Suspension Damper Bypass Flow Paths for Bottom-Out Resistance
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Solution Overview
Problem
Conventional vehicle suspension systems experience a constant damping rate throughout the stroke, leading to the risk of 'bottoming out' and potential damage as they near full compression or extension, which is not effectively mitigated by existing technologies.
Innovation Solution
A vehicle suspension damper design featuring a cylinder with compression and rebound chambers, a piston, and multiple bypass fluid flow paths that increase damping rate near full compression by forcing fluid through fewer flow paths, thereby increasing the opposing force and reducing the likelihood of 'bottoming out'.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a constant damping rate is used throughout the stroke, then the damping component structure is simple, but the suspension risks bottoming out and potential damage near full compression or extension
Solution Approach 1:
The patent implements variable damping rate by making the damping characteristic dynamic rather than static. The damping rate changes automatically with piston position through the progressive valve mechanism, allowing the damper to adapt its damping force based on the stroke position, thereby preventing bottoming out while maintaining structural simplicity
Solution Approach 2:
The patent changes the damping parameter (damping rate) as a function of piston position. By using a progressive valve with increasing orifice area toward the bottom of the stroke, the damping rate parameter is dynamically adjusted based on position, transforming a constant parameter system into a variable parameter system that prevents bottoming out
2Reliability
If the damping rate is increased near full compression, then the risk of bottoming out is reduced, but the device complexity increases
Solution Approach 1:
The damping component is segmented into multiple flow paths with different characteristics. The progressive valve divides the fluid flow into multiple channels that are progressively activated or adjusted based on piston position, allowing complex variable damping behavior to be achieved through simpler modular segments rather than a single complex mechanism
Solution Approach 2:
The progressive valve acts as an intermediary mechanism that automatically adjusts the damping rate based on piston position. This intermediary component mediates between the simple constant-damping structure and the desired variable-damping performance, achieving the latter without requiring complex active control systems or multiple separate 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
The solution effectively increases damping rate as the damper nears full compression, reducing the risk of damage by enhancing the opposing force, thus preventing the suspension from 'bottoming out'.
Implementation Method 1
a damping liquid within the cylinder and a bypass fluid flow path connecting the compression chamber and the rebound chamber
Data Source
AI summary
An apparatus and system are disclosed that provide position sensitive suspension damping. A damping unit includes a piston mounted in a fluid-filled cylinder. A vented path in the piston may be fluidly coupled to a bore formed in one end of the piston rod, creating a flow path for fluid to flow from a first side of the piston to a second side of the piston during a compression stroke. The flow path may be blocked by a needle configured to engage the bore as the damping unit is substantially fully compressed, thereby causing the damping rate of the damping unit to increase. In one embodiment, the piston includes multiple bypass flow paths operable during the compression stroke or the rebound stroke of the damping unit. One or more of the bypass flow paths may be restricted by one or more shims mounted on the piston.