Damper valve arrangement for a vibration damper of a motor vehicle

Abstract

The invention relates to a vibration damper of a motor vehicle, having an outer tube and an inner tube, which is arranged coaxially to the outer tube, and a working piston, which is arranged to be axially movable in the inner tube and divides an inner space of the inner tube into a working chamber on the piston rod side and a working chamber remote from the piston rod, a damper valve device, which is arranged in the working piston, wherein the damper valve device has a damper valve housing, a coil unit, which is arranged in the damper valve housing and has a coil carrier and a coil wound on the coil carrier, and a separating element for sealing the coil unit relative to the damper valve housing, and an armature chamber, which is arranged in the coil unit and in which an axially movable armature is arranged, wherein the separating element is formed from plastic.

Description

Technical Field

[0001] The present invention relates to a damping valve device for a vibration damper for a motor vehicle, wherein the damping valve device has a main valve and a pilot valve. Background Technology

[0002] DE 10 2020 215 480 A1 discloses a vibration damper with a damping valve device, wherein the damping valve device has a pilot valve or a main valve that can be set via a magnetic coil. During operation of the damping valve device, a gas chamber is formed within the housing portion where the magnetic coil is arranged, and the gas chamber needs to be continuously vented. Summary of the Invention

[0003] Therefore, the object of the present invention is to provide a damping valve device for a vibration damper, wherein the damping valve device vents air in a low-cost and simple manner.

[0004] According to the invention, the objective can be achieved by a vibration damper having a damping valve device having the features of independent claim 1. Advantageous improvements can be derived from the dependent claims.

[0005] According to a first aspect, a vibration damper for a motor vehicle includes: an outer tube and an inner tube, the inner tube being arranged coaxially with the outer tube; and a working piston arranged axially within the inner tube, dividing the internal space into a piston rod-side working chamber and a working chamber away from the piston rod. A damping valve device is arranged within the working piston, the damping valve device comprising: a damping valve housing; a coil unit arranged within the damping valve housing, the coil unit having a coil carrier and a coil wound on the coil carrier; and a separation element for sealing the coil unit relative to the damping valve housing and / or for separating hydraulic oil and gas within the damping valve housing (particularly the coil unit). An armature chamber is provided within the coil unit, and an axially movable armature is installed within the armature chamber. The separation element is preferably formed of plastic. In particular, the separation element is entirely made of plastic.

[0006] A particular advantage is that the separator element can be mass-produced very simply and at low cost. Because the separator element is formed of plastic, it is particularly easy to integrate additional structures or channels for venting or fluid passage. The separator element is preferably designed as a hollow cylindrical component with an open or closed bottom, so as to at least partially surround the armature chamber.

[0007] For example, the damping valve device is a pressure limiting valve, which may preferably be pilot-controlled or directly controlled. A damping valve device designed as a pilot-controlled pressure limiting valve preferably includes, in addition to the main valve: a pilot valve having a pilot working chamber and a sliding plunger disposed in the pilot working chamber and movable axially by means of an armature; and a connecting passage disposed between the pilot control chamber and the pilot working chamber and fluidly connecting the pilot control chamber and the pilot working chamber to each other. The main valve, having a main piston, is preferably configured for closing and opening the damping valve device, particularly the pressure limiting valve. The main piston is preferably movable axially by means of an armature and / or a dominant hydraulic pressure in the pilot control chamber.

[0008] The pilot control chamber should be understood as a hydraulic chamber, preferably adjacent to the main piston and preferably subjected to hydraulic pressure in the closing direction of the main valve. The pilot control chamber is preferably arranged on the main piston in a position opposite to the springback main control chamber and the compression main control chamber. For example, the main piston is designed such that the end face of the main piston facing the compression main control chamber or the springback main control chamber and subjected to the hydraulic pressure of the compression main control chamber or the springback main control chamber is larger than the end face of the main piston facing the pilot control chamber and subjected to the hydraulic pressure of the pilot control chamber.

[0009] For example, a damping valve device is arranged in a vibration damper for a motor vehicle. The vibration damper is, for example, a single-tube vibration damper or a multi-tube vibration damper, such as a two-tube vibration damper. For example, the vibration damper includes an outer tube that forms the outer surface of the vibration damper, particularly the housing. An inner tube, also called a damper tube, is arranged inside the outer tube and is coaxial with it. A compensation chamber is formed between the outer and inner tubes, preferably at least partially filled with hydraulic fluid. For example, the compensation chamber is partially filled with gas.

