehicle body.

[0022] A rubber dust cover 49 may be provided to cover the telescopic portion of the spring 22 and shock absorber 24 to protect the spring 22 and shock absorber 24 from dust, water, and other contaminants. Although other types of springs, such as coil springs, may be used, the spring 22 in the illustrated example is an air spring that includes an air bladder 40 that extends annularly around the upper portion of the shock absorber 24 and longitudinally between the lower spring seat 34 and the upper spring seat 36.

[0023] Shock absorber 24 includes a sliding piston 42 slidably engaged within pressure tube 30, a piston rod 44 connected to sliding piston 42, and a rod guide 46 located at the upper end of pressure tube 30. Piston rod 44 extends upward from sliding piston 42, through rod guide 46, to an upper rod end 48. Upper rod end 48 is connected to top mount 38 and, therefore, to a resilient component of the vehicle.

[0024] The sliding piston 42 is slidably disposed within the pressure tube 30 and divides the internal volume of the pressure tube 30 into a first working chamber 50 and a second working chamber 52. The piston rod 44 is connected to the sliding piston 42 and passes through the first working chamber 50 and the rod guide 46, which closes the upper end of the first working chamber 50.

[0025] During compression and extension (e.g., rebound) motions of the shock absorber 24, hydraulic fluid or oil moves from the first working chamber 50 to the second working chamber 52, or from the second working chamber 52 to the first working chamber 50. This provides a damping effect that can be plotted as a frequency versus dissipation response curve, with the dissipation response increasing at an increasingly faster rate as the frequency of the damped vibration increases. The shock absorber assembly 20 has externally mounted electromechanical valves 54a, 54b for dynamically controlling the flow of fluid between the first and second working chambers 50, 52, thereby controlling the damping rate of the shock absorber 24. The shock absorber assembly 20 also includes an externally mounted accumulator 56. During operation, hydraulic fluid or oil is allowed to flow between the accumulator 56 and the shock absorber 24 to provide pressure and temperature compensation.

[0026] Figure 2A portion of the lower housing 26 of the shock absorber assembly 20 is shown, including the mounting fixture 32 (i.e., the rocker arm). The lower housing 26 includes a pair of hydraulic port mounts 58 and a pair of hydraulic port protection plugs 60 mounted within the hydraulic port mounts 58. As will be discussed in greater detail below, each hydraulic port protection plug 60 has a self-closing pressure relief port 62 configured to open or close in response to pressure changes resulting from pressurization or depressurization of the shock absorber 24 and / or movement of the piston 42 and piston rod 44 during or after assembly and after installation of the hydraulic port protection plug 60. Therefore, it should be understood that the hydraulic port protection plugs 60 are designed and configured to be installed on the hydraulic port mounts 58 of the lower housing 26 of the shock absorber 24 when the shock absorber 24 is in a pre-installed state and does not contain a working volume of oil. In this sense, the hydraulic port protection plugs 60 can be considered shipping and / or storage plugs, designed to be removed when the shock absorber assembly 20 is installed on a vehicle and subsequently filled with a working volume of hydraulic fluid or oil. In other words, the hydraulic port protection plug 60 is not designed or intended to remain installed on the shock absorber 24 after the shock absorber assembly 20 is fully installed on the vehicle. This is because the hydraulic connectors and the hydraulic lines of the hydraulic crossover circuit should be connected to the hydraulic port base 58 when the shock absorber assembly 20 is fully installed on the vehicle.

[0027] Each hydraulic port base 58 also includes a threaded hole 64 for attaching a pressurized tool assembly (e.g., 8A to 11AAttached to each hydraulic port seat 58 are a plurality of hydraulic port protection plugs (shown in FIG. 1 ). As will be described in detail below, the hydraulic port protection plugs 60 are designed and configured to be installed on the hydraulic port seats 58 of the lower housing 26 of the shock absorber 24 during assembly, before the shock absorber 24 is charged with pressurized air or gas. This differs from conventional shipping plugs, which cannot be installed prior to charging / pressurization because they lack any openings to allow pressurized air or gas to pass through. Conventional shipping plugs also present a problem: after the shipping plugs are installed, if the piston rod 44 moves due to pressure generated by the piston 42 in the first and / or second working chambers 50, 52, the shipping plugs can become dislodged / blown out of the hydraulic port seats 58. The hydraulic port protection plugs 60 described herein address these issues and thus can achieve higher cleanliness requirements because the self-closing pressure relief vents 62 allow air and / or pressurized gas to flow through the hydraulic port protection plugs 60 during pressurization or depressurization of the shock absorber 24 and / or during or after assembly, as well as during movement of the piston 42 and piston rod 44 after the hydraulic port protection plugs 60 are installed. Due to the geometry and internal drilling of the shock absorber assembly 20, it can be difficult to drain hydraulic fluid or oil from the shock absorber assembly 20 before the hydraulic port protection plug 60 is inserted. Therefore, in addition to preventing foreign matter from entering the shock absorber 24, the self-closing pressure relief vent 62 also prevents any hydraulic fluid or oil remaining during assembly or testing of the shock absorber 24 from escaping during shipping, handling, or storage. Consequently, over time, a small stream of hydraulic fluid or oil may accumulate behind the hydraulic port protection plug 60 after it is installed.

[0028] refer to Figure 3 and Figure 4 The hydraulic port protection plug 60 includes a cap portion 66 and a tubular body 68. The cap portion 66 has a disc-shaped end wall 70. The tubular body 68 extends from the end wall 70 of the cap portion 66 to define an open cavity 72 within the tubular body 68. Therefore, the open cavity 72 has an open end and an opposite end defined by the end wall 70 of the cap portion 66. The tubular body 68 has a body diameter BD. The disc-shaped end wall 70 of the cap portion 66 extends radially outward from the tubular body 68 to define a cap diameter CD that is larger than the body diameter BD.

[0029] The self-closing pressure relief vent 62 extends through a disc-shaped end wall 70 of the cap portion 66 and is arranged to communicate with an open cavity 72 in the tubular body 68. Figures 2 to 4In the illustrated embodiment, the self-closing pressure relief vent 62 is a seam extending through the end wall 70 of the cap portion 66, but as will be discussed in detail below, the self-closing pressure relief vent 62 can also have other configurations. At least a portion of the disc-shaped end wall 70 of the cap portion 66 is made of an elastic material, allowing the self-closing pressure relief vent 62 to open and close in response to pressure changes. This function will be explained in more detail below. By way of example, and not limitation, the elastic material can be nitrile butadiene rubber (NBR), which has a hardness of approximately 70 Shore A, sufficient to prevent unwanted leakage through the self-closing pressure relief vent 62.

