Suspension Piston Shim Support to Prevent Coining
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Solution Overview
Problem
Existing suspension assemblies face issues with shim deformation and permanent deformation (coining) during high-pressure events, leading to reduced performance and increased leakage, which are not effectively addressed by existing designs.
Innovation Solution
Incorporation of support surfaces on the dished piston to distribute stress and prevent shim deformation by allowing shim deflection into a moat, thereby maintaining preload and reducing coining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shims are allowed to deflect into the moat during high-pressure events, then shim deformation is reduced, but the piston structure becomes more complex
Solution Approach 1:
The piston surface is segmented into multiple distinct zones: the moat area for shim deflection, support surfaces for stress distribution, and a rim area for sealing. This segmentation allows each zone to perform its specific function independently, reducing overall shim deformation while maintaining a manageable structural complexity through functional zonation.
Solution Approach 2:
Different regions of the piston are given different local properties: the moat provides a recessed area for controlled deflection, support surfaces provide elevated stress-distribution zones, and the rim provides a sealing boundary. This local differentiation allows the piston to handle high-pressure events effectively without requiring complete structural redesign.
2Reliability
If support surfaces are added to distribute stress, then shim deformation is reduced, but manufacturing complexity increases
Solution Approach 1:
The support surfaces and moat geometry are designed to automatically position and support the shim stack before high-pressure events occur. The support surfaces are pre-configured at specific heights and locations to engage the shim edges during deflection, ensuring proper stress distribution is established in advance rather than requiring active control during operation.
Solution Approach 2:
The moat is designed with a curved, dish-shaped geometry that naturally guides shim deflection along a controlled arc. This curvature allows shims to deflect smoothly into the moat while maintaining contact with the support surfaces, reducing stress concentration points and simplifying the manufacturing requirements compared to sharp-edged or flat geometries.
3Stability of the object's composition
If shims deflect into the moat, then coining is prevented, but the device complexity increases
Solution Approach 1:
The moat acts as a pre-configured cushioning zone that absorbs and distributes the forces from shim deflection before they can cause coining (permanent deformation). By providing this cushioning capacity in advance through the moat's recessed geometry and support surfaces, the system prevents structural integrity loss without requiring complex active protection mechanisms.
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 introduction of support surfaces on the piston effectively reduces shim deformation, maintaining preload and preventing coining, thus enhancing the durability and performance of the suspension assembly.
Implementation Method 1
support surfaces on the dished piston to distribute stress and prevent shim deformation
Implementation Method 2
allowing shim deflection into a moat, thereby maintaining preload and reducing coining
Data Source
AI summary
A piston with support surfaces is disclosed. The piston can include a shim sealing surface formed around an outer circumference of the piston configured to be in contact with a cover shim of a shim stack to prevent fluid from entering a cavity of a moat of the piston during a checked condition of a suspension assembly associated with the piston and configured to allow the fluid to pass between the cover shim and the shim sealing surface when pressure is applied to a moat side of said cover shim. The piston can further include a plurality of support surfaces configured to be in contact with the cover shim during the compression condition and not be in contact with the cover shim during a preload condition when a damper is not experiencing said checked condition.