[0010] Preferably, a working piston connected to the piston rod is arranged inside an inner tube to allow movement within the inner tube, wherein the inner tube preferably serves as a guide for the working piston. For example, a damping valve device is arranged on the working piston. The working piston specifically divides the internal space of the inner tube into a first working chamber on the piston rod side and a second working chamber away from the piston rod.

[0011] The vibration damper preferably has a sealing package that fluid-tightens the internal space of the outer tube at the piston rod side. In contrast to the sealing package, the internal space of the outer tube is preferably fluid-tightened by means of a base component at the end away from the piston rod. A base valve, mounted on the end of the inner tube away from the piston rod, is specifically arranged on the base component.

[0012] The damping valve device includes: a preferably cylindrical damping valve housing, which is substantially tubular; and a top portion of the housing, which is mounted on or formed as a single component with the damping valve housing. For example, the damping valve housing has a connection area with one or more connecting contacts for supplying current to the damping valve device. The connecting contacts for supplying current are preferably connected to a drive unit.

[0013] The damping valve device preferably has an actuator in the form of an electromagnet, particularly a coil unit having a coil with multiple windings made of conductive wire. The coil unit is preferably arranged within the housing of the damping valve device and includes, for example, a coil carrier on which the coil windings are wound. Preferably, the coil at least partially or completely surrounds an armature chamber that extends centrally in the axial direction. The armature is preferably mounted within the armature chamber in a manner capable of axial movement. The armature is preferably attached to be slidable in the axial direction within the armature chamber, and for example, the armature includes a central armature rod, which is, for example, tubular in form and extends centrally through the armature chamber in the axial direction. The armature chamber is preferably defined by a cylindrical electrode that is at least partially hollow, which preferably serves as a guide for the armature.

[0014] The coil is preferably designed and arranged such that, when energized, it generates a magnetic field with magnetic field lines that preferably extend substantially axially within the armature chamber. The armature is preferably made of a magnetizable or magnetic material and is capable of axial movement by means of the magnetic field generated by the coil.

[0015] The electrode particularly has an upper tubular region with a particularly constant inner diameter, which is preferably in the form of a hollow cylinder and extends, for example, axially from the separating element beyond the armature. This upper hollow cylindrical region abuts in the axial direction a lower region with an increasing diameter, wherein the outer surface of the electrode preferably extends to and at least partially abuts the damping valve housing, and is fluidly sealed relative to the damping valve housing via, for example, a sealing ring. The damping valve housing at least partially or completely surrounds the valve region (not shown) in both the axial and circumferential directions. The electrode is particularly in the form of a multi-part, integral, or single-part component. Below the electrode, particularly in the compression direction D, a working chamber is adjacent, which is, for example, in the form of a pilot working chamber.

[0016] The damping valve assembly optionally includes a main valve and a pilot valve. The pilot valve is preferably arranged downstream of the main valve in the flow direction during both the compression and rebound phases of the vibration damper. Specifically, the damping valve assembly is capable of being circulated by hydraulic fluid in both directions. Preferably, the damping valve assembly arranged in the working piston has a specific main valve and / or a specific pilot valve. For example, a seal, particularly a sealing ring, is mounted on the working piston to fluid-tightly seal the working piston relative to the damper tube.

[0017] Furthermore, the damping valve assembly may optionally include a comfort valve. The comfort valve is preferably configured such that hydraulic fluid can flow through it in both the compression and rebound directions. The comfort valve specifically includes at least one comfort spring disc assembly, which, for example, includes at least one or more spring discs located on a comfort valve seat. The comfort valve is fluidly connected (preferably directly connected) to a working chamber remote from the piston rod. Preferably, the comfort valve is arranged in the working chamber remote from the piston rod and specifically forms the end of the working piston pointing towards the base valve.

[0018] During operation of the damping valve device and while the piston rod moves in the compression direction, hydraulic fluid preferably flows from the working chamber away from the piston rod into an optional comfort valve and then into the compression main control chamber, where the pressure in the compression main control chamber causes the main piston to be subjected to an opening force and move axially upward. During this process, the main piston is lifted from the main valve seat, and the hydraulic fluid flows through the main flow channel to the rebound main control chamber, particularly to the second fluid channel, and subsequently into the piston rod-side working chamber. Simultaneously, particularly hydraulically parallel to this, a portion of the hydraulic fluid flows into the pilot control chamber and subjectes the main piston to a closing force in the direction of the main valve seat. This closing force determines the opening width of the main valve, which in turn determines the damping force of the damping valve device. The pressure in the pilot control chamber is preferably set by a pilot valve, where hydraulic fluid flows from the pilot control chamber into the pilot working chamber through a connecting channel, which is opened by a sliding plunger. The opening width of the connecting channel (particularly the outflow cross-section) preferably depends on the axial position of the sliding plunger set by a magnetic coil. In the closed position of the pilot valve, the sliding plunger preferably fully closes the connection channel, causing the hydraulic pressure in the pilot control chamber to increase to its maximum value and the main valve to close (because the main piston is pressed against the main valve seat). In the open position of the pilot valve, the connection channel is at least partially opened by the sliding plunger.