[0030] refer to Figures 5A to 5B Each hydraulic port mount 58 on the lower housing 26 of the shock absorber assembly 20 includes a hydraulic port 74 positioned adjacent the threaded bore 64. Both the hydraulic port 74 and the threaded bore 64 extend into the lower housing 26. The threaded bore 64 terminates at a closed end. In contrast, the hydraulic port 74 is arranged to be in fluid communication with one of the first and second working chambers 50 and 52 of the shock absorber 24. The hydraulic port 74 is configured to receive a hydraulic connector coupled to a hydraulic line of a hydraulic crossover circuit that is connected to one or more other shock absorbers 24 of the vehicle. Thus, the hydraulic port 74 is a stepped bore comprising a primary opening 76, a smaller secondary opening 78, and a chamfered edge 80.

[0031] The size and geometry of the primary opening 76, secondary opening 78, and chamfered edge 80 of the hydraulic port 74 may vary depending on the particular hydraulic connector. Figures 5A to 5B In the example shown, the main opening 76 of the hydraulic port 74 has a main opening diameter PD of approximately 16 millimeters (mm), and the secondary opening 78 has a secondary opening diameter SD of approximately 10 millimeters (mm). Figures 6A to 6B In the example shown, the main opening 76' of the hydraulic port 74' has a main opening diameter PD' of approximately 17 millimeters (mm), and the secondary opening 78' has a secondary opening diameter SD' of approximately 10 millimeters (mm). Figures 6A to 6B The chamfered edge 80' of the hydraulic port seat 58' on the lower housing 26' shown in FIG. Figures 5A to 5B The examples shown in have different geometries. 7A to 7B In the example shown, the main opening 76 ″ of the hydraulic port 74 ″ has a main opening diameter PD″ of approximately 15 millimeters (mm), and the secondary opening 78 ″ has a secondary opening diameter SD″ of approximately 10 millimeters (mm). 7A to 7B The chamfered edge 80" of the hydraulic port seat 58" on the lower housing 26" is shown in FIG. Figures 5A to 5B and Figures 6A to 6BThe examples shown in FIG have different geometries. It should be understood that the various sizes and geometries described herein are exemplary only and are not limiting. However, it should be understood that an advantage of the hydraulic port protection plugs 60 described herein is that they are designed to be inserted into and adequately secured in hydraulic ports 74, 74', 74" having a variety of different sizes and geometries, and therefore can function in a wider range of applications than conventional plugs. This means that fewer sizes and variations are required to cover a range of different hydraulic ports 74, 74', 74", thereby saving costs and increasing efficiency on the assembly line.

[0032] Figures 8A to 8B Two different configurations of hydraulic port protection plugs 160, 260 are shown, each having a self-closing pressure relief vent 162, 262 in the form of a seam. The hydraulic port protection plugs 160, 260 also have a cap portion 166, 266 and a tubular body 168, 268. The tubular body 168, 268 extends from the cap portion 166, 266 and has a geometry configured to be inserted into a main opening 176, 276 in a hydraulic port 174, 274 provided in the lower housing 26 of the shock absorber assembly 20. The main opening 176, 276 in the hydraulic port 174, 274 has a main opening diameter PD. The cap portion 166, 266 of the hydraulic port protection plug 160, 260 includes an end wall 170, 270 from which the tubular body 168, 268 extends to define an open cavity 172, 272 within the tubular body 168, 268, one end of which is bounded by the end wall 170, 270. The end wall 170, 270 of the cap portion 166, 266 extends radially outward from the tubular body 168, 268 to define a cap diameter CD that is greater than the main opening diameter PD.

[0033] Figures 8A to 8B The tubular body 168, 268 of the hydraulic port protection plug 160, 260 shown in FIG also includes a deflectable flange 182, 282 that extends outwardly from the tubular body 168, 268 at a location longitudinally spaced from the end wall 170, 270. In other words, the deflectable flange 182, 282 extends radially outwardly from the centerline 184, 284 of the hydraulic port protection plug 160, 260 and is configured to seal against the inner surface 186, 286 of the hydraulic port 174, 274 in the lower housing 26 of the shock absorber assembly 20.

[0034] Figures 8A to 8BThe pressurizing tool assembly 165, 265 is shown secured in abutment with the hydraulic port base 58 on the lower housing 26 by bolts 88, which are threaded into threaded holes 64 in the hydraulic port base 58. At least a portion of the cap portion 166, 266 of the hydraulic port protection plug 160, 260 is made of an elastic material. When pressurized air or gas is supplied to the pressurizing tool assembly 165, 265, the elastic material allows the self-closing pressure relief vent 162, 262 to open. At this point, the pressurized air or gas enters the hydraulic port 174, 274 through the self-closing pressure relief vent 162, 262, thereby pressurizing the first and / or second working chambers 50, 52 of the shock absorber 24. If negative pressure (e.g., vacuum pressure) is applied to the pressurizing tool assembly 165, 265, depressurizing the first and / or second working chambers 50, 52 of the shock absorber 24, the pressurized air or gas can flow in the opposite direction. When the pressurizing tool assembly 165, 265 is removed, if the pressure in the hydraulic port 174, 274 increases due to the movement of the piston 42 and the piston rod 44 after the hydraulic port protection plug 174, 274 is inserted into the hydraulic port 174, 274, the elastic / resilient properties of the cap portion 166, 266 of the hydraulic port protection plug 160, 260 allow the pressure to be discharged from the hydraulic port 174, 274 through the self-closing pressure relief vent 162, 262. For example, if the piston rod 44 is extended, the pressure in the first working chamber 50 can increase, thereby increasing the pressure in the hydraulic port 174, 274 in fluid communication with the first working chamber 50. Conversely, if the piston rod 44 is compressed, the pressure in the second working chamber 52 increases, thereby increasing the pressure in the hydraulic port 174, 274 in fluid communication with the second working chamber 52. The elastic / resilient nature of the cap portions 166, 266 of the hydraulic port protection plugs 160, 260 allows pressure to escape from the hydraulic ports 174, 274 through the self-closing pressure relief vents 162, 262. This prevents the hydraulic port protection plugs 160, 260 from blowing out of the hydraulic ports 174, 274 when the piston rod 44 is extended or compressed. This also allows the piston rod 44 of the shock absorber assembly 20 to be moved to a fully compressed stroke position for shipping, which reduces the overall length of the shock absorber assembly 20 during shipping, thereby lowering packaging and shipping costs.

