Shock Absorber Outer Tube Slot for Force Distribution
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Solution Overview
Problem
Shock absorbers in vehicle suspension systems face increased operational forces, particularly in hybrid-electric and battery-electric vehicles, leading to higher costs, complexity, and size issues due to existing solutions that enhance material thickness and quality to withstand these forces.
Innovation Solution
The design incorporates an elongated slot in the outer tube to distribute forces across a larger area, allowing for thinner tubes and a simpler design, along with an electronic control unit to adjust damping levels dynamically, reducing the overall size and weight of the shock absorber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If material thickness and material type are increased to withstand operational forces, then strength is improved, but cost and weight increase
Solution Approach 1:
The patent introduces a force distribution mechanism that spreads loads across multiple dimensions within the shock absorber structure. The force distribution mechanism includes multiple reaction members arranged in different orientations, distributing forces across the outer tube in multiple directions rather than concentrating them at single points, thereby reducing the required material thickness while maintaining strength
Solution Approach 2:
The force distribution mechanism segments the force-bearing function into multiple reaction members instead of relying on a single thick-walled tube. Each reaction member handles specific force components, allowing the outer tube to be thinner while the collective arrangement provides the necessary strength to withstand operational forces
2Strength
If material thickness and material type are increased to withstand operational forces, then strength is improved, but device complexity increases
Solution Approach 1:
The outer tube serves multiple functions: it contains the working fluid, provides structural support, and acts as a mounting surface for the force distribution mechanism. The reaction members simultaneously provide structural support and guide the working fluid flow. This multi-functionality reduces the need for additional specialized components that would increase complexity
3Reliability
If additional components are added to withstand forces and control fluid flow, then reliability is improved, but device complexity increases
Solution Approach 1:
The force distribution mechanism is integrated directly into the outer tube structure, with reaction members mounted on the outer tube that serve both structural and fluid guidance functions. The valve assembly is combined with the force distribution mechanism, allowing the same components to handle both mechanical loads and fluid control, thereby improving reliability without proportionally increasing complexity
4Strength
If tube thickness is increased to withstand operational forces, then strength is improved, but volume increases
Solution Approach 1:
The force distribution mechanism distributes loads across the outer tube surface in multiple directions, utilizing the available surface area more efficiently. This allows the use of thinner tube walls since the distributed loads create lower stress concentrations, thereby reducing the overall volume of the shock absorber while maintaining strength
Solution Approach 2:
The reaction members are positioned at specific locations on the outer tube where forces are most critical, providing localized reinforcement rather than requiring uniform thickening of the entire tube. This selective reinforcement approach maintains strength where needed while keeping the overall tube volume minimized
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 configuration effectively manages operational forces, reduces the size and weight of the shock absorber, and continuously adjusts damping to improve vehicle ride quality and handling across varying road conditions.
Implementation Method 1
The elongated slot distributes forces across a larger area
Implementation Method 2
A valve fluidly connects the intermediate chamber and the reserve chamber
Implementation Method 3
Shock absorbers in vehicle suspension systems are subject to large forces during operation
Data Source
AI summary
A shock absorber for a suspension system of a vehicle includes an intermediate tube on an inner tube defining an intermediate chamber between the inner tube and the intermediate tube. The shock absorber includes an outer tube and the inner tube and the intermediate tube are in the outer tube. The outer tube defines a reserve chamber between the outer tube and the intermediate tube. A valve fluidly connects the intermediate chamber and the reserve chamber. An elongated slot is in the outer tube between the valve and the reserve chamber.