[0019] According to the first embodiment, the separating element is manufactured using an injection molding process. Injection molding enables precise molding, which is particularly relevant for sealing surfaces and fits. By using injection molding to manufacture the separating element, undercuts or fastening extensions at the separating element can be achieved without cumbersome rework. Different plastics can be considered for high-temperature resistance or high chemical resistance, adaptable to specific applications. For example, the separating element is formed from one of the following plastics: PPS (polyphenylene sulfide), PEEK (polyether ether ketone), PPSU (polyphenylene sulfone) or PSU (polysulfone), PVDF (polyvinylidene fluoride), PEI (polyetherimide), or PES (polyethersulfone).

[0020] The separating element is arranged axially between the coil (particularly the coil carrier) and the damping valve housing, and in this case preferably at least partially defines the central armature chamber. For example, the separating element has a hollow cylindrical form, which is open particularly in the direction of the main valve, and preferably abuts against the inner surface of the damping valve housing in the radial direction, particularly in a fluid-tight manner. With this arrangement, the interior of the armature chamber is preferably sealed relative to the external fluid region on the one hand, and on the other hand, a region for venting or a region for servicing the venting fluid flow is provided without the need for additional connecting elements.

[0021] According to another embodiment, the separating element has a fluid channel extending radially, having a circular or polygonal cross-section, and fluidly connected to the armature chamber. The radial fluid channel facilitates venting from the armature chamber and ensures directional flow, thereby rapidly removing air pockets. The channel cross-section varies according to, for example, the desired flow rate and is configured to be polygonal for relatively high flow rates or circular for uniform flow. The fluid channel can be directly integrated into the separating element via injection molding, saving additional components and simplifying assembly. The fluid channel preferably extends entirely radially and specifically opens to the upper end of the armature chamber. During operation of the vibration damper, gas (especially air) accumulates at the upper end of the armature chamber pointing towards the closure. The fluid channel preferably opens into the armature chamber at its highest axial position, allowing the gas to preferably be completely vented from the armature chamber.

[0022] According to another embodiment, the damping valve housing has a radially extending orifice that is fluidly connected to a fluid passage and has a diameter larger than that of the fluid passage. The relatively large orifice in the damping valve housing simplifies manufacturing and simultaneously allows for defining the actual flow cross-section in the separation element. For example, additional elements such as filters or valve inserts can be integrated into such an orifice as needed. The relatively small diameter in the separation element can cause flow throttling, which is advantageous for fine-tuning the damping characteristics.

[0023] The orifice and fluid channel are preferably arranged at the same axial height and, in particular, aligned with each other. For example, the fluid channel opens directly into the orifice, or a fluid chamber is formed between the fluid channel and the orifice.

[0024] According to another embodiment, the diameter of the fluid channel corresponds to 1.5 to 5 times, particularly 2 to 3 times, the diameter of the orifice. Preferably, the ratio between the fluid channel diameter and the orifice diameter is adapted according to the viscosity, pressure level, and / or temperature of the hydraulic fluid used. According to the inventors' findings, the specified ratio of diameters ensures optimal venting of the armature chamber and reliably prevents noise generation.

[0025] According to another embodiment, the separating element is material-to-substance bonded to the coil carrier. Preferably, the separating element is bonded to the coil carrier by bonding, welding, or molding. In this way, a durable and robust connection is achieved between the coil carrier and the separating element, which avoids gaps and leaks. Furthermore, the material-to-substance bonding reduces the need for additional fastening elements and improves installation space efficiency. Due to the robust material-to-substance bonding, the separating element remains in a stable position even under varying temperatures and vibrations, and noise during vibration damper operation is avoided.

[0026] According to another embodiment, the separating element is directly attached to the coil carrier via an injection molding process. The coil carrier is preferably placed in an injection molding tool, such that the separating element to be manufactured by the injection molding process is attached to the coil carrier in a single working step. Such an injection molding process is inexpensive and easy to perform. Furthermore, the injection molding process allows for the formation of complex geometries, such as grooves or channels, thereby saving further rework steps, which further simplifies production. The coil carrier and coil are preferably overmolded via an injection molding process.