[0035] Figure 8A and Figure 8B The difference is that they show different sealing arrangements. Figure 8A In FIG, the pressurizing tool assembly 165 includes an O-ring seal 190 that extends around the cap portion 166 of the hydraulic port protection plug 160 and radially outward. Figure 8B In FIG. 2 , the pressurizing tool assembly 265 includes an O-ring seal 290 that abuts against the disc-shaped end wall 270 of the cap portion 266 of the hydraulic port protection plug 260 . Figure 8BThe tubular body 268 of the hydraulic port protection plug 260 shown in FIG has an annular groove 292 that accommodates another O-ring seal 294 arranged to contact and seal with the inner surface 286 of the hydraulic port 274. In addition to these differences, Figure 8A and Figure 8B The illustrated hydraulic port protection plugs 160 and 260 are similar in structure and function similarly.

[0036] Figure 9A and Figure 9B Two alternative configurations of hydraulic port protection plugs 360, 460 are shown, each having a self-closing pressure relief port 362, 462 incorporated into a one-way duckbill valve 396, 496. The hydraulic port protection plugs 360, 460 also have a cap portion 366, 466 and a tubular body 368, 468. The tubular body 368, 468 extends from the cap portion 366, 466 and has a geometry configured to be inserted into a main opening 376, 476 in a hydraulic port 374, 474 disposed in the lower housing 26 of the shock absorber assembly 20. The main opening 376, 476 in the hydraulic port 374, 474 has a main opening diameter PD. The cap portion 366, 466 of the hydraulic port protection plug 360, 460 includes an end wall 370, 470 and a tubular body 368, 468 extending from the end wall 370, 470 to define an open cavity 372, 472 within the tubular body 368, 468, with one end of the tubular body being bounded by the end wall 370, 470. The end wall 370, 470 of the cap portion 366, 466 extends radially outward from the tubular body 368, 468 to define a cap diameter CD that is larger than the main opening diameter PD.

[0037] Figures 9A to 9B The tubular body 368, 468 of the hydraulic port protection plug 360, 460 shown in FIG also includes a deflectable flange 382, ​​482 that extends outwardly from the tubular body 368, 468 at a location longitudinally spaced from the end wall 370, 470. In other words, the deflectable flange 382, ​​482 extends radially outwardly from the centerline 384, 484 of the hydraulic port protection plug 360, 460 and is configured to seal against the inner surface 386, 486 of the hydraulic port 374, 474 in the lower housing 26 of the shock absorber assembly 20.

[0038] Figures 9A to 9BThe pressurizing tool assembly 365, 465 is shown secured in abutment with the hydraulic port seat 58 on the lower housing 26 by bolts 88 threaded into threaded holes 64 of the hydraulic port seat 58. A one-way duckbill valve 396, 496 includes a resilient valve throat 398, 498 extending from the end wall 370, 470 into the open cavity 372, 472, thereby being concentrically disposed within the tubular body 368, 468 of the hydraulic port protection plug 360, 460. The elastic / resilient nature of the valve throat 398, 498 allows the self-closing pressure relief port 162, 262 at the end / tip of the valve throat 398, 498 to open when pressurized air or gas is supplied to the pressurizing tool assembly 365, 465. This allows the shock absorber 24 to be primed without removal after the hydraulic port protection plug 360, 460 is installed in the hydraulic port 174, 274.

[0039] Figure 9A and Figure 9B The difference is that they show different sealing arrangements. Figure 9A In FIG, the pressurizing tool assembly 365 includes an O-ring seal 390 that surrounds and extends radially outwardly around the cap portion 366 of the hydraulic port protection plug 360. In contrast, in FIG. Figure 9B , the tubular body 468 of the hydraulic port protection plug 460 has an annular groove 492 that retains an O-ring seal 494 that is arranged to contact and seal with the inner surface 486 of the hydraulic port 474. In addition to these differences, Figure 9A and Figure 9B The hydraulic port protection plugs 360 and 460 shown in FIG. 1 are similar in structure and function similarly.

[0040] Figure 10 Another alternative configuration of a hydraulic port protection plug 560 is shown, in which a resealable puncture area 587 in the hydraulic port protection plug 560 is provided with a self-closing pressure relief vent 562. The hydraulic port protection plug 560 includes a cap portion 566 and a tubular body 568. The tubular body 568 extends from the cap portion 566 and has a geometry configured to be inserted into a main opening 576 of a hydraulic port 574 provided in the lower housing 26 of the shock absorber assembly 20. The main opening 576 in the hydraulic port 574 has a main opening diameter PD. The cap portion 566 of the hydraulic port protection plug 560 includes an end wall 570, from which the tubular body 568 extends to define an open cavity 572 within the tubular body 568, one end of which is bounded by the end wall 570. The end wall 570 of the cap portion 566 extends radially outward from the tubular body 568 to define a cap diameter CD that is larger than the main opening diameter PD.

[0041] Figure 10The pressurizing tool assembly 565 is shown secured in abutment with the hydraulic port base 58 on the lower housing 26 by bolts 88 threaded into threaded holes 64 in the hydraulic port base 58. The pressurizing tool assembly 565 includes an O-ring seal 590 that annularly surrounds and extends radially outward from the cap portion 566 of the hydraulic port protective plug 560. At least a portion of the end wall 570 of the cap portion 566 is formed from an elastomeric material within a resealable puncture area 587 disposed at or near the centerline 584 of the hydraulic port protective plug 560. Optionally, a stopper 589 is provided in the end wall 570 of the cap portion 566, aligned with the centerline 584 and the resealable puncture area 587, to ensure proper alignment of the needle 591 with the resealable puncture area 587. When needle 591 is inserted into resealable puncture area 587, pressurized air or gas supplied to pressurization tool assembly 165, 265 can pass through self-closing pressure relief port 562 formed by needle 591. Similarly, needle 591 can be inserted into resealable puncture area 587 to relieve pressure from hydraulic port 574, thereby accommodating the movement of piston 42 and piston rod 44. Needle 591 or a similar suction tool can also be used as a suction device to remove any hydraulic fluid or oil remaining in hydraulic port 574 before removing hydraulic port protection plug 560 on the automotive production line. This can be used in all embodiments described herein, thereby providing a cleaner environment on the automotive production line.

