Double-Chamfered HCS Sleeve for Smoother Compression Stops

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Solution Overview

Problem

Conventional hydraulic compression stop sleeves in damper assemblies fail to effectively manage sudden increases in compressive force during the compression stroke, leading to jarring deceleration and requiring costly, high-strength materials for manufacturing.

Innovation Solution

A tubular hydraulic compression stop sleeve with radially inwardly extending ribs that guide the piston apart from the chamfer opening, reducing sudden compressive force and allowing for manufacturing using a pull broaching process without additional machining, thus reducing material costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If conventional hydraulic compression stop sleeves are used, then the damper assembly can provide compression stop function, but sudden increases in compressive force occur during compression stroke causing jarring deceleration

Engineering Contradiction:

Improvecompressive force managementVSAvoiddeceleration smoothness

Core Design Contradiction:

ForceVSEase of operation

Solution Approach 1:

The HCS sleeve incorporates a progressive compression stop mechanism where the piston travels through a curved path defined by the chamfer opening geometry. This dynamic path progression converts the sudden compressive force into a progressive force increase, allowing the damping force to build gradually rather than abruptly, thereby eliminating jarring deceleration while maintaining effective compression stop function

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The invention changes the geometric parameters of the HCS sleeve by providing a chamfer opening with specific angular orientation (e.g., 45 degrees) and progressive depth. This parameter change in the opening geometry creates a controlled progressive engagement path for the piston, transforming the force application characteristics from sudden to progressive, thus resolving the contradiction between force management and deceleration smoothness

Inventive Principle:

Principle #35Parameter changes

2Strength

If high-strength materials are used to withstand sudden compressive force increases, then the HCS sleeve can handle peak forces, but manufacturing costs increase

Engineering Contradiction:

Improvepeak force承受能力VSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The chamfer opening geometry is designed beforehand to progressively cushion the compression force. The angled chamfer surface creates a gradual engagement path that cushions the piston's entry into the HCS sleeve, distributing the peak force over a longer time period and reducing the instantaneous force spike. This allows the use of less expensive materials that can withstand the reduced peak forces

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The invention converts the potentially harmful sudden force spike into a beneficial progressive force application. By designing the chamfer opening to create progressive engagement, the harmful abrupt force increase is transformed into a beneficial controlled force progression, allowing standard materials to handle the loads effectively without requiring costly high-strength materials

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Manufacturing precision

If additional machining operations are performed on the HCS sleeve, then manufacturing precision can be improved, but manufacturing complexity and cost increase

Engineering Contradiction:

ImproveHCS sleeve dimensional accuracyVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The HCS sleeve is designed with the chamfer opening and progressive compression path built into the basic sleeve structure before any machining operations. The preliminary design of the chamfer geometry establishes the progressive compression characteristics in the raw or near-net-shape component, eliminating the need for subsequent complex machining operations to create the compression path, thus reducing manufacturing complexity while maintaining precision

Inventive Principle:

Principle #10Preliminary action

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 solution provides a progressive increase in damping force, reduces peak force generation, and simplifies manufacturing by using less expensive materials while preventing sudden compressive force increases, enhancing the performance and cost-effectiveness of damper assemblies.

Implementation Method 1

The HCS body defines a plurality of ribs extending radially inwardly from the chamfer opening and configured to guide the HCS piston apart from the chamfer opening as the HCS piston enters the HCS sleeve

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS20240280159A1Double chamfered hydraulic compression stop sleeve

Publication Date: 2024.08.22 BEIJING WEST IND CO LTD

AI summary

A damper assembly with a hydraulic compression stop (HCS) includes a tube defining an interior chamber. The damper assembly also includes a piston assembly slidably disposed in the tube. The piston assembly includes an HCS piston. The HCS piston includes a piston extension with a piston ring disposed thereupon. The damper assembly also includes an HCS sleeve. The HCS sleeve includes an HCS body having a tubular shape and defining a chamfer opening for receiving the HCS piston. The HCS body defines a plurality of ribs extending radially inwardly from the chamfer opening and configured to guide the HCS piston apart from the chamfer opening as the HCS piston enters the HCS sleeve.