[0027] According to another embodiment, a flux plate is located between the coil carrier and the separation element. The flux plate is used to conduct the magnetic flux generated by the coil and forms a magnetic circuit together with the armature, pole, and valve housing. The flux plate is, for example, in the form of a ring or a disk, particularly in the form of a ring-disc. The flux plate preferably abuts directly against the pole, the damping valve housing, and especially the coil carrier. The flux plate, pole, damping valve housing, coil, and armature are preferably configured and arranged to form a magnetic circuit.

[0028] The flux plate is preferably used for orienting the magnetic field and, in particular, for positioning to effectively influence the magnetic flux of the coil and align it specifically with the armature. The flux plate preferably has orifices, holes, or cutouts to improve fastening, especially during the overmolding process.

[0029] The flux plate preferably has multiple cuts that extend axially through the thickness of the flux plate and are, for example, in the form of slits. Preferably, the cuts are used for fastening the flux plate to a separation element, which is molded onto the flux plate, particularly by injection molding. The flux plate preferably has a recess at its outer periphery, which may optionally be rectangular. The coil carrier preferably has an axial protrusion that extends along the recess and is used, for example, for mounting the coil carrier.

[0030] According to another embodiment, the flux plate is formed of a magnetic or magnetizable material. Preferably, the flux plate is entirely composed of a magnetic or magnetizable material. For example, the flux plate is formed of steel (especially low-carbon steel), such as non-alloy structural steel or ferritic stainless steel. The high permeability of the material results in relatively low magnetic scattering losses, which increases the transmission of force to the armature.

[0031] According to another embodiment, the flux plate is connected to the separation element via an injection molding process. The flux plate is preferably placed in an injection molding tool, allowing the plastic to achieve a reliable material-locked bond during the casting operation. Cutouts in the flux plate, or optionally the structure of the flux plate's surface, preferably facilitate the inflow of plastic and its adhesion to the flux plate. An integrated assembly consisting of a coil, coil carrier, and flux plate preferably reduces potential contact corrosion and simplifies the installation of the element in the vibration damper.

[0032] According to another embodiment, two sealing rings are arranged circumferentially around the separating element, abutting against both the inner sides of the separating element and the damping valve housing, with a fluid passage disposed between the sealing rings. The outer diameter of the separating element is preferably smaller than or corresponds to the inner diameter of the damping valve housing, such that the separating element abuts against the damping valve housing or forms a small gap between the damping valve housing and the separating element. Specifically, the separating element has two circumferentially extending grooves on its outer periphery, each groove containing a sealing ring. The fluid passage preferably extends between the sealing rings. The fluid passage preferably opens at a location between the two sealing rings, on the circumferential outer surface of the separating element. The sealing rings are, for example, of the same form and are specifically arranged coaxially with each other.

[0033] The arrangement of the sealing elements creates a defined region between the two sealing rings, within which a radially extending flow channel adjacent to the fluid passage is provided. This arrangement ensures that hydraulic fluid does not flow uncontrollably through the separating element, but is instead guided in a directional manner via the provided fluid passage. The clearance at the separating element ensures that the sealing rings reliably remain in place, thereby ensuring a permanent tight connection under varying operating conditions.

[0034] According to another embodiment, a fluid chamber is provided between the orifice and the fluid channel, and this fluid chamber is formed by a gap in the separating element. The fluid chamber preferably serves as a stabilizing or collecting volume, for example, in which entrained gas accumulates and is removed in a directional manner. The gap is preferably formed on the outside of the separating element. Preferably, the gap is formed at the outer opening of the fluid channel. The gap is particularly arranged between two sealing rings. The gap is, for example, circular or polygonal in form, for example, to accommodate flow conditions or attenuate peak pressure. Attached Figure Description

[0035] The invention will now be discussed in more detail with reference to several exemplary embodiments and the accompanying drawings.

[0036] Figure 1 A schematic diagram of a vibration damper in a longitudinal sectional view according to an exemplary embodiment is shown.

[0037] Figure 2 A schematic diagram in a longitudinal sectional view shows details of the damping valve device of a vibration damper according to an exemplary embodiment.

[0038] Figure 3 A schematic diagram of the coil unit of a damping valve device according to an exemplary embodiment is shown in a longitudinal sectional view and a perspective view.

[0039] Figure 4 A schematic diagram of the coil unit of a damping valve device according to another exemplary embodiment is shown in a longitudinal sectional view and a perspective view.

