Integrated Shock Absorber with Nested Valve Core and Pilot Valve
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Solution Overview
Problem
Existing shock absorbers in automobiles have issues with numerous parts, low integration, inefficient space utilization, and difficult assembly, leading to a large volume and high machining costs.
Innovation Solution
A shock absorber design incorporating a cylinder, piston, flow regulating valve, valve core, and pilot valve, with integrated air channels and one-way valves, reducing parts and enhancing integration and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the shock absorber uses numerous separate parts for damping adjustment, then the damping can be adjusted, but the integration level is low and assembly is difficult
Solution Approach 1:
The patent combines the valve core, pilot valve, and air channels into an integrated assembly where the valve core is movably arranged within the piston and the pilot valve is connected to the valve core. The air channels are formed directly within the piston structure, merging multiple components into a unified assembly that reduces part count while maintaining damping adjustability through valve core movement.
Solution Approach 2:
The piston serves multiple functions: it divides the cylinder into compression and rebound chambers, contains the flow regulating valve for damping control, houses the air channels for pressure equalization, and provides mounting for the valve core and pilot valve. This multi-functional design reduces the need for separate components.
2Adaptability or versatility
If the shock absorber has numerous parts and low integration, then damping adjustment is possible, but the space utilization rate is low and volume is large
Solution Approach 1:
The valve core is nested within the piston, and the pilot valve is connected to and integrated with the valve core assembly. The air channels are formed within the piston body itself, creating a nested arrangement where components are housed within each other or within the main piston structure, maximizing space utilization and minimizing overall volume.
Solution Approach 2:
The air channels are configured to extend in multiple directions within the piston, with one part of the first air channel configured in the valve core and another part configured in the pilot valve. This three-dimensional integration of channels through different spatial dimensions allows efficient space utilization while maintaining all necessary functions.
3Adaptability or versatility
If the shock absorber has numerous parts and low integration, then damping adjustment is possible, but assembly is difficult and machining costs are high
Solution Approach 1:
By integrating the air channels directly into the piston structure and combining the valve core with the pilot valve assembly, the number of separate machining operations and assembly steps is reduced. The integrated design allows for fewer mating surfaces, fewer fasteners, and simplified alignment requirements during assembly.
Solution Approach 2:
The shock absorber is segmented into functional modules: the piston as a complete assembly containing chambers, valves, and channels; the valve core as a movable control element; and the pilot valve connected to the valve core. This modular segmentation allows each module to be manufactured and tested separately then assembled as a complete unit, simplifying the overall manufacturing process.
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 achieves a high level of integration, efficient space utilization, easy assembly, and lower machining costs while providing stable shock absorption.
Implementation Method 1
The first return elastic member is installed in the first air channel and two ends abut against an inner wall surface of the first air channel and the first closure member, respectively, so that the first closure member abuts against the first channel member and closes the first channel.
Implementation Method 2
The second return elastic member is installed in the second air channel and two ends abut against the second channel member and the second closure member, respectively, so that the second closure member abuts against the second support ring table and closes the second air channel.
Implementation Method 3
a main function of the shock absorber is to suppress the reciprocating vibration of the spring
Implementation Method 4
When the valve core moves, the flow regulating valve is controlled by the pilot valve, so as to regulate a flow rate of a fluid between the compression chamber and the rebound chamber.
Data Source
Figure 1
Figure 2~3
Figure 4~6
AI summary
A shock absorber (1) and a vehicle (2) having same. The shock absorber (1) comprises a cylinder (100), a piston (200), a flow regulating valve (300), a valve core (400), and a pilot valve (500). The piston (200) is movably provided in the cylinder ( 100), and the piston (200) divides the cylinder (100) into a compression chamber(101) and a rebound chamber (102); the flow regulating valve (300) is provided in the piston (200) and separately communicated with the compression chamber ( 101) and the rebound chamber (102); the valve core (400) is movably provided in the piston (200), the pilot valve (500) is connected to the valve core (400), and when the valve core (400) moves, the flow regulating valve (300) is controlled by means of the pilot valve (500); the shock absorber (1) is provided with a first air channel (410) and a second air channel (420), the first air channel (410) is communicated with spaces on two sides of the moving direction of the valve core (400) and communicated with the rebound chamber(102), the second air channel (420) is communicated with the spaces on two sides of the moving direction of the valve core (400) and provided in the valve core (400), a part of the first air channel (410) is provided in the valve core (400), and the other part of the first air channel (410) is provided in the pilot valve (500). The shock absorber (1) has the advantages of high integration, few parts, easy assembly, and low machining costs.