[0042] Figures 11A to 11B Two additional configurations of hydraulic port protection plugs 660, 760 are shown, each having a self-closing pressure relief vent 662, 762 in the form of a seam. The hydraulic port protection plugs 660, 760 also have a cap portion 666, 766 and a tubular body 668, 768. The tubular body 668, 768 extends from the cap portion 666, 766 and has a geometry configured to be inserted into a main opening 676 of a hydraulic port 674 provided in the lower housing 26 of the shock absorber assembly 20. The main opening 676 in the hydraulic port 674 has a main opening diameter PD. The cap portion 666, 766 of the hydraulic port protection plug 660, 760 includes an end wall 670, 770 from which a tubular body 668, 768 extends to define an open cavity 672, 772 within the tubular body 668, 768, one end of which is bounded by the end wall 670, 770. The end wall 670, 770 of the cap portion 666, 766 extends radially outward from the tubular body 668, 768 to define a cap diameter CD that is larger than the main opening diameter PD.

[0043] Figure 11AThe pressurizing tool assembly 665 is shown, which is fixed in an abutting arrangement with the hydraulic port base 58 on the lower housing 26 by means of bolts 88, which are threaded into threaded holes 64 of the hydraulic port base 58. At least a portion of the cap portion 666, 766 of the hydraulic port protection plug 660, 760 is made of an elastic material, which allows the self-closing pressure relief port 662, 762 to open when pressurized air or gas is supplied to the pressurizing tool assembly 665, or when the pressure in the hydraulic port 674 increases due to movement of the piston 42 and piston rod 44 after the hydraulic port protection plug 674, 674 is inserted into the hydraulic port 674.

[0044] Figure 11A and Figure 11B 6 and 782 are different in that they illustrate different deflectable flanges 682 and 782 that are designed to seal against an inner surface 686 of the hydraulic port 674 in the lower housing 26 of the shock absorber assembly 20 . Figure 11A The hydraulic port protection plug 660 shown in FIG has a deflectable flange 682 including a disc-shaped flange portion 693 extending radially outward from a centerline 684 of the hydraulic port protection plug 660 and having a flange diameter FD that is greater than the main opening diameter PD of the hydraulic port 674. The deflectable flange 682 of the hydraulic port protection plug 660 also includes an annular wall 695 extending axially from the disc-shaped flange portion 693. Thus, the annular wall 695 is concentrically disposed in a radially spaced relationship with a portion of the tubular body 668, such that the deflectable flange 682 has a T-shaped cross-section before the hydraulic port protection plug 660 is installed in the hydraulic port 674. In other words, before the hydraulic port protection plug 660 is installed in the hydraulic port 674, the disc-shaped flange portion 693 is disposed at a perpendicular angle A relative to the tubular body 668. Since the flange diameter FD is larger than the main opening diameter PD of the hydraulic port 674 , the deflectable flange 682 deflects when the tubular body 668 is inserted into the hydraulic port 674 , which makes the deflectable flange 682 have a Y-shaped cross-section after the hydraulic port protection plug 660 is installed to the hydraulic port 674 .

[0045] Figure 11B The illustrated hydraulic port protective plug 760 has a deflectable flange 782 comprising a pair of disc-shaped flange portions 797, 799 extending radially outwardly away from a centerline 784 of the hydraulic port protective plug 760. The disc-shaped flange portions 797, 799 are arranged at first and second oblique angles A1, A2 relative to the tubular body 768 such that the deflectable flange 782 has a V-shaped cross-section before the hydraulic port protective plug 760 is installed in the hydraulic port 674.

[0046] A method of assembling the shock absorber assembly 20 is also provided. Figure 12The method includes step 802 of installing the piston 42 and piston rod 44 within a shock absorber housing (e.g., the lower housing 26 of the shock absorber 24); and step 804 of inserting one or more hydraulic port protection plugs 60 into one or more hydraulic ports 74 in the shock absorber housing 26. Following step 804, the method proceeds to step 806 of introducing pressurized air or gas through the self-closing pressure relief vent 62 in the hydraulic port protection plug 60 after the hydraulic port protection plug 60 has been inserted into the hydraulic port 74 to bias the piston 42 and piston rod 44 to a mid-stroke position (i.e., approximately halfway between the fully compressed and fully extended stroke positions). By way of example and not limitation, this step may include installing the pressurizing tool assembly 165 onto the hydraulic port mount 58 and providing pressurized air at a pressure of approximately 3 bar. As previously mentioned, performing step 806 after installing conventional shipping plugs was not possible because they completely blocked the hydraulic ports 74. After step 806, the method can proceed to step 808, where the assembly of the shock absorber assembly 20 is continued and completed with the piston 42 and piston rod 44 in the mid-stroke position. It should be understood that steps 802 through 806 can be performed in a cleanroom to reduce the chance of contamination, while step 808, where the assembly of the shock absorber assembly 20 is continued and completed, can be performed outside the cleanroom because the hydraulic port protection plugs 60 function to prevent contaminants from entering the hydraulic ports 74 of the shock absorber assembly 20. It should also be understood that the purpose of pressurizing step 806 is to prevent the piston rod 44 from moving inwardly into the shock absorber housing 26 during installation of several modular components (such as the airbag 40) thereon. The positive pressure of approximately 3 bar within the first and second working chambers 50 and 52 of the shock absorber 24 helps prevent movement of the piston rod 44 during assembly.

[0047] The method may further include step 810 of depressurizing the hydraulic port 74 with the hydraulic port protection plug 60 installed in the hydraulic port 74; and step 812 of moving the piston 42 and piston rod 44 to a fully compressed stroke position with the hydraulic port protection plug 60 installed in the hydraulic port 74 to place the shock absorber assembly 20 in the shipping configuration. Similarly, steps 810 and 812 have previously been unable to utilize conventional shipping plugs because conventional shipping plugs do not allow air to escape from the hydraulic port 74 for depressurization and, if installed when the piston rod 44 is moved to the fully compressed stroke position, could easily blow out of the hydraulic port 74. Previously, the shipping plugs had to be removed during any pressurization or depressurization operations, as well as in any event where the piston rod 44 needed to be moved. The need to remove the shipping plugs during these operations created a risk of contaminants entering the hydraulic port 74 during assembly.