[0040] Figure 5 A schematic diagram of the flow plate of a damping valve device according to an exemplary embodiment is shown. Detailed Implementation

[0041] Figure 1 A vibration damper 10 is shown, wherein the vibration damper 10 is a multi-tube vibration damper, such as a two-tube vibration damper. The vibration damper 10 has an outer tube 12, which forms the outer surface of the vibration damper 10, particularly the housing. An inner tube 14, also referred to as a damper tube, is arranged inside the outer tube 12 and is coaxial with the outer tube. A compensation chamber 16 is formed between the outer tube 12 and the inner tube 14, which is preferably at least partially filled with hydraulic oil. For example, the compensation chamber 16 is partially filled with gas.

[0042] A working piston 18, connected to piston rod 20, is arranged within inner tube 14 to allow movement within the inner tube 14, wherein the inner tube preferably forms a guide for the working piston 18. The working piston 18 has a damping valve device 54. The working piston 18 divides the internal space of the inner tube 14 into a first working chamber 22 arranged on the piston rod side and a second working chamber 24 arranged away from the piston rod.

[0043] The internal space of the outer tube 12 is fluidly sealed on the piston rod side by means of a sealing package 34. Opposite to the sealing package 34, at the end away from the piston rod, the internal space of the outer tube 12 is fluidly sealed by means of a base member 36. For example, a base valve 38 is arranged on the base member 36, specifically mounted on the end of the inner tube 14 away from the piston rod. For example, the base valve 38 is a check valve capable of flow in two directions or only one direction. The second working chamber 24 is preferably fluidly connected to the compensation chamber 16 via the base valve 38. The piston rod-side ends of the inner tube 14 and the outer tube 12 are preferably fastened to the sealing package 34. For example, the piston rod 20 has an optional spring stop that, in the case of movement in the spring direction Z, is subjected to a spring force via a spring element 42.

[0044] Figure 2 An exemplary damping valve device 54 is shown, preferably arranged in the working piston 18 of the vibration damper 10. The damping valve device 54 is, for example, in the form of a pilot-controlled or directly controlled pressure limiting valve, and includes a damping valve housing 45, preferably cylindrical, and a housing top portion 44, the housing being, for example, substantially tubular, with the housing top portion integrally formed, for example, with the damping valve housing 45. A piston rod 20 is preferably mounted on the housing top portion 44. The housing top portion 44 has, for example, a connection area (not shown) for current supply to the damping valve device 54, the connection area having one or more connecting contacts. The connecting contacts for current supply are preferably connected to a drive unit.

[0045] For example, the damping valve device 54 has an actuation region 48 and a valve region (not shown). The actuation region 48 is arranged, for example, in the upper region of the damping valve device 54 closer to the piston rod 20, and preferably substantially above the valve region 50, particularly in the rebound direction Z. The actuation region 48 preferably includes an actuator in the form of an electromagnet. The electromagnet includes a coil unit 30 having a coil 52 with windings of multiple conductive wires. The coil wires are preferably formed of a conductive material coated with an insulating layer. The coil 52 is preferably arranged within and concentric with the damping valve housing 45. For example, the coil 52 abuts against the inner wall of the damping valve housing 45. A separating element 56 is arranged, for example, axially between the coil 52 and the top portion 44 of the housing. The coil 52 preferably abuts against and is particularly fastened to the separating element 56. The separating element 56 is, for example, formed of plastic. The coil unit 30 includes, for example, a coil carrier 28 and a separating element 56, on which windings, particularly the wires of the coil 52, are wound. The coil 52 at least partially or completely surrounds an armature chamber 60 that extends centrally in the axial direction. The armature 62 is mounted within the armature chamber 60 in a manner that allows it to move axially. The coil unit 30 also includes, for example, contact elements 32 for establishing electrical contact with an external power source.

[0046] The armature 62 is preferably cylindrical and has a diameter slightly smaller than that of the armature chamber 60, such that the armature 62 is preferably attached to be slidable in the axial direction. For example, the armature 62 includes a central armature rod 65, which, for example, has a circular cross-section and extends centrally through the armature chamber 60 in the axial direction. The armature rod 65 is preferably tubular. The armature chamber 60 is preferably defined by a cylindrical electrode 64 that is at least partially hollow. The electrode 64 preferably has a base and is configured to open in a direction specifically in the valve region. The electrode 64 is preferably formed of a magnetizable or magnetic material and, for example, has a magnetic separation device (not shown).

