Nested Multi-Stage Air Shock for Long Travel and Short Compression
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Solution Overview
Problem
Conventional shock absorbers for four-wheel drive vehicles have a limited travel range, making them inadequate for off-road environments, as their extended length is typically less than twice their compressed length, which complicates installation on production-based vehicles used in industries like construction and mining.
Innovation Solution
A multiple stage air shock design is developed, allowing for an extended length greater than twice the compressed length by using a series of interconnected shock units, where each unit's working tube serves as the shaft for the next, enabling a fully compressed shock to extend significantly, suitable for long travel requirements without protruding excessively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a single shaft shock absorber design is used, then the compressed length is short, but the extended length is less than twice the compressed length, limiting travel range
Solution Approach 1:
The shock absorber is divided into multiple independent stages, each with its own shaft and working tube. The first stage has shaft 14 and working tube 12, the second stage has shaft 18 and working tube 16, and so on. Each stage can compress and extend independently, allowing the overall shock to achieve extended length greater than twice the compressed length while maintaining a compact compressed size suitable for vehicle installation.
2Length of moving object
If long travel shock absorbers with 12+ inches shaft length are used, then off-road capability is improved, but compressed length becomes too long for production vehicle installation
Solution Approach 1:
The shock absorber employs a nested configuration where the second stage shaft 18 is received within the first stage working tube 12, the third stage shaft 22 is received within the second stage working tube 16, and so forth. This nesting arrangement allows multiple stages to be compacted into a small space when compressed, achieving a compressed length suitable for production vehicle installation while providing sufficient travel range when extended.
3Length of moving object
If multiple independent shock units are connected in series, then extended length increases, but device complexity increases
Solution Approach 1:
Each stage in the shock absorber uses the same basic components (shaft, working tube, piston, seals) that perform multiple functions. The shaft of one stage serves as both the moving element for that stage and the containing structure for the next stage. This multi-functionality reduces overall complexity despite having multiple stages, as each component serves dual purposes in the series configuration.
Data Source
AI summary
Disclosed herein is a process suitable for constructing a multiple stage air shock. The multiple stage air shock is unique among shocks in that the multiple stage design possesses qualities not available to other shock absorbers. The process includes a means for determining the compressed and extended lengths of the air shock based on the lengths of the parts for each stage. This means refers to one methodology and offers the air shock an extended length that is greater than twice its compressed length, an optimized extended length, and a construction capability based on adding stages. In particular, the extended length-compressed length relationship is a quality inherently unobtainable by current shock absorbers. The process also includes a means of determining the spring rate. This means refers to a second methodology and offers the capability to both set-up the air shock with a relatively linear spring rate and make the relatively linear spring rate more linear.