Vehicle Vibration Damper Rebound Stop With Snap-Fit Spring Mount
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Solution Overview
Problem
Existing vibration dampers with hydraulic rebound stops require precise manufacturing tolerances, making them expensive to produce while aiming for reliable damping in the rebound stage.
Innovation Solution
A vibration damper design featuring a rebound stop arrangement with an additional piston and a spring element attached to the piston rod, utilizing a sleeve-shaped receptacle and a snap-action connection for cost-effective production and enhanced damping performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precise manufacturing tolerances are used for rebound stop components, then reliable damping is achieved, but manufacturing cost increases significantly
Solution Approach 1:
The patent replaces expensive metal components with plastic components that have built-in tolerance compensation. The additional piston and rebound stop receptacle are made from plastic material that inherently absorbs manufacturing tolerances, eliminating the need for expensive precision machining while maintaining reliable damping function.
Solution Approach 2:
The patent changes the material parameter from metal to plastic, which fundamentally alters the tolerance characteristics. Plastic material allows for larger manufacturing tolerances while maintaining functional reliability, directly resolving the contradiction between reliable damping and manufacturing cost.
2Reliability
If metal components are used for the additional piston and rebound stop receptacle, then transverse forces are compensated, but manufacturing complexity and cost increase
Solution Approach 1:
The patent uses plastic material with embedded tolerance compensation features that combines the structural integrity needed for transverse force compensation with the manufacturing simplicity of plastic molding. This composite approach eliminates complex metal machining while maintaining the necessary mechanical properties.
Solution Approach 2:
The patent substitutes metal components with plastic components that achieve the same transverse force compensation function through molded-in features rather than precision machining, significantly reducing manufacturing complexity and cost.
3Ease of manufacture
If snap-action connection is used for the spring element, then manufacturing cost is reduced, but precise interaction must be ensured
Solution Approach 1:
The patent changes the connection mechanism from traditional rigid fastening to snap-action connection, which relies on elastic deformation and friction rather than precision machining. The plastic material's inherent elasticity enables precise interaction through the snap-action mechanism without requiring tight manufacturing tolerances.
Solution Approach 2:
The snap-action connection uses simple plastic deformation and friction-based holding instead of expensive precision fastening mechanisms, achieving both cost reduction and precise interaction through the inherent properties of plastic material.
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 design achieves reliable damping in the rebound stage with reduced manufacturing costs by using a cost-effective plastic material for the additional piston and a snap-action connection, ensuring precise interaction between the spring element and piston rod.
Implementation Method 1
a spring element (44) which is arranged at least partially within the rebound stop receptacle (40) and is fastened to the additional piston (30)
Implementation Method 2
a damper tube (14) which is filled with hydraulic fluid, a working piston (18) which is connected to a piston rod (20) and is arranged such that it can be moved to and from within the damper tube (14)
Data Source
AI summary
A vibration damper for a vehicle includes a damper tube, a working piston and a rebound stop arrangement. The damper tube is filled with hydraulic fluid. The working piston is connected to a piston rod and is arranged such that it can be moved within the damper tube. An interior space of the damper tube is divided by way of the working piston into a first working space and a second working space. The rebound stop arrangement includes an additional piston (30) which is attached to the piston rod and encloses the piston rod concentrically. A sleeve-shaped rebound stop receptacle is attached to the damper tube for receiving the additional piston in the rebound stage. The rebound stop arrangement has a spring element which is arranged at least partially within the rebound stop receptacle. The spring element is fastened to the additional piston.