[0047] The coil 52 is preferably designed and arranged such that, when energized, it generates a magnetic field with magnetic field lines that preferably extend substantially axially within the armature chamber 60. The armature 62 is preferably formed of a magnetizable or magnetic material and is movable axially according to the magnetic field generated by the coil 52.

[0048] The electrode 64 has an upper tubular region with a particularly constant inner diameter, which is preferably in the form of a hollow cylinder and extends, for example, axially from the separating element 56 beyond the armature 62. The upper hollow cylindrical region abuts in the axial direction a lower region with an increasing diameter, wherein the outer surface of the electrode 64 preferably extends to and at least partially abuts the damping valve housing 45, and is fluidly sealed relative to the damping valve housing 45 via, for example, a sealing ring. The damping valve housing 45 at least partially or completely surrounds the valve region (not shown) in both the axial and circumferential directions. The electrode 64 is particularly in the form of a multi-part, integral, or single-part component. Below the electrode 64, particularly in the compression direction D, a working chamber is adjacent, which is, for example, in the form of a pilot working chamber 26.

[0049] The valve region (not shown) includes, for example, a main valve and optionally a pilot valve. Preferably, the main valve and / or pilot valve are saturated with hydraulic fluid as the piston rod moves in the rebound direction Z and the compression direction D. A seal, such as a sealing ring, is preferably mounted on the working piston 18, which fluidly seals the working piston 18 relative to the damper tube 14. This seal preferably abuts against the outer surface of the working piston 18 and the inner surface of the damper tube 14 in a fluidly sealed manner. Furthermore, the damping valve assembly 54, particularly the valve region (not shown), optionally includes a comfort valve. The comfort valve is preferably configured such that it is saturated with hydraulic fluid in both the compression direction D and the rebound direction Z. The comfort valve specifically includes at least one comfort spring disc assembly, which, for example, includes at least one or more spring discs located on a comfort valve seat. The comfort valve is fluidly connected (preferably directly connected) to the working chamber 24 remote from the piston rod. Preferably, the comfort valve is arranged in the working chamber 24 remote from the piston rod and specifically forms the end of the working piston 18 pointing towards the base valve 36.

[0050] During operation of the damping valve assembly 54, as the piston rod moves in the rebound direction Z, hydraulic fluid preferably flows into the main valve and the pilot valve, and subsequently optionally through the comfort valve. The main valve preferably includes a main piston arranged to be axially movable within the main working chamber. The main piston preferably divides the main working chamber into a compression main control chamber, a rebound main control chamber, and a pilot control chamber. The hydraulic pressure in the second working chamber 24, located away from the piston rod, preferably dominates in the compression main control chamber, while the pressure in the first piston rod-side working chamber 22 preferably dominates in the rebound main control chamber.

[0051] In the open position of the main valve, a main flow channel is formed between the main piston and the main valve seat, which forms a fluid connection between the first and second working chambers 22 and 24.

[0052] The pilot valve specifically includes a sliding plunger arranged to be axially movable within the pilot working chamber 26. The sliding plunger (not shown) preferably abuts against the armature 62, particularly the armature rod 65, at its end remote from the main valve, such that movement of the armature 62 and movement of the sliding plunger are coupled, at least when the armature 62 moves in the direction of the sliding plunger. In the closed position of the pilot valve, the sliding plunger preferably abuts against the pilot valve seat, such that there is no fluid flow between the pilot control chamber and the pilot working chamber 26 of the main valve.

[0053] During operation of the damping valve assembly 54, as the piston rod 20 moves along the compression direction D, hydraulic fluid flows into an optional comfort valve and into the compression main control chamber. Due to the pressure in the compression main control chamber, the main piston experiences an opening force and moves axially upward. During this process, the main piston rises from the main valve seat, and hydraulic fluid flows through the main flow passage to the rebound main control chamber. Simultaneously, a portion of the hydraulic fluid flows into the pilot control chamber, subjecting the main piston to a closing force in the direction of the main valve seat. This closing force determines the opening width of the main valve, particularly the cross-section of the main flow passage, which determines the damping force of the damping valve assembly 54. The pressure in the pilot control chamber is set by a pilot valve, through which hydraulic fluid flows from the pilot control chamber into the pilot working chamber 26, which is opened by a sliding plunger. The axial position of the sliding plunger is set by a magnetic coil 54, specifically predetermined. In the closed position of the pilot valve, the sliding plunger preferably fully closes the pilot working chamber 26, causing the hydraulic pressure in the pilot control chamber to increase to its maximum value, and the main valve closes and preferably experiences a force in the closing direction (because the main piston is pressed against the main valve seat).

