Jounce Bumper Projection Layout for Soft Initial Compression
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Solution Overview
Problem
Existing spring elements for vehicle shock absorbers face challenges in achieving soft initial force absorption while maintaining progressive stiffness as deformation increases, which affects suspension comfort and safety.
Innovation Solution
A spring element with a base body and end portion featuring multiple projections of varying lengths along the circumference, where only a portion initially contacts the damper cap, reducing initial deformation resistance and progressively increasing stiffness as more projections engage, enhancing both softness and stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the spring element uses a uniform circumferential geometry, then the structural simplicity is maintained, but the initial deformation resistance cannot be softened while maintaining progressive stiffness
Solution Approach 1:
The end portion of the spring element is segmented into multiple projections (at least three) spaced apart circumferentially. Each projection has a distinct length, creating asymmetric contact points with the damper cap. This segmentation allows only a portion of the circumference to initially contact the damper cap, reducing initial deformation resistance while maintaining overall structural integrity.
Solution Approach 2:
The projections are designed with asymmetric lengths in the longitudinal direction, arranged such that lengths increase monotonously in the circumferential direction. This asymmetric geometry creates a progressive engagement mechanism where projections contact the damper cap sequentially during compression, enabling soft initial deformation that transitions to progressive stiffness as more projections engage.
2Ease of operation
If the spring element is designed for soft initial deformation, then suspension comfort is improved, but the progressive stiffness with increasing deformation is reduced
Solution Approach 1:
The spring element transitions from a static uniform geometry to a dynamic progressive engagement system. During compression, the asymmetric projections engage the damper cap sequentially, creating a dynamic force-travel characteristic. The monotonic increase in projection lengths ensures that as deformation progresses, more projections come into contact, dynamically increasing the deformation resistance and providing progressive stiffness.
Solution Approach 2:
The projections are pre-configured with distinct lengths arranged in monotonic order around the circumference, preparing the spring element for progressive engagement before compression begins. This preliminary asymmetric configuration ensures that during initial compression, only the shortest projection contacts the damper cap first, providing soft initial deformation, while longer projections are positioned to engage sequentially as compression increases.
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 design reduces initial deformation resistance and progressively increases compression resistance, improving the spring element's ability to absorb forces effectively, thereby enhancing vehicle suspension comfort and safety.
Implementation Method 1
the base body being elastically deformable between an uncompressed basic state and a compressed state in which the base body is at least partially compressed in the direction of the longitudinal axis, thereby dissipating energy by deforming
Data Source
AI summary
A spring element, in particular a jounce bumper, for a vehicle shock absorber contains a longitudinal axis, a base body extending along the longitudinal axis, and an end portion configured for contact against a damper cap of the vehicle shock absorber. The base body is elastically deformable between an uncompressed basic state and a compressed state in which the base body is at least partially compressed in the direction of the longitudinal axis. The end portion contains at least three projections that are spaced apart from one another in a circumferential direction, and protrude from the base body in the direction of the longitudinal axis. Each of the projections has a distinct length in the direction of the longitudinal axis, and the projections are arranged along the circumference of the end portion such that the lengths of the projections increase monotonously in the circumferential direction.