Damper Housing With Variable Wall Thickness For Heat Transfer

Solution Overview

Problem

Existing damper housings have a decreased internal volume and reduced heat transfer due to a narrowed end section with a thicker wall thickness, leading to increased mass and reduced damping forces, particularly in twin-tube dampers during the rebound stroke.

Innovation Solution

The narrowed end section of the damper housing is formed with a second predetermined wall thickness less than the extended main section, increasing internal volume and heat transfer by compressing the preformed tube between a broaching die and a calibrating mandrel, and an intermediate conical section is created to connect the narrowed and extended sections, enhancing precision and production simplicity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the narrowed end section is formed with a thicker wall thickness to increase strength, then the structural strength is improved, but the internal volume decreases and heat transfer is reduced

Engineering Contradiction:

Improvestructural strengthVSAvoidinternal volume

Core Design Contradiction:

StrengthVSVolume of stationary object

Solution Approach 1:

The patent applies local quality by creating different wall thicknesses in different sections of the tube. The extended main section has a first wall thickness while the narrowed end section has a second, greater wall thickness. This allows the narrowed end section to have enhanced strength where needed while the overall internal volume is optimized for heat transfer.

Inventive Principle:

Principle #3Local quality

2Strength

If the narrowed end section is formed with a thicker wall thickness to increase strength, then the structural strength is improved, but the mass increases and fuel economy decreases

Engineering Contradiction:

Improvestructural strengthVSAvoidmass

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies local quality by creating different wall thicknesses in different sections of the tube. The extended main section has a first wall thickness while the narrowed end section has a second, greater wall thickness. This allows the narrowed end section to have enhanced strength where needed while the overall internal volume is optimized for heat transfer.

Inventive Principle:

Principle #3Local quality

3Strength

If the narrowed end section is formed with a thicker wall thickness to increase strength, then the structural strength is improved, but the heat transfer capability is reduced

Engineering Contradiction:

Improvestructural strengthVSAvoidheat transfer

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The patent applies local quality by creating different wall thicknesses in different sections of the tube. The extended main section has a first wall thickness while the narrowed end section has a second, greater wall thickness. This allows the narrowed end section to have enhanced strength where needed while the overall internal volume is optimized for heat transfer.

Inventive Principle:

Principle #3Local quality

4Manufacturing precision

If the preformed tube is compressed between the broaching die and calibrating mandrel to form the narrowed end section, then the manufacturing precision is improved, but the device complexity increases

Engineering Contradiction:

Improveforming precisionVSAvoidmanufacturing device complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent uses a calibrating mandrel as an intermediary tool during the broaching process. The mandrel with its narrowed head provides internal support and defines the final dimensions of the narrowed end section while the broaching die applies external compression. This intermediary tool enables precise forming without requiring an overly complex manufacturing system.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 increases internal volume and heat transfer while maintaining external dimensions, reducing mass and improving damper performance with a lighter, cost-effective construction method.

Implementation Method 1

compressing the preformed tube between the first broaching die and the narrowed head of the calibrating mandrel to sandwich the preformed tube

Methodology Applied

Scientific EffectCompression: Compression

Data Source

PatentUS10850584B2Damper housing and a method for manufacturing the damper housing

Publication Date: 2020.12.01 BEIJING WEST IND CO LTD

AI summary

A damper housing disposed on a center axis includes an extended mains section and a narrowed end section. The narrowed end section has a second predetermined wall thickness less than the first predetermined wall thickness of the extended main section. An intermediate conical section, connecting the narrowed end section and the extended main section, has an intermediate conical section wall thickness equal to the second predetermined wall thickness at an internal inclination angle relative to the center axis. A method for manufacturing the damper housing using a preformed tube, a first broaching die, a calibrating mandrel, and a swaging die is performed by compressing the preformed tube between the first broaching die and the narrowed head of the calibrating mandrel and compressing the preformed tube between the swaging die and the intermediary section of the calibrating mandrel to form the narrowed end section and the intermediate conical section, respectively.