[0054] Figure 3The coil unit 30 and the separating element 56 are shown in perspective and longitudinal sectional views. The separating element 56 is configured, for example, as a hollow cylinder with a cylindrical base. Preferably, the hollow cylindrical separating element 56 is configured to be open in the direction of the coil 52. An armature chamber 60 is arranged within the separating element 56, which is at least partially defined by the separating element 56. The separating element 56 preferably has a radial fluid channel 40, which is arranged and configured for at least partial or complete drainage of the armature chamber 60. Preferably, the armature chamber 60 is at least partially filled with gas, particularly air, and partially filled with hydraulic fluid. The gas is particularly arranged at the upper end of the armature chamber 60 in the direction of rebound. Preferably, the fluid channel 40 extends only in the radial direction and opens into the armature chamber 60, particularly at the upper end of the armature chamber in the direction of rebound. The separating element 56 preferably has a connection region 46 abutting against the coil carrier 28. The connecting region 46 preferably extends only beyond a sub-section of the separating element 56. The flux plate 50 is preferably arranged between the coil 52 (particularly the coil carrier 28) and the separating element 56. The flux plate 50 is particularly in the form of a circular disc and is preferably entirely or partially formed of metal, particularly a magnetically permeable or magnetizable material. The flux plate 50 preferably rests directly against the separating element 56 and the coil carrier 28.

[0055] The separating element 56 is specifically made of plastic. The separating element 56 is preferably manufactured by injection molding. Two sealing rings 68 and 70 are specifically arranged circumferentially around the separating element 56, abutting against the inner side of the separating element 56 and the damping valve housing 45. The outer diameter of the separating element 56 is preferably smaller than or corresponds to the inner diameter of the damping valve housing 45, such that the separating element 56 abuts against the damping valve housing 45 or forms a small gap between the damping valve housing 45 and the separating element 56. Specifically, the separating element 56 has two circumferentially extending grooves on its outer periphery, each groove accommodating a sealing ring 68 or 70. A fluid passage 40 preferably extends between the sealing rings 68 and 70. The fluid passage 40 preferably opens at a location between the two sealing rings 68 and 70, on the circumferential outer surface of the separating element 56. For example, the sealing rings 68 and 70 have the same form and are specifically arranged coaxially with each other. Preferably, a hole 58 is provided in the damping valve housing 45, which is arranged to be aligned with and fluidly connected to the fluid passage 40.

[0056] The orifice 58 in the damping valve housing 45 preferably has a smaller diameter than the diameter of the fluid passage 40 in the separating element 56. In particular, the diameter of the fluid passage 40 corresponds to 1.5 to 5 times, especially 2 to 3 times, the diameter of the orifice 58. In particular, the fluid passage has a rounded, polygonal, quadrilateral, rectangular, square, circular, or elliptical cross-section.

[0057] During the operation of the damping valve device 54 in the compression phase, hydraulic fluid preferably flows from the pilot working chamber 26 into the armature chamber 60 through the interior of the tubular armature rod 65, and then into the first working chamber through the fluid passage 40 and the orifice 58. The armature chamber 60 is preferably fluidly connected to the first working chamber 22 via the orifice 58 and the fluid passage 40.

[0058] The separating element 56 is preferably fixedly connected to the coil carrier 28, particularly by material locking to the coil carrier 28. The separating element 56 is preferably connected to the coil carrier 28 via injection molding. The separating element 56 is molded onto the coil carrier 28, preferably surrounding the coil carrier 28, particularly by injection molding. The separating element 56 is particularly fixedly connected to the flow plate 50, preferably by material locking to the flow plate 50. Preferably, the separating element 56 is connected to the flow plate 50 via injection molding, and particularly molded onto the flow plate.

[0059] Figure 4 Another exemplary embodiment of the coil unit 30 is shown, which is related to Figure 2 and Figure 3 The coil unit 30 in the text is mostly the same, the difference is that Figure 4 The separating element 56 has a gap 72 formed on its outer side. Preferably, the gap 72 is located at the outer opening of the fluid channel 40. The gap 72 is particularly arranged between the two sealing rings 68, 70, and preferably forms a fluid chamber 74 arranged between the orifice 58 and the fluid channel 40.

