Flexible Floating Disc Damper for NVH Reduction
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Solution Overview
Problem
Existing shock absorbers provide the same magnitude of damping force regardless of the stroke length, leading to noise, vibration, and harshness issues due to pressure waves generated during varying vehicle maneuvers.
Innovation Solution
A damper system with a stroke-dependent damper assembly featuring a flexible floating disc that adjusts damping based on stroke length, using tapered cavities and strategically placed holes to control fluid flow and reduce pressure waves, providing a 'soft, hydraulic stop' for smoother operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a stroke dependent damper assembly with resilient travel stops is used to provide different damping forces during small and large strokes, then multi-force damping capability is improved, but pressure waves are generated that can vibrate the piston rod and cause noise
Solution Approach 1:
The patent employs a flexible floating disc made of elastomeric material that flexes during compression and rebound strokes. This flexible disc replaces the traditional resilient travel stops and acts as a compliant element that absorbs pressure waves through elastic deformation, thereby reducing noise and vibration while maintaining the stroke-dependent damping capability. The flexible disc is biased by a spring to maintain contact with the piston rod, ensuring continuous damping adjustment.
Solution Approach 2:
The flexible floating disc serves as an intermediary element between the piston rod and the resilient travel stops. It mediates the interaction by absorbing and dampening pressure waves through its elastic properties, preventing direct transmission of harmful vibrations to the piston rod while still allowing the stroke-dependent damping function to operate effectively.
2Device complexity
If the same magnitude of damping force is provided regardless of stroke length, then device simplicity is maintained, but ride comfort and handling characteristics deteriorate during varying vehicle maneuvers
Solution Approach 1:
The patent implements a dynamic damping system where the damping force automatically adjusts based on the stroke length. The flexible floating disc moves axially relative to the piston rod, changing its position and flexing characteristics during compression and rebound strokes. This dynamic adjustment provides soft damping during small strokes for ride comfort and firm damping during large strokes for handling stability, without requiring complex external control systems.
Solution Approach 2:
The stroke-dependent damping adjustment occurs automatically through the mechanical interaction between the flexible floating disc, spring bias, and resilient travel stops. The system self-regulates the damping force based on the instantaneous stroke length, eliminating the need for external sensors, actuators, or control electronics, thus maintaining relative system simplicity while achieving adaptive performance.
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 system achieves improved noise, vibration, and harshness reduction by varying damping force with stroke length, reducing pressure waves and allowing for a more comfortable ride and increased travel distance within a given shock absorber length.
Implementation Method 1
The flexible floating disc is made of a resilient material such that the flexible floating disc is adapted to flex into the proximal tapered cavity when the flexible floating disc makes contact with the proximal chamber surface
Implementation Method 2
By controlling the fluid flow between the two working chambers, a pressure drop is built up between the two working chambers. Because the compression valving and the rebound valving each has the ability to limit the flow of hydraulic fluid, the shock absorber is able to produce damping forces that counteract oscillations/vibrations
Data Source
AI summary
A damper system for a vehicle including a pressure tube, piston assembly, and stroke dependent damper assembly. The stroke dependent damper assembly is coupled to a piston rod at a position below the piston assembly. The stroke dependent damper assembly includes a disc chamber that slidably receives a flexible floating disc. The disc chamber has proximal and distal chamber surfaces, which can include holes. The flexible floating disc is moveable between a first position where it contacts the proximal chamber surface and a second position where it contacts the distal chamber surface. The proximal chamber surface defines a proximal tapered cavity and the distal chamber surface defines a distal tapered cavity. The flexible floating disc is resilient and can flex into the proximal tapered cavity or the distal tapered cavity when it makes contact with the proximal chamber surface or the distal chamber surface.