Jounce Bumper Flexible Striker Cap Insert Design
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Solution Overview
Problem
Current suspension systems face challenges in managing impact loads effectively, leading to the need for heavier, more rugged vehicle components due to the limited energy absorption of traditional jounce bumper assemblies, which compromises driving comfort and controllability.
Innovation Solution
A jounce bumper system with a flexible striker cap and an insert positioned between the flexible and rigid striker caps, enhancing energy absorption and durability by allowing additional deformation during impact events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid metallic striker plate is used in the jounce bumper assembly, then structural strength is improved, but energy absorption capacity deteriorates
Solution Approach 1:
The striker cap is designed with non-uniform wall thickness, featuring a thicker first wall portion and a thinner second wall portion. This local quality variation allows different regions of the same component to serve different functions: the thicker first wall provides structural strength while the thinner second wall enhances energy absorption through controlled deformation during impact events.
Solution Approach 2:
The jounce bumper assembly combines multiple materials with different properties: a rigid metallic striker plate for structural support, a flexible striker cap (thermoplastic or thermosetting elastomeric polymer) for energy absorption, and a jounce bumper (polymer or foam material). This composite material approach allows the assembly to simultaneously achieve structural strength and energy absorption capacity.
2Reliability
If heavier, more rugged vehicle components are used to manage impact loads, then reliability is improved, but weight increases
Solution Approach 1:
The flexible striker cap is designed with variable wall thickness parameters, creating regions of different structural rigidity. The thinner second wall portion allows for controlled deformation and energy absorption, while maintaining overall component reliability. This parameter optimization enables effective impact load management without requiring heavier materials.
Solution Approach 2:
The flexible striker cap acts as an intermediary element between the rigid striker plate and the jounce bumper. It mediates the impact forces by deforming in a controlled manner, absorbing energy that would otherwise be transmitted to the rigid components and vehicle chassis, thereby improving reliability without increasing weight.
3Loss of energy
If the striker cap is made more flexible to increase energy absorption, then energy absorption capacity is improved, but structural strength deteriorates
Solution Approach 1:
The striker cap incorporates local quality variations through non-uniform wall thickness distribution. The first wall portion is thicker to maintain structural strength, while the second wall portion is thinner to enable flexible deformation and energy absorption. This spatial differentiation of material properties resolves the contradiction between strength and flexibility.
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 system increases energy absorption by up to 50 Joules, improving the durability and performance of the suspension components while enabling the use of lighter materials without compromising driving comfort or controllability.
Implementation Method 1
The flexible striker cap is spaced apart from the second end of the jounce bumper in a first position and contacts the second end in a second position. During impact events, the flexible striker cap deforms to allow additional deformation of the jounce bumper, thereby increasing energy absorption.
Implementation Method 2
The flexible striker cap defines a cavity and an insert is received within the cavity. The insert positioned between the flexible and rigid striker caps enhances energy absorption by allowing additional deformation during impact events, increasing the system's capacity to absorb up to 50 Joules of energy.
Data Source
AI summary
Apparatus are provided for a jounce bumper system for use with a damper. The jounce bumper system includes a first mount and a jounce bumper having a first end coupled to the first mount and a second end. The jounce bumper system includes a flexible striker cap spaced apart from the second end of the jounce bumper in a first position. The flexible striker cap includes a first surface in contact with the second end in a second position and defines a cavity opposite the first surface. The jounce bumper system further includes an insert received within the cavity.