[0048] The method may further include step 814 of removing the hydraulic port protection plugs 60 from the hydraulic ports 74 in the shock absorber housing 26; step 816 of installing a hydraulic fitting in each of the hydraulic ports 74; and step 818 of injecting hydraulic fluid or oil into the hydraulic ports 74. It should be understood, therefore, that the shock absorber assembly 20 described herein may be shipped "dry" to the customer, without injecting hydraulic fluid or oil until after the shock absorber assembly 20 is installed on the vehicle. Step 814 may further include extracting residual hydraulic fluid or oil from the hydraulic ports 74 by inserting an extraction tool into the self-closing pressure relief port 62 in the hydraulic port protection plug 60 prior to removing the hydraulic port protection plug 60 from the hydraulic ports 74, so that any hydraulic fluid or oil that collects in the hydraulic ports 74 behind the hydraulic port protection plug 60 during shipping or storage does not flow out when the hydraulic port protection plug 60 is removed. It should be further appreciated that in step 814 , it is easier to remove the hydraulic port protection plug 60 from the hydraulic port 74 because the self-closing pressure relief port 62 in the hydraulic port protection plug 60 prevents a vacuum from forming in the hydraulic port 74 , thereby making removal of the hydraulic port protection plug 60 more difficult.

[0049] Furthermore, step 804 of inserting the hydraulic port protection plug 60 into the hydraulic port 74 in the shock absorber housing 26 is performed regardless of any specific positioning of the piston 42 and piston rod 44 within the shock absorber housing 26. This also differs from conventional shipping plugs. Previously, when the shipping plug was inserted into the compression-side hydraulic port 74 (i.e., the hydraulic port 74 arranged in fluid communication with the second working chamber 52), the piston rod 44 had to be fully compressed. Then, when the shipping plug was inserted into the rebound-side hydraulic port 74 (i.e., the hydraulic port 74 arranged in fluid communication with the second working chamber 50), the piston rod 44 had to be fully extended to prevent the shipping plug from blowing out of the hydraulic port. Once this was done, the piston rod 44 would naturally return to its mid-stroke position, and the shock absorber assembly 20 would then be shipped in this state.

[0050] Figure 13A and Figure 13BAnother exemplary hydraulic port protection plug 160' is shown, which is designed to be inserted into a hydraulic port 174' in the lower housing 26 of the shock absorber 24 and remain in the hydraulic port 174' during and after the hydraulic coupling 161' is connected to the hydraulic port 174'. In the example shown, the hydraulic coupling 161' is a hydraulic connector with a flange 165' that divides the hydraulic connector into an inner portion 167' and an outer portion 169'. Both the inner portion 167' and the outer portion 169' are tubular. The inner portion 167' of the hydraulic connector is designed to be inserted into the hydraulic port 174' by pressing / pushing the inner portion 167' of the hydraulic connector through the hydraulic port protection plug 160'. The outer portion 169' of the hydraulic connector is designed to be connected to the terminal end of a hydraulic line (not shown). The flange 165' is configured to mate with / abut the hydraulic port base 58 on the lower housing 26 of the shock absorber 24 and includes a hole 171' that aligns with the threaded hole 64 in the hydraulic port base 58, so that the bolt 88 can be inserted through the hole 171' in the flange 165' and tightened into the threaded hole 64, thereby fixing the flange 165' in a tight abutting relationship with the hydraulic port base 58. It should be understood that the hydraulic coupling 161' does not require the use of a separate hydraulic connector, but can be integrated into the terminal end of the hydraulic line, whether or not the flange 165' is present.

[0051] The hydraulic port protection plug 160' includes a cap portion 166' and a tubular body 168'. The tubular body 168' has a body diameter BD and extends longitudinally from the cap portion 166' to the plug end 159'. The cap portion 166' of the hydraulic port protection plug 160' extends radially outward from the tubular body 168' to define a cap diameter CD that is larger than the body diameter BD. The tubular body 168' has a geometry configured to be inserted into the hydraulic port 174' in the lower housing 26 of the shock absorber 24. The hydraulic port protection plug 160' can be made of a deformable material, such as an elastic material, and has a natural length NL extending longitudinally to include the cap portion 166' and the tubular body 168'. By way of example, and not limitation, the elastic material can be nitrile rubber (NBR) having a hardness of approximately 70 Shore A. The natural length NL of the hydraulic port protection plug 160' is equal to the total length of the hydraulic port protection plug 160' in an uncompressed, unconstrained state.

[0052] The hydraulic port protection plug 160' includes a pierceable seal 162' configured to receive an inner portion 167' of the hydraulic coupling 161' so that the hydraulic port protection plug 160' seals the hydraulic coupling 161' within the hydraulic port 174' of the lower housing 26 when installed. Figure 13B As shown. The pierceable seal 162' of the hydraulic port protection plug 160' is formed by a pierceable wall 170' and at least one seam 173' extending through the pierceable wall 170'. 14A to 14D As shown, the pierceable seal 162' can include any number of seams 173'. In embodiments where the pierceable seal 162' includes multiple seams 173' in the pierceable wall 170' (e.g., 14B to 14D As shown, a plurality of seams 173' intersect at a centerline 184' of the hydraulic port protection plug 160' in a staggered manner to define a plurality of wedge-shaped sections 185' in the pierceable wall 170'. In addition to providing a passageway for inserting the inner portion 167' of the hydraulic coupling 161', it should be understood that the seams 173' of the pierceable seal 162' can also provide all of the same functions of the self-closing pressure relief vent 62 described above.

[0053] exist 13A to 13B and 14A to 14D In the illustrated embodiment, the pierceable wall 170' is coplanar with the cap portion 166' of the hydraulic port protective plug 160' and has a flat, planar, disc-like shape in the pre-installed state of the hydraulic port protective plug 160'. A tubular body 168' extends from the cap portion 166' to define a cavity 172' having an open end and an opposite end bounded by the pierceable wall 170'. Figure 13B As shown, during installation, inner portion 167' of hydraulic coupler 161' is received within cavity 172' of tubular body 168' when inner portion 167' of hydraulic coupler 161' is pushed through seam 173' in pierceable wall 170'.

