Integrated Damper Bushing for Lower-Cost Rebound Cushioning
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Solution Overview
Problem
Conventional monotube damper assemblies require expensive, high-mass materials and complex manufacturing processes, leading to increased costs and a higher likelihood of component failure.
Innovation Solution
The integration of the bushing and cushioning device into a single, homogeneous material reduces the number of components and manufacturing steps, allowing for the use of inexpensive, lightweight materials like organic polymers and composites, which can be produced via simple processes such as injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional separate bushing and spring components are used, then functional performance is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent combines the bushing and spring into a single integrated component made from a viscoelastic polymer material. This merging eliminates the need for separate manufacturing and assembly processes for these two components, directly reducing manufacturing cost and complexity while maintaining their respective functions - the bushing provides friction reduction and the spring provides cushioning.
Solution Approach 2:
The integrated component performs multiple functions simultaneously: it acts as both a bushing (reducing friction between moving parts) and a spring (providing cushioning and energy absorption). This multi-functionality is achieved through the viscoelastic properties of the polymer material, which exhibits both elastic deformation (spring behavior) and friction-reducing characteristics (bushing behavior).
2Reliability
If expensive high-mass materials are used for bushing and spring, then durability is improved, but material cost and weight increase
Solution Approach 1:
The patent employs viscoelastic polymer materials that combine the beneficial properties of both elastic materials (for spring function) and friction-reducing materials (for bushing function). This composite material approach replaces traditional separate metal components, reducing weight while maintaining durability through the material's inherent shock absorption and wear-resistant properties.
Solution Approach 2:
The invention changes the material parameter from traditional metal materials to viscoelastic polymer materials. This parameter change enables the material to exhibit both elastic recovery (for cushioning) and low friction characteristics (for bushing function), achieving the same durability requirements with significantly reduced weight and cost.
3Ease of manufacture
If multiple separate components are assembled, then functional requirements are met, but assembly complexity and failure points increase
Solution Approach 1:
By merging the bushing and spring into a single monolithic component, the patent eliminates the assembly step required to join these parts. This reduction in assembly steps directly reduces manufacturing complexity and eliminates potential failure points at the interface between separate components, such as fasteners, adhesives, or interference fits.
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
This approach decreases material and manufacturing costs while minimizing the risk of component failure, enabling the production of durable and cost-effective fluid damper assemblies with improved lubrication distribution and reduced friction.
Implementation Method 1
The bushing and spring are integral with one another and of a homogeneous material... made of inexpensive, lightweight and strong materials... organic polymers and composites
Data Source
Figure 1
Figure 2~2A
Figure 3
AI summary
A fluid damper assembly (20) includes a housing (22) that defines a chamber (34). A rod (56) extends into the chamber (34) and is axially moveable relative to the housing (22). A bushing (70) is disposed about the rod (56) and is fixed relative to the housing (22) for guiding the rod (56) during the axial movement of the rod (56). A piston (66) is connected to the rod (56) and is disposed in axially sliding engagement with the housing (22) in the chamber (34) in a compression stroke and in a rebound stroke in response to relative movement between the rod (56) and the housing (22). A cushioning device (86) extends from the bushing (70) and biases the piston (66) toward the compression stroke for dampening movement of the piston (66) during the rebound stroke of the piston (66). The cushioning device (86) and the bushing (70) are integral with one another and of a homogeneous material. The fluid damper assembly provides for numerous advantages of reducing material and manufacturing costs, and reducing the likelihood of failure during operation.