Integrated Hydraulic Bump Stop Assembly for Shock Bottoming Control
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Solution Overview
Problem
Conventional shock absorbers with integrated bump stops made of rubber or urethane dissipate energy into suspension rebound, causing stress and offering little damping, while separate hydraulic bump stops are costly, labor-intensive, and not integrated with the shock absorbers, leading to potential damage and an uncomfortable ride.
Innovation Solution
A hydraulic bump stop assembly featuring a telescoping hydraulic cylinder with an outer and inner coaxial cylinder, where the inner cylinder slides within the outer, creating a damping effect through fluid communication and adjustable orifices to control damping ratios, integrated with the shock absorber to prevent bottoming out.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional rubber or urethane bump stops are used, then the shock absorber is protected from bottoming out, but energy is dissipated into suspension rebound causing stress on the shock and offering little damping
Solution Approach 1:
The patent replaces conventional rubber or urethane bump stops with a hydraulic bump stop assembly that uses hydraulic fluid and orifices to provide damping. The hydraulic system dissipates energy through fluid resistance rather than elastic rebound, reducing stress on the shock absorber while maintaining protection from bottoming out.
Solution Approach 2:
The patent incorporates adjustable orifices that can be modified to change damping ratios. This allows the hydraulic system to adapt its energy dissipation characteristics, providing customizable damping levels to optimize both protection and energy management based on specific application requirements.
2Loss of energy
If separate hydraulic bump stops are used, then effective damping is achieved, but additional space is required and installation becomes more complex and costly
Solution Approach 1:
The patent integrates the hydraulic bump stop assembly directly with the shock absorber by coupling the telescoping hydraulic cylinder to the shock body. This merging of functions eliminates the need for separate mounting operations, reduces installation complexity, and lowers overall system cost while maintaining effective damping performance.
Solution Approach 2:
The integrated design allows the shock absorber assembly to perform multiple functions: primary shock absorption and secondary bump stopping with adjustable damping. This multi-functionality reduces the number of separate components needed and simplifies the overall suspension system architecture.
3Loss of energy
If separate hydraulic bump stops are used, then damping is provided, but additional labor and material costs are incurred
Solution Approach 1:
By integrating the hydraulic bump stop assembly with the shock absorber as a single unit, the patent reduces the total number of parts that need to be manufactured and assembled. This consolidation lowers material costs, reduces assembly labor, and simplifies quality control processes while delivering the same damping performance.
4Device complexity
If conventional bump stops are used, then simple structure is maintained, but rebound control is insufficient causing uncomfortable ride
Solution Approach 1:
The patent employs hydraulic fluid and orifices to create a damping system that controls rebound motion more effectively than solid rubber or urethane bump stops. The fluid resistance provides progressive damping that smooths out suspension movements, improving ride comfort while maintaining a relatively simple overall structure.
Solution Approach 2:
The adjustable orifices allow the damping characteristics to be optimized for different ride comfort requirements. By modifying orifice size or configuration, the system can be tuned to provide appropriate rebound control while maintaining structural simplicity.
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 telescoping hydraulic cylinder provides effective damping during compression and expansion, preventing shock absorber bottoming out, reducing stress on components, and allowing adjustable damping ratios for improved ride comfort and safety.
Implementation Method 1
Oil is used inside and moves through orifices much like a standard shock. This allows the bump to effectively dampen, or slow, the suspension movement through its final inches of travel.
Implementation Method 2
hydraulic fluid is expelled from or drawn into the telescoping cylinder, respectively, through at least one orifice between the telescoping cylinder and at least one hydraulic fluid line
Data Source
AI summary
Embodiments of a hydraulic bump stop assembly may include a telescoping hydraulic cylinder containing hydraulic fluid. The telescoping cylinder may be located on a vehicle shock. Components of the shock may engage and compress the telescoping cylinder during the final stages of compression of the shock to prevent the shock from bottoming out. The telescoping cylinder has damping properties during compression and expansion due to hydraulic fluid being forced through orifices of one or more hydraulic fluid lines to and from a reservoir. Damping ratios may be adjusted by adjusting the size of the orifices. In some embodiments, the damping ratios may be adjusted remotely, such as from the driver compartment of the vehicle.