Suspension Damper Pressure Relief Valve Layout for Internal Pressure Control
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Solution Overview
Problem
Current vehicle suspension damper designs face challenges in managing internal pressures, which can exceed design requirements, leading to potential safety and durability issues due to the reliance on externally mounted electromechanical valves for controlling fluid flow during extension and compression motions.
Innovation Solution
The integration of internally positioned rebound and compression chamber pressure relief valves within the damper, which allow fluid flow when pressure thresholds are exceeded, providing additional pressure relief without increasing the damper's length or reducing its travel capabilities, and utilizing externally mounted control valves to regulate fluid flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If externally mounted electromechanical valves are used to control fluid flow, then damping control is achieved, but internal pressures can exceed design requirements
Solution Approach 1:
A pressure relief valve is introduced as an intermediary component between the compression chamber and rebound chamber. This valve activates when compression chamber pressure exceeds a predetermined threshold, providing a safety mechanism that releases excess pressure and prevents system failure while working alongside the external electromechanical valve.
Solution Approach 2:
The pressure relief valve is pre-configured with a predetermined activation pressure threshold. This beforehand cushioning mechanism ensures that when compression pressure builds up to dangerous levels, the valve automatically activates to release pressure, preventing exceedance of design requirements and protecting the system from damage.
2Reliability
If pressure relief valves are added to manage internal pressures, then safety and durability are improved, but device complexity increases
Solution Approach 1:
The pressure relief valve is integrated within the existing damper structure, merging its function into the overall valve system. Rather than adding a completely separate external component, the pressure relief functionality is combined with the existing valve architecture, reducing the increase in device complexity while maintaining improved pressure management capability.
3Reliability
If the damper structure is modified to include internal pressure relief valves, then pressure control is improved, but manufacturing complexity increases
Solution Approach 1:
The pressure relief valve is designed as a separate, modular component that can be independently manufactured and then assembled into the damper. This segmentation allows for specialized manufacturing of the pressure relief mechanism using optimal processes, while the overall damper assembly remains relatively simple to manufacture by integrating this pre-manufactured component.
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 manages high internal pressures, enhancing safety and durability by preventing pressure exceedance without adding length or restricting travel, while allowing dynamic control of damping rates through external valves.
Implementation Method 1
configured to permit fluid flow through the at least one rebound chamber pressure relief passageway in one direction from the rebound chamber to the compression chamber when fluid pressure in the rebound chamber exceeds a blow-off pressure threshold of the rebound chamber pressure relief valve
Implementation Method 2
a spring positioned in the plunger bore that biases the plunger towards the first piston rod end such that the plunger pulls the valve head against the second piston end to obstruct fluid flow
Data Source
Figure 1
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Figure 3
AI summary
A damper with inner and outer tubes, a piston rod extending between first and second piston rod ends, and a piston mounted to the second piston rod end. The piston is disposed within the pressure tube to define rebound and compression chambers. A fluid transport chamber is positioned between the inner and outer tubes and an intake valve assembly, abutting one end of the pressure tube inside the outer tube, and defines at least one intermediate chamber that is arranged in fluid communication with at least one externally mounted, electro-mechanical control valve. A rebound chamber pressure relief valve, mounted inside the piston and piston rod end, releases excess fluid pressure in the rebound chamber. A compression chamber pressure relief valve, mounted inside the intake valve assembly, releases excess fluid pressure in the compression chamber.