Suspension Damper Mount Assembly with Dual-Stage Jounce Bumper
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Solution Overview
Problem
Current suspension damper systems face challenges in absorbing the increased forces generated by larger diameter tires without compromising ride quality, handling, packaging, or styling, and often result in increased vehicle mass and cost.
Innovation Solution
A mount assembly for a suspension damper featuring a piston rod, a jounce bumper made of a deformable material, and a jounce bumper cup with a load mount portion, designed to absorb energy from axial forces, allowing for increased displacement and energy absorption without affecting vehicle performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If larger diameter low profile tires are used, then vehicle performance and handling are improved, but higher forces are generated during impact events that exceed the absorption capacity of conventional suspension dampers
Solution Approach 1:
The jounce bumper is divided into two distinct components: an inner bumper made of a harder deformable material and an outer cup made of a softer deformable material. This segmentation allows each component to contribute differently to energy absorption - the inner bumper provides initial resistance while the outer cup deforms more easily to absorb additional energy, collectively handling the higher forces from larger tires without compromising suspension reliability
Solution Approach 2:
The invention employs composite material construction by combining two different deformable materials with distinct properties. The inner bumper uses a harder material for initial force resistance, while the outer cup uses a softer material for enhanced energy absorption. This composite approach enables the suspension system to manage the increased forces from larger diameter tires while maintaining reliable performance
2Force
If shock damping is modified to absorb higher forces, then impact force absorption is improved, but ride quality and handling performance are compromised
Solution Approach 1:
Different regions of the jounce bumper assembly have different material properties tailored to specific functions. The inner bumper uses a harder material localized for initial contact and force distribution, while the outer cup uses a softer material localized for energy absorption. This local quality differentiation allows the system to absorb impact forces without adversely affecting ride quality and handling characteristics
Solution Approach 2:
The invention changes the material parameters of the jounce bumper components to optimize performance. By selecting appropriate deformable materials with specific hardness and elasticity parameters for each component, the system can absorb higher impact forces while maintaining the ride quality and handling performance necessary for comfortable vehicle operation
3Stability of the object's composition
If the jounce bumper cup wall portion extends sufficiently around the jounce bumper, then the jounce bumper is retained in position, but the structure becomes more complex
Solution Approach 1:
The jounce bumper cup integrates multiple functions into a single component: it retains the jounce bumper through its wall portion, absorbs energy through its deformable material, and mounts to the suspension assembly. This merging of functions reduces the need for separate retention mechanisms and simplifies the overall structure while maintaining stable jounce bumper positioning
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 mount assembly effectively absorbs additional energy, providing improved displacement and energy absorption capabilities, thus addressing the challenges of larger tire forces without impacting vehicle imperatives like ride quality or increasing mass.
Implementation Method 1
The jounce bumper is formed of a first deformable material selectable for absorbing energy from an axial force applicable through the piston rod
Implementation Method 2
The jounce bumper cup is formed of a second deformable material selectable for absorbing additional energy from such axial force
Data Source
AI summary
A mount assembly for a suspension damper is provided which includes a piston rod extending about an axis and a mount housing. A jounce bumper is axially positioned about the piston rod and has an end surface and a radially outer surface. The jounce bumper is formed of a first deformable material selectable for absorbing energy from an axial force applicable through the piston rod. A jounce bumper cup formed of a second deformable material selectable for absorbing additional energy fits onto the end surface of the jounce bumper. The jounce bumper cup has a wall portion extending sufficiently around the radially outer surface of the jounce bumper to retain it in position and a load mount portion extending to the mount housing and being configured to absorb the additional energy.