Shock Absorber Insert Sleeve for Low-Foam Fluid Transfer
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Solution Overview
Problem
There is a need for cost-effective damper designs that provide a secondary passageway for electromechanical valves in shock absorbers without compromising performance, particularly in semi-active shock absorbers used in automotive suspension systems.
Innovation Solution
The design incorporates a pressure tube, a reserve tube, and a fluid transfer tube with a piston assembly, a reservoir chamber, and a sealing collar and insert that create a fluid transfer channel, reducing internal volume and foaming, while allowing for cheaper, lighter, quieter, and easier manufacturing, assembly, and disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional secondary passageway design is used for the electromechanical valve, then the shock absorber performance is maintained, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent merges the secondary passageway function into the intermediate chamber structure itself, eliminating the need for separate passageway components. The intermediate chamber serves dual purposes: as a fluid reservoir and as the pathway for the electromechanical valve, thereby reducing part count and manufacturing complexity while maintaining performance.
Solution Approach 2:
The intermediate chamber is designed to perform multiple functions simultaneously: it acts as a fluid reservoir, provides a secondary passageway for the electromechanical valve, and serves as a structural support element. This multi-functionality reduces the overall component count and simplifies manufacturing while preserving shock absorber performance.
2Object-generated harmful factors
If the internal volume of the intermediate chamber is reduced, then foaming of the fluid is reduced, but the chamber may become too small to accommodate necessary components
Solution Approach 1:
The patent applies local quality by creating a fluid transfer channel with specific geometric characteristics (narrower passage) in a localized region of the intermediate chamber. This localized volume reduction at the channel location suppresses foaming where fluid turbulence occurs, while the rest of the intermediate chamber maintains sufficient volume to accommodate the electromechanical valve and other components.
Solution Approach 2:
The fluid transfer channel is designed to extend in the longitudinal dimension rather than requiring large radial or axial volume. This dimensional approach allows the channel to provide adequate fluid transfer capability while occupying minimal space within the intermediate chamber, thus reducing foaming without compromising component accommodation.
3Reliability
If multiple sealing components (o-rings) are used to seal the intermediate chamber, then sealing reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and eliminates the o-ring sealing components from the intermediate chamber assembly. Instead of using flexible o-rings that require installation and maintenance, the design employs integrated rigid sealing features directly formed on the intermediate chamber and adjacent components, thereby reducing device complexity and part count while maintaining sealing reliability.
Solution Approach 2:
The intermediate chamber and adjacent components are designed with self-sealing features through precision-machined mating surfaces and integrated sealing geometries. The structure itself provides the sealing function without requiring separate sealing components, making the system self-sufficient and reducing overall complexity.
Data Source
AI summary
A shock absorber including a pressure tube, a piston assembly slidably disposed within the pressure tube, and a fluid transfer tube that extends about the pressure tube, and a reserve tube that extends about the fluid transfer tube is provided. The piston assembly divides an inner volume of the pressure tube into first and second working chambers. An intermediate chamber between the pressure tube and the fluid transfer tube is arranged in fluid communication with the first working chamber. A reservoir chamber between the fluid transfer tube is arranged in fluid communication with the intermediate chamber. An insert is disposed within the intermediate chamber, reducing the volume of the intermediate chamber and defining a fluid transfer channel between the first working chamber and the reservoir chamber.