Pre-assembled Piston Accumulator Insert for Damper
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Solution Overview
Problem
Current damper designs are bulky and costly due to the inclusion of a valve block providing mutual hydraulic connections, check valves, and a bulky accumulator, which increases the size and expense of the damper.
Innovation Solution
The damper design incorporates a floating piston accumulator and multiple external control valves mounted to a side collector, featuring an intake valve assembly, accumulator insert with a floating piston, and pressurized chamber, which eliminates the need for mechanical attachment of the intake valve assembly and allows for easier coating of the outer tube with high-temperature paint, reducing manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a valve block providing mutual hydraulic connections, check valves, and a bulky accumulator is included in the damper, then the damping control function is improved, but the damper size and cost increase
Solution Approach 1:
The damper is divided into separate functional modules: the accumulator is positioned externally rather than integrated into the valve block, and control valves are mounted on the outer tube rather than embedded in a central valve block. This segmentation allows each component to be optimized independently and reduces the overall damper volume by eliminating the need for a bulky integrated valve block.
Solution Approach 2:
The control valves are mounted on the outer surface of the outer tube in a radial arrangement, utilizing the external surface area rather than requiring internal space. This dimensional reorganization allows for effective damping control while maintaining a compact internal structure, reducing the overall damper volume.
2Reliability
If a valve block providing mutual hydraulic connections, check valves, and a bulky accumulator is included in the damper, then the damping control function is improved, but the damper cost increases
Solution Approach 1:
By segmenting the damper into separate modules (accumulator, control valves, valve assembly), each component can be manufactured independently using standard processes and then assembled. This reduces tooling costs and allows for economies of scale in manufacturing individual components, lowering the overall damper cost while maintaining full damping control functionality.
Solution Approach 2:
The outer tube serves multiple functions: it contains the damping fluid, provides mounting surfaces for control valves, and acts as a structural element. This multi-functionality reduces the number of separate components needed, simplifying manufacturing and reducing costs while maintaining effective damping control.
3Strength
If the intake valve assembly is mechanically attached to the outer tube, then the structural integrity is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The intake valve assembly is designed as a separate, modular component that can be independently manufactured and then attached to the outer tube. This segmentation allows for simplified manufacturing of each part using standard processes, reducing overall manufacturing complexity while maintaining structural integrity through proper attachment design.
4Reliability
If high-temperature paint coating is applied to the outer tube, then the corrosion resistance is improved, but seal compatibility issues arise
Solution Approach 1:
The outer tube is painted with corrosion-resistant coating before the seals are installed. This preliminary action allows the high-temperature paint to be applied without concern for seal damage, as the seals are added after the painting and curing process. This sequence eliminates seal compatibility issues while maintaining the corrosion resistance benefits of the coating.
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 design reduces manufacturing complexity and cost by eliminating the need for mechanical attachment and high-temperature seal compatibility issues, while maintaining effective damping performance through controlled fluid flow during compression and extension strokes.
Implementation Method 1
The pressurized chamber contains a pressurized fluid, such as a pressurized gas, which operates to bias the floating piston towards the intake valve assembly
Implementation Method 2
The floating piston is disposed inside the accumulator sleeve between the intake valve assembly and the closed end of the accumulator sleeve. The pressurized chamber is positioned longitudinally between the floating piston and the closed end of the accumulator sleeve
Implementation Method 3
The intake valve assembly includes one or more intake valves that control fluid flow through the intake valve assembly between the intermediate chamber(s) and the fluid transport chamber
Implementation Method 4
an accumulation chamber is positioned longitudinally between the intake valve assembly and the floating piston. The accumulation chamber is arranged in fluid communication with the collector chamber
Data Source
AI summary
A damper with inner and outer tubes and a piston disposed within the inner tube to define first and second working chambers. A fluid transport chamber is positioned between the inner and outer tubes. A collector chamber is positioned outside the outer tube. An intake valve assembly, abutting one end of the inner tube, is positioned inside the outer tube. An accumulator insert with an open end abutting the intake valve assembly is positioned inside the outer tube. The accumulator insert includes an accumulator sleeve, a floating piston, and a pressurized chamber. The floating piston is disposed inside the accumulator sleeve and the pressurized chamber is positioned between the floating piston and a closed end of the accumulator sleeve. An accumulation chamber is positioned between the intake valve assembly and the floating piston and the accumulator sleeve includes one or more apertures arranged in fluid communication with the collector chamber.