Coil-Over Damper Bypass Control With an Internal Floating Piston
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Solution Overview
Problem
Existing coil over damper systems lack the ability to adjust bypass characteristics without complete disassembly and modification of flow ports, and the resistance to flow through check shims is minimal and digressive, limiting meaningful adjustment of damping forces.
Innovation Solution
The damper design incorporates an internal floating piston and a nitrogen spring or polymer/steel spring to control the opening and closing of bypass ports, allowing for external adjustment of damping characteristics by varying the pressure or spring rate, enabling progressive resistance to flow during damping events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If check shims are used to control bypass flow, then the damper can provide basic compression and rebound damping, but the resistance to flow is minimal and digressive, limiting meaningful adjustment of bypass characteristics
Solution Approach 1:
The patent employs a progressive valve with a conical needle that dynamically adjusts the bypass port opening based on applied force. As force increases, the needle lifts progressively to open the bypass port, providing non-linear, progressive resistance to flow. This dynamic adjustment mechanism enables meaningful control of bypass characteristics without requiring complex discrete adjustment mechanisms.
Solution Approach 2:
The progressive valve changes the flow resistance parameter continuously based on the applied load. The conical needle geometry creates a progressive opening area as force increases, transforming the fixed parameter approach of check shims into a dynamic parameter system that adapts to varying damping conditions.
2Ease of operation
If check shims are used to control bypass flow, then the damper structure remains simple, but adjustment of bypass characteristics requires complete disassembly and modification of flow ports
Solution Approach 1:
The progressive valve is designed as a self-adjusting component that automatically modulates bypass flow based on the applied force during damping events. The conical needle responds autonomously to load changes, lifting to open the bypass port when force increases and closing when force decreases, eliminating the need for manual adjustment or disassembly.
Solution Approach 2:
The valve provides continuous, dynamic adjustment of bypass characteristics during operation rather than requiring static pre-setting. The progressive opening mechanism allows the damper to adapt to varying terrain and loading conditions in real-time without human intervention.
3Force
If multiple flow ports are used to adjust bypass characteristics, then the damper can provide varying resistance, but the adjustment requires changing the number and size of flow ports through disassembly
Solution Approach 1:
The progressive valve dynamically controls the effective opening area of the bypass port during operation. The conical needle's position varies continuously with applied force, providing progressive resistance control without requiring physical modification of the port structure itself.
Solution Approach 2:
The conical needle acts as an intermediary element between the applied force and the bypass port opening. It translates varying force levels into corresponding opening areas, mediating the relationship between load and flow resistance without requiring direct modification of the flow ports.
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 provides effective control of oil pressure and adjustable damping characteristics, allowing for instant external adjustment of the damper system without the need for check shims or plates, enhancing the ability to fine-tune damping forces for improved vehicle ride quality.
Implementation Method 1
an internal floating piston and a nitrogen spring or polymer/steel spring to control the opening and closing of bypass ports
Implementation Method 2
a piston manages rebound and compression in the damper through ports that are covered with flexible steel discs or a flexible metal shim stack that allows the bypass flow in only one direction
Data Source
AI summary
A damper for use with an automotive coil over shock absorber. An outer damping sleeve is retained over the exterior surface of an inner body and includes a plurality of bypass ports to alternately align and unalign with bypass ports of the inner body to regulate a bypass flow of damping oil between an interior volume and an outer passage, thereby allowing variable damping control of the damper. The outer damping sleeve is connected to an internal floating piston (IFP) which rides inside the inner body. A control spring is retained for applying a force to the IFP to limit the free movement of the IFP and thereby control a damping force of the damper during the damping event. Increased pressure in the hydraulic damping oil causes the IFP to move, causing the bypass ports to open and close depending on the forces subject to the damper.