Bypass Port Piston With Check Shims for Bottom-Out Damping

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional shock absorbers face issues with bottoming out and topping out, leading to rider discomfort and potential damage, while previous prevention designs are costly and have excessive dead length.

Innovation Solution

The implementation of bypass ports within the main damping piston of a shock absorber, which simulate internal bypass shocks without adding bleed to the system, using position-sensitive and velocity-sensitive check shims to control fluid flow and prevent bottoming out and topping out, reducing manufacturing costs and dead length.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional shock absorbers are used, then the structure is simple and cost-effective, but bottoming out and topping out occur causing rider discomfort and potential damage

Engineering Contradiction:

Improveprevention of bottoming out and topping outVSAvoidrider discomfort and shock damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The piston is divided into multiple sections with different damping characteristics. The bypass ports are segmented into compression bypass ports and rebound bypass ports, allowing independent control of compression and rebound damping. This segmentation enables the shock absorber to prevent bottoming out and topping out while maintaining a relatively simple overall structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bypass ports act as intermediary flow paths that activate under specific conditions (high compression or rebound forces). These ports provide an alternative fluid flow route when the primary damping channels reach their limits, preventing bottoming out and topping out without requiring complex additional components.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If internal bypass shocks are simulated, then bottoming out and topping out are prevented, but manufacturing costs and dead length increase

Engineering Contradiction:

Improveprevention of bottoming out and topping outVSAvoidmanufacturing costs and dead length

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The bypass ports are integrated directly into the piston structure rather than being separate components. The compression bypass ports and rebound bypass ports are merged into the piston body, eliminating the need for separate bypass assemblies. This integration reduces manufacturing complexity and dead length while maintaining the bottoming out and topping out prevention functionality.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The piston serves multiple functions: it provides primary damping through standard ports, prevents bottoming out through compression bypass ports, and prevents topping out through rebound bypass ports. This multi-functionality eliminates the need for separate bottoming out prevention devices, reducing overall system complexity and manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution effectively prevents bottoming out and topping out while minimizing dead length and manufacturing costs, providing a high-performance damping system with adjustable damping rates and reduced risk of shock absorber damage.

Implementation Method 1

using position-sensitive and velocity-sensitive check shims to control fluid flow

Methodology Applied

Scientific EffectPosition-sensitive check shim mechanism:

Implementation Method 2

using position-sensitive and velocity-sensitive check shims to control fluid flow

Methodology Applied

Scientific EffectVelocity-sensitive check shim mechanism:

Implementation Method 3

bypass ports within the main damping piston of a shock absorber, which simulate internal bypass shocks without adding bleed to the system

Methodology Applied

Scientific EffectPressure differential: Pressure Gradient

Data Source

PatentUS20230082373A1Bypass port piston

Publication Date: 2023.03.16 FOX FACTORY INC

AI summary

Described herein is a bypass port piston comprising: a main damping piston, wherein the main damping piston has a plurality of standard ports, wherein the main damping piston has at least one bypass port, face shims disposed on at least one side of the main damping piston such that fluid flow through the plurality of standard ports is restricted, at least one check spring coupled to the main damping piston, at least one check shim disposed to cover the at least one bypass port and coupled to the at least one check spring, wherein the at least one check spring keeps the at least one check shim in an open position, and a position sensitive spring disposed to close the check shim as the main damping piston is pressed against the position sensitive spring.