[0054] The hydraulic port 174' in the lower housing 26 of the shock absorber 24 includes a stepped bore 175' with a first stepped portion 176' and a stepped bore 177'. Figure 13B As shown, the geometry of the first stepped portion 176' is designed to receive the tubular body 168' of the hydraulic port protection plug 160' (and can also receive the inner portion 167' of the hydraulic coupler 161' when the inner portion 167' of the hydraulic coupler 161' is inserted into the cavity 172' of the hydraulic port protection plug 160' in the installed state). The stepped hole 177' is longitudinally located between the hydraulic port base 58 and the first stepped portion 176', and its geometry is designed to receive the cap portion 166' of the hydraulic port protection plug 160'. In particular, the diameter of the first stepped portion 176' is equal to the body diameter BD of the hydraulic port protection plug 160', so that the tubular body 168' of the hydraulic port protection plug 160' is sealed with the first stepped portion 176' of the hydraulic port 174'. As shown Figure 13A and Figure 13BAs shown, when flange 165' of hydraulic coupler 161' is tightened against hydraulic port base 58, hydraulic port protection plug 160' is also designed to compress longitudinally within hydraulic port 174'. This compression is due to the relative geometries of hydraulic port protection plug 160' and hydraulic port 174'. Specifically, the combined height OH (i.e., overall depth) of first stepped portion 176' and stepped hole 177' of hydraulic port 174' is less than the natural length NL of hydraulic port protection plug 160'. This allows hydraulic port protection plug 160' to compress longitudinally within hydraulic port 174' when flange 165' of hydraulic coupler 161' is tightened against hydraulic port base 58.

[0055] The step hole 177' has a step hole diameter CBD and a step hole height CBH (ie, step hole depth). Figure 13A and Figure 13B In the example shown, the cap portion 166' of the hydraulic port protection plug 160' has a raised edge 179' that extends circumferentially around a bowl-shaped recess 181' in the cap portion 166' of the hydraulic port protection plug 160'. The raised edge 179' allows the cap portion 166' of the hydraulic port protection plug 160' to be compressed in an uncompressed state (e.g., Figure 13A As shown) has a cap height CH greater than the step hole height CBH, so that when the flange 165' of the hydraulic coupling 161' is tightened with the hydraulic port base 58 (as shown) Figure 13B (As shown), cap portion 166' is locally compressed in the longitudinal direction. This compression of cap portion 166' forms a fluid-tight seal between cap portion 166' of hydraulic port protection plug 160' and flange 165' of hydraulic coupler 161'. Step hole diameter CBD can be larger than cap diameter CD to provide clearance for cap portion 166' to flatten and expand radially when flange 165' of hydraulic coupler 161' is tightened to hydraulic port base 58. Therefore, stepped hole 177' has a larger diameter than first stepped portion 176'.

[0056] The inner portion 167' of the hydraulic coupling 161' has an inner length IL that extends longitudinally from the flange 165' to the inner end 183' of the hydraulic coupling 161'. Figure 13A and Figure 13B In the example shown, the inner length IL of the inner portion 167' of the hydraulic coupling 161' is less than the total height OH (i.e., the total depth) of the first stepped portion 176' and the stepped hole 177' of the hydraulic port 174', so that the plug end 159' is in the installed state (e.g., Figure 13B 183 ' of the hydraulic coupling 161 '.

[0057] like Figure 15As shown, the abutment between the flange 165' of the hydraulic coupling 161' and the hydraulic port base 58 prevents the hydraulic coupling from shaking excessively in the installed state, but this requires the bolts 88 to be tightened. Figure 16 An alternative embodiment is shown, which 13A to 13B and 14A to 14C The embodiment shown has the same features, but the inner portion 167 ″ of the hydraulic coupling 161 ″ is extended so that the inner length IL ″ of the hydraulic coupling 161 ″ is greater than the total height OH ″ (i.e., the total depth) of the first stepped portion 176 ″ of the hydraulic port 174 ″ and the stepped hole 177 ″. Figure 16 Many elements of the exemplary hydraulic port protection plug 160 ″ and hydraulic coupling 161 ″ shown in FIG are identical or substantially identical to those in the above-described embodiments and therefore will not be described in detail. Instead, equivalent elements shared between the various embodiments have the same or corresponding reference numerals. For example, Figure 16 Reference number 160'' in Figure 13A and Figure 13B The reference number 160' in FIG. 1 corresponds to the reference number 160' in FIG. 1 , and so on.

[0058] exist Figure 16 In the illustrated embodiment, to accommodate the longer inboard length IL" of hydraulic coupler 161", hydraulic port 174" includes a second stepped portion 178" whose geometry is designed to receive inboard end 183" of hydraulic coupler 161" with a close tolerance fit. This close tolerance fit between second stepped portion 178" of hydraulic port 174" and inboard end 183" of hydraulic coupler 161" provides hydraulic coupler 161" with greater stability and resistance to wobbling, even when bolts 88 are not fully tightened. Therefore, in this embodiment, inboard end 183" of hydraulic coupler 161" passes through cavity 172" in tubular body 168" of hydraulic port protection plug 160" and extends therefrom, positioned further inward relative to plug end 159". Consequently, first stepped portion 176" has a larger diameter than second stepped portion 178". Optionally, the inner end 183 ″ of the hydraulic coupling 161 ″ may include a circumferential groove 192 ″ having an O-ring seal 194 ″ fixed therein. The O-ring seal 194 ″ is configured to seal the second stepped portion 178 ″ of the hydraulic port 174 ″ to improve sealing.

[0059] Figure 17 and 18A to 18B Another hydraulic port protection plug 260' is shown, which has the same 13A to 13B All features are the same as those of the embodiments shown, but Figure 17 and 18A to 18BThe hydraulic port protection plug 260' in the embodiment has a pierceable wall 270' longitudinally spaced from the cap portion 266'. Figure 17 and 18A to 18B Many elements of the exemplary hydraulic port protection plug 260' and hydraulic coupling 261' shown in FIG are identical or substantially identical to those in the above-described embodiments and are therefore not described in detail. Instead, equivalent elements shared between the embodiments are given the same or corresponding reference numerals. For example, Figure 17 and 18A to 18B Reference number 260' corresponds to Figure 13A and Figure 13B Reference number 260' in , and so on.

