Hydraulic Jounce Bumper Piston Layout for Higher Stroke Efficiency
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Solution Overview
Problem
Existing hydraulic jounce bumper designs face challenges in compactness due to limited space in vehicle or bike suspension systems, leading to compromises in stroke and overall length, and issues with thread lockers breaking off and internal floating piston travel limitations.
Innovation Solution
The design incorporates a new piston with internal threads that eliminate the need for an intermediate post, reducing dead length and allowing for increased stroke, along with a side oil fill and shorter negative spring to further minimize dead length and enhance packaging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a conventional piston with intermediate post is used, then the assembly is straightforward, but the dead length increases and stroke is reduced
Solution Approach 1:
The patent removes the intermediate post component from the conventional piston assembly. By integrating the threading directly into the piston body, the design eliminates the separate post element, thereby reducing the overall dead length and increasing the effective stroke of the jounce bumper.
Solution Approach 2:
The patent combines the functions of the intermediate post and the piston into a single integrated piston structure. The piston body directly incorporates the threading that previously required a separate post, merging multiple components into one and reducing the total length occupied by non-active elements.
2Reliability
If thread lockers are used on interrupted threads, then assembly is secured, but thread lockers can break off and create debris
Solution Approach 1:
The patent eliminates the need for thread lockers by removing the interrupted threading design. With continuous threads and no intermediate post, the assembly secures the piston without requiring additional locking mechanisms, thereby preventing thread locker failure and debris generation.
Solution Approach 2:
The patent uses the piston body itself as the intermediary structure that provides both the threading and the structural integrity needed for secure assembly, eliminating the need for separate thread locker intermediaries that can fail and create debris.
3Productivity
If the internal floating piston travel is limited, then the overall length is controlled, but the stroke efficiency is reduced
Solution Approach 1:
The patent removes the constraints that previously limited internal floating piston travel. By eliminating the intermediate post and reconfiguring the piston assembly, the design allows the internal floating piston to travel further, increasing stroke efficiency without proportionally increasing the overall length.
4Volume of moving object
If space in suspension system is limited, then packaging is compact, but stroke and overall length must be compromised
Solution Approach 1:
The patent removes the intermediate post and reduces the negative spring length, extracting unnecessary volume from the assembly. This enables more efficient packaging within limited suspension space while maintaining or increasing the effective stroke through the integrated piston design.
Solution Approach 2:
The patent employs a nested arrangement where the piston is integrated within the damper body, and the shaft telescopes within the damper assembly. This nested configuration maximizes packaging efficiency by minimizing the external envelope while preserving internal stroke capacity.
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 solution reduces the overall dead length, increases the internal floating piston travel, and improves packaging efficiency, while also simplifying the manufacturing process and reducing the risk of thread locker debris.
Implementation Method 1
a compression chamber (132) defined within the damper body (112) and in fluid communication with an interior of the shaft (102) through a first set of compression ports (222)
Implementation Method 2
a rebound chamber (230) in fluid communication with the compression chamber (132) through a second set of rebound ports (223)
Implementation Method 3
negative spring (108) disposed between the shaft (102) and the damper body (112)
Data Source
AI summary
Disclosed herein is a hydraulic jounce bouncer comprising a damper body, a shaft telescopically engaged with the damper body, a piston slidably disposed within the damper body and threadedly coupled to a first end of the shaft, wherein the piston has at least one compression port therethrough, and a negative spring disposed between the shaft and the damper body.