Hydraulic Rebound Stop Damper Assembly for Harshness Reduction
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Solution Overview
Problem
Existing hydraulic rebound stop features in suspension systems do not completely eliminate impact harshness, leading to mechanical wear and tear and an unpleasant riding experience, despite efforts to improve damping force.
Innovation Solution
A damper assembly with a hydraulic rebound stop mechanism featuring a cylindrical tube, a movable piston with a piston rod, a rebound stop, and a rebound spring, which compresses when the rebound stop contacts the piston, enhancing damping force and reducing harsh rebound movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If prior art HRS features (additional piston in secondary cylinder or piston ring engagement) are used to increase damping force during rebound, then impact harshness at full extension is reduced, but mechanical wear and tear persists and unpleasant disruptions to riding experience continue
Solution Approach 1:
The rebound stop mechanism is segmented into distinct functional components: a rebound stop element on the piston rod, a rebound spring, and a rebound stop chamber. This segmentation allows each component to perform its specific function independently, reducing mechanical wear by distributing forces across separate elements rather than concentrating wear at a single contact point between piston and cylinder wall.
Solution Approach 2:
The rebound spring is positioned to engage the rebound stop element before the piston reaches full extension. This beforehand cushioning compresses the spring progressively as the piston approaches end-of-travel, absorbing impact energy before it can cause harsh mechanical contact and wear between the piston rod and cylinder wall.
2Object-affected harmful factors
If prior art HRS features are used to increase damping force, then rebound impact is reduced, but complete elimination of harshness is not achieved
Solution Approach 1:
The rebound stop chamber is filled with hydraulic fluid that provides progressive resistance as the piston approaches full extension. This hydraulic damping works in conjunction with the mechanical rebound spring to create a smooth, progressive deceleration of the piston, completely eliminating harsh rebound impact by distributing the stopping force over a longer distance and time period.
Solution Approach 2:
The invention merges multiple damping mechanisms into a unified rebound stop system: the mechanical rebound spring provides initial progressive resistance, while the hydraulic fluid in the rebound stop chamber provides additional viscous damping. This combination of mechanical and hydraulic elements achieves complete elimination of harsh rebound impact that neither mechanism could achieve alone.
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 improved longevity of operational life and further reduces unpleasant harsh rebound movements by effectively managing the rebound process through a tuned rebound spring and hydraulic rebound stop mechanism.
Implementation Method 1
A rebound spring pushes the HRS piston from a direction of the first end of the piston towards the rebound stop
Implementation Method 2
The piston rod is slidable within the HRS piston in the rebound direction until the rebound stop contacts the HRS piston and causes the rebound spring to compress
Data Source
AI summary
A damper assembly for a suspension system of an associated vehicle. The damper assembly comprises a cylindrical tube extending along an axis and defining a chamber. A piston is located in the chamber and is moveable along the axis in a compression direction and a rebound direction. The piston includes a piston rod extending from a first end to a piston head. A rebound stop is located on the piston rod between the first end and the piston head. A hydraulic rebound stop (“HRS”) piston is located in a HRS chamber. A rebound spring biasing the HRS piston towards the adaptor plate in the HRS chamber. The piston rod is slideably received within the HRS piston in the rebound direction until the rebound stop contacts the rebound head and causes the rebound spring to compress.