Monotube Damper Rebound Stop Sleeve for Secure HRS Retention
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Solution Overview
Problem
Hydraulic rebound stop arrangements in damper assemblies, particularly in monotube designs, face challenges during manufacturing and component retention over the damper assembly's lifetime.
Innovation Solution
A monotube damper assembly with a hydraulic rebound stop (HRS) assembly featuring a tubular HRS sleeve and flange portion that engages a corresponding ledge to secure the HRS assembly within the housing, utilizing a design with recesses that gradually decrease in depth to prevent movement towards the assembly's end, supported by a HRS support ring to counter fluid pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a hydraulic rebound stop arrangement is used in a monotube damper assembly, then enhanced damping force is generated, but manufacturing difficulty increases and component retention becomes problematic
Solution Approach 1:
The HRS assembly is segmented into distinct functional components: a support ring that interfaces with the housing ledge, and a sleeve with recesses that contains the hydraulic mechanism. This segmentation allows each component to be optimized independently for manufacturing while ensuring proper assembly and function within the monotube damper assembly.
Solution Approach 2:
Instead of using complex retention mechanisms to secure the HRS assembly, the design inverts the approach by using the flange portion extending from the tubular portion to naturally engage with the housing ledge, allowing the assembly to self-retain through its structural geometry rather than requiring additional fastening components.
2Force
If a hydraulic rebound stop arrangement is used in a monotube damper assembly, then enhanced damping force is generated, but component retention over lifetime deteriorates
Solution Approach 1:
The design inverts the retention approach by allowing the HRS assembly to self-secure through its flange portion engaging the housing ledge, rather than requiring external retention mechanisms. This geometric self-retention ensures reliable component positioning throughout the damper assembly's operational lifetime.
Solution Approach 2:
The HRS assembly is designed to self-retain within the housing through the engagement of its flange portion with the housing ledge, eliminating the need for separate retention mechanisms. The assembly automatically maintains its position and function throughout the product lifecycle through this self-service retention mechanism.
3Reliability
If the HRS assembly is secured using traditional retention methods, then component retention may be achieved, but manufacturing complexity increases
Solution Approach 1:
The HRS assembly is divided into a support ring and a sleeve with integrated flange, where each segment serves a specific function. The flange portion of the tubular portion integrates the retention function directly into the structural component, reducing overall assembly complexity while ensuring reliable retention.
Solution Approach 2:
The tubular portion of the HRS assembly serves multiple functions: it provides structural support, contains the hydraulic rebound mechanism, and through its flange portion, provides self-retention within the housing. This multi-functionality reduces the need for separate components, simplifying the overall device while maintaining reliability.
Data Source
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AI summary
A monotube damper assembly (20) includes a housing (22) defining a main compartment (30, 32, 34) extending along a center axis (A) between a first end ((26) and a second end (28); and a hydraulic rebound stop (HRS) assembly (170, 270, 370) disposed within the housing (22) adjacent to the first end (26) and including an HRS sleeve (174, 274, 374) having a tubular portion (176, 276, 376) and a flange portion (178, 278, 378) extending radially outwardly from the tubular portion (176, 276, 376) at a first axial end (180) thereof and configured to engage a corresponding ledge (184, 284, 384) for locating the HRS assembly (170, 270, 370) in the main compartment (30, 32, 34) and preventing the HRS assembly (170, 270, 370) from moving toward the second end (28), the tubular portion (176, 276, 376) defining a plurality of recesses (188) each extending axially from a second axial end (182) of the tubular portion (176, 276, 376) opposite the first axial end (180) and having a depth that gradually decreases along a length of the tubular portion (176, 276, 376) toward the flange portion (178, 278, 378). An HRS assembly (170, 270, 370) for a monotube damper assembly (20) is also provided.