[0060] Figure 5 An exemplary embodiment of the flow plate 50 is shown. The flow plate is preferably formed of steel and particularly abuts against the damping valve housing 45. The flow plate 50 preferably has a plurality of (e.g., four) cutouts 76, which extend axially through the thickness of the flow plate 50 and are, for example, in the form of grooves. Preferably, the cutouts 76 are used for fastening the flow plate 50 to a separating element 56, which is molded onto the flow plate 50 by an injection molding process. The flow plate 50 has, for example, a recess 78 at its outer periphery, which is, for example, rectangular in form. The coil carrier 28 preferably has an axial protrusion that extends along the recess 78 and is used, for example, for mounting the coil carrier 28.

[0061] List of reference numerals

[0062] 10 Vibration dampers

[0063] 12 outer tubes

[0064] 14 Inner tube

[0065] 16 Compensation Chambers

[0066] 18 Working piston

[0067] 20 Piston Rod

[0068] 22 First / Piston Rod Side Working Chamber

[0069] 24 Second / Working chamber furthest from the piston rod

[0070] 26 Pilot Working Chamber

[0071] 28 Coil Carrier

[0072] 30 coil units

[0073] 32 Contact elements

[0074] 34. Closed package

[0075] 36 Base components

[0076] 38 Base valve

[0077] 40 Fluid Channels

[0078] 42 Spring elements

[0079] 44 Top portion of the casing

[0080] 45 Damping valve housing

[0081] 46 Connecting Area

[0082] 48 Drive Area

[0083] 50 Flux Plate

[0084] 52 coils

[0085] 54 Damping valve device

[0086] 56 Separating elements

[0087] 58 holes

[0088] 60 Armature chamber

[0089] 62 Armature

[0090] 64 diode

[0091] 65 Armature rod

[0092] 68 Sealing ring

[0093] 70 Sealing ring

[0094] 72 gap

[0095] 74 Fluid Chamber

[0096] 76 Incisions

[0097] 78 recesses.

Claims

1. A vibration damper (10) for a motor vehicle, comprising: Outer tube (12) and inner tube (14), the inner tube being configured to be coaxial with the outer tube, and The working piston (18) is arranged to be axially movable within the inner tube (14) and divides the internal space of the inner tube (14) into a piston rod-side working chamber (22) and a working chamber (24) away from the piston rod. A damping valve device (54) is arranged in the working piston (18), wherein the damping valve device (54) has: Damping valve housing (45). A coil unit (30), the coil unit being arranged within the damping valve housing (45) and having a coil carrier (28) and a coil (52) wound on the coil carrier, and Separating element (56), the separating element being used to separate hydraulic oil and gas within the coil unit (30) and / or the damping valve housing (45), and An armature chamber (60) is arranged within the coil unit and an armature (62) capable of axial movement is arranged within the armature chamber. Its features are, The separating element (56) is made of plastic.

2. The vibration damper (10) according to claim 1, wherein the separation element (56) is manufactured by means of an injection molding process.

3. The vibration damper (10) according to any one of the preceding claims, wherein the separation element (56) has a fluid channel (40) that extends radially, has a circular or polygonal cross-section, and is fluidly connected to the armature chamber (60).

4. The vibration damper (10) according to claim 3, wherein the damping valve housing (45) has a hole (58) extending in a radial direction and directly fluidly connected to the fluid channel (40), and wherein the diameter of the fluid channel (40) is smaller than the diameter of the hole (58).

5. The vibration damper (10) according to claim 4, wherein the diameter of the fluid channel (40) corresponds to 1.5 to 5 times, particularly 2 to 3 times, the diameter of the hole (58).

6. The vibration damper (10) according to any one of the preceding claims, wherein the separating element (56) is materially locked to the coil carrier (28).

7. The vibration damper (10) according to any one of the preceding claims, wherein the separating element (56) is connected to the coil carrier (28) by means of an injection molding process.

8. The vibration damper (10) according to any one of the preceding claims, wherein a flux plate (50) is arranged between the coil carrier (28) and the separation element (56).

9. The vibration damper (10) according to claim 8, wherein the flux plate (50) is made of a magnetic or magnetizable material.

10. The vibration damper (10) according to claim 8 or 9, wherein the separation element (56) is connected to the flux plate (50) by means of an injection molding process.

11. The vibration damper (10) according to any one of the preceding claims, wherein two sealing rings (68, 70) are arranged circumferentially around the separating element (56), the two sealing rings abutting against the separating element (56) and against the inner side of the damping valve housing (45), and wherein the fluid passage (40) is arranged between the sealing rings (68, 70).

12. The vibration damper (10) according to claim 11, wherein the fluid chamber (74) is arranged between the orifice (58) and the fluid channel (40) and is formed by the gap (72) in the separation element (56).

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