Monolithic Shock Body With Check Valves for Lower Assembly Cost
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Solution Overview
Problem
The manufacturing cost of mechanical assemblies, such as shock absorbers, is high due to the number of components involved, and existing 3D printing processes do not fully leverage their potential to reduce component count.
Innovation Solution
A shock absorber body assembly formed as a single component using a material additive manufacturing process, incorporating a cylinder cavity, a reservoir cavity, and fluid pathways with integrated check and adjustable valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional multi-component assembly processes are used for shock absorbers, then functional requirements can be met, but manufacturing cost and assembly complexity increase significantly
Solution Approach 1:
The patent combines multiple previously separate components (cylinder body, reservoir, fluid pathways, check valves, and adjustable valves) into a single monolithic structure formed by additive manufacturing. This merging eliminates the need for assembly of multiple parts, directly reducing manufacturing cost and assembly complexity while maintaining all required functions.
Solution Approach 2:
The single-component shock absorber body performs multiple functions simultaneously: it provides structural housing (cylinder and reservoir), contains fluid pathways for hydraulic fluid flow, incorporates check valves for directional flow control, and includes adjustable valves for damping control. This multi-functionality in a single component resolves the contradiction by eliminating the need for separate components for each function.
2Reliability
If multiple separate components are assembled to form the shock absorber body, then functional performance can be achieved, but manufacturing and assembly costs increase
Solution Approach 1:
By merging all functional elements into a single additive-manufactured component, the patent eliminates assembly operations and associated costs while maintaining functional integrity. The monolithic structure ensures reliable fluid pathways and valve operations without the risks of assembly errors or connection failures.
3Productivity
If conventional manufacturing processes are used for shock absorber assemblies, then standard components can be produced, but the number of parts and assembly steps significantly increases manufacturing complexity
Solution Approach 1:
The patent merges multiple components into a single additive-manufactured part, eliminating the need for assembly operations. This directly improves productivity by reducing the number of assembly steps from multiple component installations to a single component installation, while the complex internal features (fluid pathways, valves) are created during the additive manufacturing process itself rather than requiring post-assembly operations.
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 significantly reduces manufacturing costs and complexity, while the integrated valves enhance damping performance and adjustability.
Implementation Method 1
a first check valve disposed in line with the first fluid pathway, where the first check valve is configured to allow hydraulic fluid flow along the first fluid pathway in a first direction between the top and bottom portions of the cylinder cavity and prevent hydraulic fluid flow in a second direction flow along the first fluid pathway
Implementation Method 2
a first adjustable valve disposed in line with the second fluid pathway, where the first adjustable valve is configured to selective limit hydraulic fluid flow along the second fluid pathway between the top and bottom portions of the cylinder cavity
Data Source
AI summary
Disclosed herein are shock absorbers and shock body assemblies, that include a cylinder cavity having first and second fluid pathways each between a top portion and a bottom portion of the cylinder cavity. A first check valve is disposed in line with the first fluid pathway, wherein the first check valve is configured to (i) allow hydraulic fluid flow in a first direction between the top and bottom portions of the cylinder cavity and (ii) prevent the hydraulic fluid flow in a second direction that is opposite the first direction. In some instances, a second check valve is disposed in line with the second fluid pathway, wherein the second check valve is configured to (i) allow the hydraulic fluid flow in the second direction between the top cylinder end and the bottom cylinder end of the cylinder cavity and (ii) prevent the hydraulic fluid flow in the first direction.