Single-Piece Shock Body With Integrated Damping Flow Paths
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Solution Overview
Problem
The manufacturing cost of mechanical equipment and devices is high due to the number of components assembled, and existing shock absorbers require multiple components and complex assembly processes, leading to inefficiencies and potential errors.
Innovation Solution
A shock absorber body assembly formed from a single component using a material additive manufacturing process, featuring a cylinder cavity and a reservoir cavity in fluid communication, with integrated fluid pathways and valves that allow for adjustable damping and reduced assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple components are assembled to form a shock absorber, then the functional requirements can be met, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent combines multiple shock absorber components (cylinder, reservoir, fluid pathways, ports) into a single monolithic body formed by additive manufacturing. This merging eliminates the need for assembly of multiple separate parts, directly reducing manufacturing cost and assembly complexity while maintaining all required functions.
Solution Approach 2:
The single shock absorber body performs multiple functions simultaneously: it serves as the cylinder housing, reservoir, fluid pathway network, and port structure. This multi-functionality is achieved through the integrated design where internal cavities and passages are formed within the monolithic structure, eliminating the need for separate components for each function.
2Productivity
If multiple components are assembled to form a shock absorber, then the functional requirements can be met, but the assembly time and potential for errors increase
Solution Approach 1:
By forming the cylinder, reservoir, and fluid pathways as a single integrated component, the patent eliminates multiple assembly steps. The monolithic structure requires no assembly of separate housing parts, fluid passages, or sealing components, directly reducing assembly time and eliminating assembly errors.
3Ease of manufacture
If traditional manufacturing processes are used, then existing components can be produced, but the number of parts and assembly steps remain high
Solution Approach 1:
The patent employs additive manufacturing (3D printing) technology, which represents a fundamental change in the manufacturing parameter from traditional subtractive or formative methods. This manufacturing approach enables the creation of complex internal geometries and integrated structures that would be impossible or extremely difficult to achieve with conventional manufacturing processes.
Solution Approach 2:
The additive manufacturing process allows multiple components to be merged into a single monolithic structure. The cylinder, reservoir, fluid pathways, and ports are all formed as one continuous piece, eliminating the need for separate manufacturing and assembly of these components.
Data Source
AI summary
Disclosed herein are shock absorbers and shock body assemblies, that include a shock body that is formed of a single part. The shock body includes a cylinder cavity and reservoir cavity that share a single separating wall and are closed on top by a single integral cap portion. Multiple fluid flow paths extend along an exterior the cylinder cavity and have top and bottom ends fluidly coupled with cylinder cavity. The shock body assembly includes multiple check valves and adjustable valves, integrated into the flow paths, that govern hydraulic flow along the flow paths to affect the damping function of the shock absorber. The shock body is formed via a material additive manufacturing process such that the shock is formed of a single material via a single continuous process.