Hydraulic Compression Stop Structure for Simpler Vibration Dampers
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Solution Overview
Problem
Existing vibration dampers with hydraulic compression stops have complex structural designs that complicate production and require additional working steps for connection, leading to increased production costs and potential instability.
Innovation Solution
A vibration damper design featuring a pressure sleeve with an encircling centering ring and a plastic-coated base, where the pressure sleeve and base are connected via a web, simplifying the connection process through plastic injection molding and optimizing structural stability with a conical supporting ring and radial ribs, allowing for unobstructed flow of damping medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pressure sleeve and base are connected via a bayonet thread or central rivet element, then the connection is secure, but the production process becomes more complicated and requires additional working steps
Solution Approach 1:
The patent merges the pressure sleeve and base into a single integrated component made entirely of plastic through injection molding. The pressure sleeve, base, and connecting elements are formed as one piece, eliminating the need for separate connection operations such as bayonet threading or riveting. This integration maintains connection stability while dramatically simplifying the production process.
Solution Approach 2:
The injection molding process itself creates the connection between the pressure sleeve and base without requiring additional assembly steps. The plastic material is molded to form both the structural components and their interconnections simultaneously, making the manufacturing process self-sufficient and eliminating auxiliary working steps.
2Ease of manufacture
If the pressure sleeve is completely manufactured from plastic with simple connection methods, then the production is simplified, but the pressure stability may be compromised
Solution Approach 1:
The patent uses a single plastic material to create a composite structure that combines the functions of the pressure sleeve, base, and connecting elements. This monolithic plastic construction provides sufficient pressure stability for the application while maintaining ease of manufacture through injection molding, eliminating the need for complex multi-material assemblies.
Solution Approach 2:
The patent employs curved and rounded geometric forms in the pressure sleeve and base design, which distribute stress more effectively throughout the plastic structure. The curved contours enhance the structural integrity of the molded parts, ensuring pressure stability is maintained despite the simplified single-material construction.
3Device complexity
If flat bottoms are used for the pressure cylinder, then the structure is simple, but the connection requires additional working steps and may be less stable
Solution Approach 1:
The patent combines the bottom surfaces of the pressure sleeve and base into a single molded feature that provides both structural support and connection functionality. The injection molding process creates an integrated bottom structure that eliminates the need for separate connection operations while maintaining structural simplicity.
Data Source
AI summary
A vibration damper having a hydraulic compression stop includes: a cylinder filled with a damping medium; a piston rod guided in the cylinder the cylinder having a first piston fastened to the piston rod and slidable on an inner wall of the cylinder; and a second piston arranged on the piston rod at an axial distance from the first piston the second piston being slidable in a pressure cylinder. The pressure cylinder is formed with respect to the cylinder by a separate plastic pressure sleeve having a bottom, and the bottom of the pressure sleeve and a coating surface of the base on a side of the base facing away from the pressure sleeve are connected to each other via at least one web.