Monolithic Shock Body With External Bypass Paths for Compact Damping
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Solution Overview
Problem
The manufacturing of shock absorbers is costly due to the assembly of multiple components, which can lead to errors, size constraints limit performance, and components can degrade or fail, resulting in inadequate damping for various impact forces.
Innovation Solution
A shock absorber body assembly formed as a single component via additive manufacturing, featuring integrated fluid pathways, check valves, adjustable valves, and a raised cooling pattern, reducing complexity and improving damping efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple components are assembled together to manufacture shock absorbers, then functional requirements can be met, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent merges multiple separate components (cylinder, bypass circuit, check valves, adjustable valve, cooling features) into a single monolithic structure manufactured via additive manufacturing. The bypass circuit is integrated directly into the cylinder wall with fluid pathways extending through the wall, eliminating the need for separate bypass assemblies and reducing the total component count while maintaining all necessary shock absorption functions.
Solution Approach 2:
The cylinder structure serves multiple functions simultaneously: it contains the hydraulic fluid, provides structural support, incorporates the bypass circuit for fluid flow, houses check valves for directional control, includes adjustable valves for damping control, and features integrated cooling channels for thermal management. This multi-functionality reduces the need for separate dedicated components.
2Reliability
If multiple components are assembled together, then functional requirements can be met, but manufacturing cost increases due to assembly processes
Solution Approach 1:
The patent combines multiple functional elements into a single additive manufacturing process, eliminating costly assembly operations including welding, sealing, and component installation. The monolithic structure requires only post-processing operations, significantly reducing labor costs and assembly-related errors while maintaining functional performance.
Solution Approach 2:
The patent replaces traditional mechanical assembly processes (welding, bolting, sealing) with additive manufacturing processes that create integrated structures in a single build operation. This substitution eliminates the need for post-assembly joining operations and reduces manufacturing complexity.
3Ease of operation
If size constraints are applied to shock absorbers, then installation requirements are met, but performance is limited
Solution Approach 1:
The patent utilizes the third dimension (vertical direction) by implementing a monolithic structure with integrated bypass circuits that extend through the cylinder wall. This allows complex fluid pathways to be created within the available footprint, achieving full damping performance without increasing the shock absorber's external dimensions beyond installation constraints.
Solution Approach 2:
The patent segments the fluid flow path into multiple pathways (main cylinder pathway and integrated bypass pathways) that operate simultaneously. This segmentation allows the shock absorber to provide progressive damping across different impact forces while maintaining a compact overall size, as each pathway can be optimized for specific flow conditions.
4Productivity
If traditional manufacturing processes are used, then production can proceed, but thermal management is inadequate
Solution Approach 1:
The patent merges the cooling function directly into the cylinder structure by integrating cooling channels within the cylinder wall. This eliminates the need for separate external cooling systems and provides continuous thermal management as part of the shock absorber's core structure, effectively dissipating heat generated during operation.
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 single-component design reduces manufacturing costs, enhances damping performance across varying impact forces, and improves thermal management, resulting in a more efficient and durable shock absorber.
Implementation Method 1
a raised cooling pattern proud of an exterior of the cylinder... configured to provide for heat transfer from hydraulic fluid within the cavity of the cylinder to an environment external to the shock absorber body assembly
Implementation Method 2
a check valve disposed in line with the first fluid pathway, the check valve configured to allow hydraulic fluid flow in a first direction between the top and bottom portions of the cylinder and prevent hydraulic fluid flow in a second direction
Data Source
AI summary
A shock absorber body assembly includes a shock body that is formed of a single component. The shock body includes a cylinder and a plurality of fluid pathways extending along an exterior of the cylinder. Each of the fluid pathways defines a respective first end of the fluid pathway in fluid communication with a top portion of the cylinder and a respective second end of the fluid pathway in fluid communication with a bottom portion of the cylinder. The plurality of fluid pathways includes a first fluid pathway and a second fluid pathway, where the first fluid pathway and the second fluid pathway have differing lengths or positions lengthwise along the exterior of the cylinder.