Main Piston Boost Valve for Large-Cylinder Damper Flow
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Solution Overview
Problem
Vehicle suspension dampers with electronic main piston valves face reduced operational characteristics when used in larger diameter cylinders due to the inability of the valve to handle increased oil flow, resulting in inhibited movement and reduced damping force.
Innovation Solution
The integration of a boost valve, which provides a second parallel flow path and amplifies damping force by clamping down on valve shims during compression, allowing the electronic main piston valve to function effectively in larger diameter cylinders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If an electronic main piston valve is used in a larger diameter cylinder, then the damper can handle larger diameter applications, but the valve cannot move through the larger column of oil effectively, reducing damping force and operational characteristics
Solution Approach 1:
The boost valve is positioned within the electronic main piston valve assembly, with the boost valve body surrounding the electronic main piston valve. The boost valve nested within the electronic valve creates a combined valving system that handles the larger oil column in larger diameter cylinders while maintaining effective damping control.
Solution Approach 2:
The boost valve acts as an intermediary component that mediates between the electronic main piston valve and the larger oil column. By introducing this intermediate valving stage, the system can effectively manage the increased oil volume in larger diameter cylinders without compromising damping force generation.
2Quantity of substance
If the electronic main piston valve size is increased to handle larger oil flow, then the valve can function in larger diameter cylinders, but the device complexity increases
Solution Approach 1:
Rather than using a single large complex valve, the patent nests a boost valve within the existing electronic main piston valve assembly. This nested configuration allows the system to handle increased oil flow capacity while reusing the electronic valve body and control mechanisms, thereby limiting the increase in overall device complexity.
Solution Approach 2:
The valving function is segmented into two separate valves: the electronic main piston valve and the boost valve. This segmentation allows each valve to be optimized for its specific function while working together to handle the total oil flow requirement, distributing the complexity across multiple simpler components rather than one complex valve.
3Force
If a boost valve is added to amplify damping force, then the electronic main piston valve can function effectively in larger diameter cylinders, but the device complexity increases
Solution Approach 1:
The boost valve is nested within the electronic main piston valve assembly, sharing the same valve body and integration points. This nested arrangement amplifies damping force through the combined action of both valves while minimizing the increase in device complexity by utilizing the existing structural framework.
Solution Approach 2:
The boost valve and electronic main piston valve are merged into a single integrated assembly that functions as a unified valving system. This combining of functions allows the system to achieve enhanced damping force while presenting a compact, integrated solution rather than separate complex components.
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 boost valve configuration increases the damping force range and operational characteristics of the electronic main piston valve, enabling its use in larger diameter cylinders while maintaining or improving damping performance.
Implementation Method 1
the boost valve clamps down on valve shims during compression
Implementation Method 2
the boost valve clamps down on valve shims during compression
Implementation Method 3
provides a second parallel flow path
Data Source
AI summary
A vehicle damper assembly is disclosed. The damper includes a cylinder having an inner diameter (ID). A rod and a piston, the piston coupled to the rod and configured to divide the cylinder into a compression side and a rebound side. An electronic valve assembly including an electronic valve body coupled with the rod on the compression side of the piston. The electronic valve body having an electronic valve body outer diameter (OD). A boost valve having a boost valve body, a boost valve area located between the electronic valve body and the boost valve body, the boost valve having a boost valve OD. The boost valve OD is larger than the electronic valve body OD, such that the boost valve is configured to allow the electronic valve assembly to operate within said cylinder ID that is too large for the electronic valve body OD.