[0060] Figure 17 and 18A to 18B The illustrated hydraulic port protection plug 260' includes a cap portion 266' and a tubular body 268'. The tubular body 268' extends longitudinally from the cap portion 266' to the plug end 259', with the cap portion 266' of the hydraulic port protection plug 260' extending radially outward from the tubular body 268'. The pierceable seal 262' is formed by a pierceable wall 270', which is longitudinally spaced from the cap portion 266' and is therefore positioned intermediately between the cap portion 266' and the plug end 259'. Thus, the pierceable wall 270' divides the tubular body 268' into a first cavity 255' located between the pierceable wall 270' and the cap portion 266' and a second cavity 272' located between the pierceable wall 270' and the plug end 259'. The first cavity 255′ opens at the cap portion 266′ and receives the inner end 283′ of the hydraulic coupler 261′ before it is advanced through the pierceable seal 262′, e.g., one or more seams 273′ in the pierceable wall 270′. The second cavity 272′ opens at the plug end 259′ and receives the inner end 283′ of the hydraulic coupler 261′ after it is advanced through the pierceable seal 262′.

[0061] Optionally, the hydraulic port protection plug 260' can include a sealing rib 253' extending circumferentially along the inner surface of the tubular body 268', such that the sealing rib 253' protrudes radially inwardly into the first cavity 255' and contacts the inner portion 267' of the hydraulic coupling 261' to provide additional sealing. The sealing rib 253' can be longitudinally spaced from the pierceable wall 270' and can be aligned with or adjacent to the cap portion 266' of the hydraulic port protection plug 260'.

[0062] Figure 19A and Figure 19B Another exemplary hydraulic port protection plug 360' is shown having the same 13A to 13B All features are the same as those of the embodiments shown, but Figure 19A and Figure 19B The hydraulic port protection plug 360' has a funnel-shaped pierceable wall 370' and a connector piercing area 387' located at or near the center line 384' of the hydraulic port protection plug 360'. Figure 19A and Figure 19B Many elements of the exemplary hydraulic port protection plug 360' shown in FIG are identical or substantially identical to those in the above-described embodiments and are therefore not described in detail. Instead, equivalent elements shared between the various embodiments have the same or corresponding reference numbers. For example, Figure 19A and Figure 19B Reference number 360' in the Figure 13A and Figure 13B The reference number 160' in FIG. 1 corresponds to the reference number 160' in FIG. 1 , and so on.

[0063] like Figure 19A and Figure 19B As shown, the funnel shape of pierceable wall 370' is designed so that residual oil or hydraulic fluid HF in hydraulic port 374' will accumulate within cavity 372' of hydraulic port protection plug 360', in the annular valley where funnel-shaped pierceable wall 370' meets tubular body 368'. A connector piercing area 387', located at or near centerline 384' of hydraulic port protection plug 360', is made of a brittle material, such as nitrile rubber (NBR) or hydrogenated nitrile rubber (HNBR), and forms pierceable seal 362'. Therefore, it will be appreciated that this geometry / arrangement reduces or prevents residual oil or hydraulic fluid HF from escaping cavity 372' when inner end 383' of hydraulic coupler / connector 361' is pushed through connector piercing area 387'.

[0064] Alternatively, Figure 19A and Figure 19B The pierceable seal 362' shown in FIG can be made of Figure 9A and Figure 9B In this arrangement, the inner end 383' of the hydraulic coupling / connector 361' is pushed through the elastic valve throat 398, 498 of the one-way duckbill valve 396, 496, which extends to the inner end of the hydraulic coupling / connector 361'. Figure 9A and Figure 9B The hydraulic port protection plugs 360 and 460 are shown in the cavity 372 and 472 defined by the tubular body 368 and 468.

[0065] 20A to 20C Another hydraulic port protection plug 560' is shown, which has the same 13A to 13B All features are the same as those of the embodiments shown, but 20A to 20C The hydraulic port protection plug 560' in FIG. 5 has a pierceable wall 570' comprising a frangible membrane 549' through which the hydraulic coupling 561' is pushed. 20A to 20C Many elements of the exemplary hydraulic port protection plug 560' and hydraulic coupling 561' shown in FIG are identical or substantially identical to those in the above-described embodiments and are therefore not described in detail. Instead, equivalent elements shared between the various embodiments are given the same or corresponding reference numerals. For example, 20A to 20C Reference number 560' corresponds to Figure 13A and Figure 13B Reference number 160' in , and so on.

[0066] like 20A to 20C As shown, a portion of the punctureable wall 570' forming the punctureable seal 562' is made of a frangible membrane 549' to define a joint puncture area 587' at or near the centerline 584' of the hydraulic port protection plug 560'. By way of example and not limitation, the frangible membrane 549' can be made of nitrile rubber (NBR) or hydrogenated nitrile rubber (HNBR). It should be understood that a portion of the punctureable wall 570' can be made of a frangible material such as NBR or HNBR, the entire punctureable wall 570' can be made of a frangible material such as NBR or HNBR, or the entire hydraulic port protection plug 560' can be made of a frangible material such as NBR or HNBR. In other words, the hydraulic port protection plug 560' can be a one-piece construction and can be made of a single material forming the cap portion 566', the tubular body 568', and the frangible membrane 549'. The hydraulic port protection plug 560' can be a one-piece construction and can be made of different materials / compounds, wherein the material forming the frangible membrane 549' is different from the material / compound forming the cap portion 566' and the tubular body 568', or alternatively, the hydraulic port protection plug 560' can be a multi-piece construction and can be made of different parts / materials / compounds, wherein the material forming the frangible membrane 549' is different from the material / compound forming the cap portion 566' and the tubular body 568'.

[0067] 20A to 20C The hydraulic port protection plug 560' shown in FIG also includes a first sealing rib 553', which is located adjacent to the pierceable wall 570'. Therefore, the pierceable wall 570' and the first sealing rib 553' are generally aligned with the cap portion 566' and are positioned radially inward. Figure 20B and Figure 20C As shown, the inner end 583' of the hydraulic coupling / connector 561' is pushed through the connector piercing area 587' of the pierceable wall 570' until the frangible membrane 549' ruptures ( Figure 20C). At this point, the ruptured frangible membrane 549' seals against the inner portion 567' of the hydraulic coupling / connector 561'. The first sealing rib 553' extends circumferentially along the inner surface of the tubular body 568', such that the first sealing rib 553' extends radially inward and contacts the inner portion 567' of the hydraulic coupling 561' to provide additional sealing.

