Base Valve Assembly for Hydraulic Compression Stop Integration
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Solution Overview
Problem
Existing hydraulic damper designs require significant modifications to incorporate effective hydraulic compression stops, which complicates their integration into existing passive damper systems.
Innovation Solution
A damper design featuring a pressure tube, piston, hydraulic compression stop assembly, and base valve assembly, where the base valve assembly includes one-way valves for fluid flow control, eliminating the need for passages or valving in the plunger, and a reserve tube creates a reservoir chamber for fluid management during compression and rebound strokes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydraulic compression stop is added to a passive damper, then the damping force during compression stroke is improved, but the device complexity and manufacturing difficulty increase significantly
Solution Approach 1:
The base valve assembly is merged with the compression stop function by integrating the valve body as the compression stop structure. The valve body directly stops the piston rod while housing the intake valve and passageways, eliminating the need for separate compression stop components and reducing overall device complexity.
Solution Approach 2:
The base valve assembly performs multiple functions: it serves as both the compression stop structure and the fluid control valve assembly. The valve body acts as the compression stop that contacts the piston rod while simultaneously housing the intake valve and providing fluid passageways, making the component universal and reducing the total number of parts.
2Force
If traditional hydraulic compression stop designs are used, then compression force is improved, but passages and valving must be added to the plunger increasing manufacturing complexity
Solution Approach 1:
The fluid control function is extracted from the plunger and relocated to the base valve assembly. The intake valve and its associated passageways are positioned in the base valve assembly rather than being integrated into the plunger, simplifying plunger manufacturing while maintaining the necessary fluid control for compression force generation.
Solution Approach 2:
The base valve assembly acts as an intermediary between the piston rod and the fluid system. Instead of modifying the plunger with complex passages and valves, the base valve assembly mediates the fluid flow to and from the compression stop chamber, achieving the desired compression force without complicating the plunger structure.
3Reliability
If a hydraulic compression stop assembly is integrated into the damper, then ride comfort is improved through additional damping force, but the manufacturing and assembly processes become more difficult
Solution Approach 1:
The compression stop assembly is merged with the base valve assembly into a single integrated component structure. The valve body serves dual purposes as both the compression stop and the valve housing, reducing the number of separate manufacturing operations and assembly steps required compared to having distinct compression stop and valve components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces end stop loads, enhances ride comfort by generating additional damping force during compression strokes, and can be easily integrated into conventional dampers without substantial structural or manufacturing changes, offering improved performance at a lower cost.
Implementation Method 1
The intake valve is constructed as a one-way valve that permits fluid to flow in one direction into the sleeve cavity through the one or more intake passageways
Implementation Method 2
The base valve assembly includes one or more compression passageways and a compression valve that is constructed as a one-way valve and permits fluid to flow in only one direction from the second working chamber to the reservoir chamber through the compression passageway(s)
Implementation Method 3
the plunger is received in sliding engagement with the sleeve cavity when the piston approaches the fully compressed position... enhances ride comfort by generating additional damping force during compression strokes
Data Source
AI summary
A damper having a pressure tube, a piston, a hydraulic compression stop assembly, and a base valve assembly is provided. The piston is arranged in sliding engagement inside the pressure tube and divides the pressure tube into first and second working chambers. The hydraulic compression stop assembly is positioned in the second working chamber and includes a sleeve and a plunger. The sleeve extends from the base valve assembly to define a sleeve cavity. The plunger extends from the piston and/or piston rod and is designed to slide into the sleeve cavity when the piston approaches a fully compressed position of the damper. The base valve assembly includes intake passageways and an intake valve. The intake valve is constructed as a one-way valve that permits fluid to flow in one direction into the sleeve cavity through the intake passageways.