Hydraulic Rebound Stop Damper With Bypass Valve for High Pressure
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Solution Overview
Problem
Existing vibration dampers with hydraulic rebound stops are expensive to manufacture and prone to damage, especially under high pressures, due to precise manufacturing tolerances required for components to compensate for transverse forces on the piston rod.
Innovation Solution
A vibration damper design featuring a rebound stop arrangement with a rebound stop piston and sleeve, incorporating a bypass channel and valve device that allows for adjustable flow cross-sections, ensuring reliable damping across varying pressures while minimizing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If precise manufacturing tolerances are used for rebound stop components, then transverse forces on the piston rod are compensated, but manufacturing costs increase significantly
Solution Approach 1:
The invention changes the geometric parameters of the rebound stop components, specifically designing the rebound stop piston with a larger diameter than the rebound stop chamber, creating intentional gaps (e.g., 0.5-2mm) between the piston and chamber walls. This parameter change eliminates the need for precise manufacturing tolerances while maintaining reliable damping performance through the controlled clearance design.
2Reliability
If traditional rebound stop design is used, then damping is provided, but the arrangement is prone to damage under high pressures
Solution Approach 1:
The invention segments the rebound stop function into multiple components: the rebound stop piston, rebound stop chamber, and bypass channel. The bypass channel provides an alternative fluid path that prevents excessive pressure buildup, protecting the rebound stop arrangement from damage while maintaining the damping function. This segmentation allows the system to handle high pressures without compromising the integrity of the rebound stop components.
3Ease of manufacture
If fixed flow resistance is used in rebound stop, then simple design is achieved, but damping performance cannot be adjusted for varying pressures
Solution Approach 1:
The invention introduces a dynamic element by making the rebound stop piston movable rather than fixed. The piston can move axially within the rebound stop chamber, automatically adjusting the flow resistance through the bypass channel based on the applied pressure. This dynamic design allows the system to adapt to varying pressure conditions without complex control mechanisms, maintaining optimal damping performance across different operating conditions.
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 design provides reliable damping at high pressures while reducing production costs by allowing for adjustable flow resistance, thus preventing damage and maintaining effective performance.
Implementation Method 1
The rebound stop piston has a bypass channel for fluidically connecting the piston-rod-side working chamber to the rebound stage working chamber
Implementation Method 2
A valve device is arranged in the rebound stop piston hydraulically in parallel to the bypass channel
Implementation Method 3
The rebound stop piston separates off a rebound stage working chamber within the rebound stop sleeve
Data Source
AI summary
A vibration damper for a vehicle comprises a damper tube filled with hydraulic fluid, a working piston which is connected to a piston rod and arranged within the damper tube so as to be movable back and forth, wherein the interior of the damper tube is divided by the working piston into a first working chamber and a second working chamber, a closure assembly which fluid-tightly closes off the damper tube at the piston rod side, a rebound stop arrangement having a rebound stop piston, which is mounted on the piston rod, and a rebound stop sleeve for receiving the rebound stop piston in the rebound stage, wherein the rebound stop piston separates off a rebound stage working chamber within the rebound stop sleeve, and wherein the rebound stop piston has a bypass channel for fluidically connecting the piston-rod-side working chamber to the rebound stage working chamber, wherein a valve device is arranged in the rebound stop piston hydraulically in parallel to the bypass channel.