Shock Shaft Bump Stop Structure for Debris Shielding and Softer Bottom-Out
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Solution Overview
Problem
Traditional bump stops in vehicle suspension systems are susceptible to debris intrusion, lack customization for varied suspension travel requirements, and contribute to impact harshness, leading to reduced shock absorber lifespan and performance.
Innovation Solution
A rubber bump stop system with a truncated dome strike pad and a splined core for self-cleaning, made from a proprietary multi-durometer rubber with a base durometer of 80 or greater, and a flanged base for secure attachment, allowing for customizable fit and enhanced debris management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional bump stops are used, then the structure is simple and easy to manufacture, but debris can intrude into the shock housing causing seal damage and fluid leakage
Solution Approach 1:
A debris shield is introduced as an intermediary component between the bump stop and the shock housing. This shield acts as a protective barrier that blocks debris from entering the shock housing and damaging seals, while allowing the bump stop to maintain its shock-absorbing function. The shield is specifically positioned to protect the seal area during bump stop operation.
Solution Approach 2:
The bump stop system is segmented into multiple functional components: the bump stop itself for shock absorption, the debris shield for protection, and the strike pad for controlled contact. This segmentation allows each component to specialize in its specific function, with the debris shield specifically addressing the debris intrusion problem without compromising the overall system performance.
2Reliability
If conventional bump stop materials are used, then the material is easy to manufacture, but the rigidity contributes to impact harshness rather than attenuating it
Solution Approach 1:
The bump stop material parameters are changed by incorporating viscoelastic properties and specific durometer ratings (e.g., 60-90 Shore A). These parameter changes enable the material to exhibit both rigidity for structural support and flexibility for impact attenuation. The material can soften during impact events to reduce harshness while maintaining dimensional stability during normal operation.
Solution Approach 2:
Composite materials are used in the bump stop construction, combining different material properties to achieve both rigidity and impact attenuation. The composite structure may include layers or regions with different material characteristics, allowing the bump stop to provide structural support where needed while absorbing and dissipating impact energy through controlled deformation in other regions.
3Adaptability or versatility
If fixed dimension bump stops are used, then the manufacturing is simplified, but the inability to accommodate varied suspension travel requirements leads to suboptimal shock performance
Solution Approach 1:
The bump stop design incorporates adjustable and configurable elements that allow adaptation to different suspension travel requirements. The strike pad position can be adjusted, and the bump stop can be configured in different orientations or positions within the housing. This dynamic configurability enables the same basic component to optimize performance across varied suspension applications without requiring completely different parts.
4Reliability
If the bump stop directly contacts the shock can, then the stopping function is effective, but debris can be forced through the seal during operation
Solution Approach 1:
The debris shield serves as an intermediary between the bump stop's stopping function and the seal protection requirement. It allows the bump stop to maintain direct contact with the shock can for effective stopping while simultaneously blocking debris from being forced through the seal during the stopping action.
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 solution effectively prevents debris intrusion, provides customizable fit options, reduces impact harshness, and extends the lifespan of shock absorbers, contributing to improved vehicle ride quality and stability.
Implementation Method 1
made from a proprietary multi-durometer rubber with a base durometer of 80 or greater
Implementation Method 2
a splined core with channels running parallel to the central shaft, which facilitates a self-cleaning mechanism by allowing debris to pass away from the shock shaft
Implementation Method 3
a rubber bump stop that effectively deadens an stops a vehicle's suspension up-travel
Data Source
AI summary
A bump stop system is designed for use in a vehicle suspension system featuring a shock assembly consisting of a shock shaft, shock can, and shock hat or shock eye. The system comprises a bump stop body configured to interact with the shock shaft and may include features such as grooves extending into the bump stop body, a composite structure of layered components, cast-in-place metal hardware for securing the bump stop, and a friction fit for placement. Additionally, the bump stop may be used with a coil spring, with the shock hat also functioning as a coil cup. The system may include an outer surface with a slit for fitting around the shock shaft, with hardware for closure. Methods for forming the bump stop involve processes such as pouring or injecting elastomeric mixtures, curing, and potential heating, with the option to serve as a spring assist and accommodate specific applications.