[0068] Figures 21A to 21C Another hydraulic port protection plug 560'' is shown, which has the same 20A to 20C All features are the same as those of the embodiments shown, but Figures 21A to 21C The hydraulic port protection plug 560'' also includes a second sealing rib 551'' longitudinally spaced apart from the first sealing rib 553'' and the pierceable wall 570''. The second sealing rib 551'' extends circumferentially along the inner surface of the tubular body 568'', so that the second sealing rib 551'' protrudes radially inward into the cavity 572'' and contacts the inner portion 567'' of the hydraulic coupling 561'' to achieve additional sealing. Figures 21A to 21C The components of the exemplary hydraulic port protection plug 560" and hydraulic coupling 561" shown in FIG. 5 are similar to those described above. 20A to 20C The elements in the embodiments shown in FIG are identical and therefore will not be described in detail. Instead, equivalent elements shared between the embodiments have the same or corresponding reference numerals. For example, Figures 21A to 21C Reference number 560'' corresponds to 20A to 20C Reference number 560' in , and so on.

[0069] Figure 22 Shown assembly Figures 13A to 21C The method of the shock absorber assembly 20 shown in FIG. Figure 22The method includes step 802': installing the piston 42 and the piston rod 44 in a shock absorber housing (e.g., the lower housing 26 of the shock absorber 24), and step 804': inserting one of the hydraulic port protection plugs 160', 160", 260', 360', 560', 560" into one of the hydraulic ports 174', 174", 274', 374', 574', 574" of the shock absorber housing 26 to place the shock absorber assembly 20 in a shipping and handling configuration. The method then proceeds to step 805 ′ of installing the shock absorber assembly 20 into the vehicle, and step 816 ′ of pressing at least a portion of the hydraulic connector 161 ″, 261 ′, 361 ′, 561 ′, 561 ″ through the pierceable seal 162 ″, 262 ′, 362 ′, 562 ′, 562 ′ in the hydraulic port protection plug 160 ″, 260 ′, 360 ′, 560 ′, 560 ″. '', the hydraulic connectors 161'', 261'', 361'', 561'', 561'' are installed in the hydraulic ports 174'', 174'', 274'', 374'', 574'', 574'', and the hydraulic port protection plugs 160'', 260'', 360'', 560'', 560'' are positioned in the hydraulic ports 174'', 174'', 274'', 374', 574'', 574''. It should be understood that steps 805' and 816' can also be performed in the reverse order, wherein the hydraulic connectors 161'', 261'', 361'', 561'', 561'' are first installed according to step 816', and then the shock absorber assembly 20 is installed in the vehicle according to step 805'.

[0070] The method further includes step 817' of connecting the hydraulic connectors 161', 261', 361', 561', 561' to hydraulic lines to fluidly connect the hydraulic ports 174', 174', 274', 374', 574', 574' of the shock absorber assembly 20 to another shock absorber of the vehicle suspension system, and step 818' of filling the shock absorber assembly 20 by supplying hydraulic fluid or hydraulic oil to the hydraulic ports 174', 174', 274', 374', 574', 574' via the hydraulic lines.

[0071] Numerous other modifications and variations of the present disclosure are possible in light of the above teachings and may be practiced other than as specifically described within the scope of the appended claims.

Claims

1. A shock absorber assembly comprising: a shock absorber having a sliding piston dividing the shock absorber into a first working chamber and a second working chamber, a piston rod mounted on the sliding piston, and a lower housing opposite to the piston rod; at least one hydraulic port disposed in a lower housing of the shock absorber; as well as a hydraulic port protection plug having a tubular body having a geometry configured to be insertable into at least one hydraulic port in the lower housing, In which, the hydraulic port protective plug includes a punctureable seal, which is configured to receive a portion of a hydraulic connector that can be inserted through the punctureable seal of the hydraulic port protective plug and inserted into at least one hydraulic port in the lower shell, so that the hydraulic port protective plug seals the hydraulic connector within at least one hydraulic port in the lower shell when in an installed state.

2. The shock absorber assembly according to claim 1, wherein: The tubular body of the hydraulic port protector defines a cavity within the hydraulic port protector with an open end and an opposite end bounded by a pierceable wall.

3. The shock absorber assembly according to claim 2, wherein: The pierceable seal is a seam extending through the pierceable wall and arranged to be in fluid communication with an open cavity defined by the tubular body of the hydraulic port protective plug.

4. The shock absorber assembly according to claim 2, wherein: The pierceable seal is a plurality of slits extending through the pierceable wall in a cross-shaped arrangement.

5. The shock absorber assembly according to claim 2, wherein: The pierceable seal is a one-way duckbill valve having an elastic valve throat extending into an open cavity defined by the tubular body of the hydraulic port protection plug.

6. The shock absorber assembly according to claim 2, wherein: At least a portion of the pierceable wall is formed from a frangible membrane to define a connector piercing area at or near a centerline of the hydraulic port protection plug.

7. The shock absorber assembly according to claim 2, wherein: The pierceable wall is planar in the pre-installed state of the hydraulic port protection plug.

8. The shock absorber assembly according to claim 2, wherein: The pierceable wall is funnel-shaped and has a connector piercing area at or near the center line of the hydraulic port protection plug.

9. The shock absorber assembly according to claim 2, wherein: The hydraulic port protection plug includes at least one sealing rib extending circumferentially along the inner surface of the tubular body.

10. The shock absorber assembly according to claim 9, wherein: The at least one sealing rib is longitudinally spaced from the pierceable wall.

11. The shock absorber assembly according to claim 9, wherein: The hydraulic port protection plug includes a cap portion extending radially outward from the tubular body.

12. The shock absorber assembly according to claim 11, wherein: The pierceable wall is coplanar with the cap portion.

13. The shock absorber assembly of claim 11, wherein: The pierceable wall is longitudinally spaced from the cap portion.

14. The shock absorber assembly of claim 1, wherein: The hydraulic port in the lower housing includes a stepped hole, wherein in the installed state, a first stepped portion of the stepped hole receives the tubular body of the hydraulic port protection plug, and a second stepped portion of the stepped hole receives the inner end of the hydraulic coupling.

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