Top-Mount Hydraulic Bump Stop for Integrated Jounce Load Damping
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Solution Overview
Problem
Current hydraulic bump stops are mounted externally to the shock absorber's load path, leading to higher loads and requiring additional bracketry, whereas the proposed top mount assembly integrates with the jounce shock to reduce load inputs and eliminate external brackets, thus addressing the inefficiencies of external mounting and space constraints.
Innovation Solution
The top mount assembly includes an attachment bracket, piston rod mount section, and cylinder section with an annular chamber and working piston, utilizing shock fluid and valving to dampen higher loads, replacing traditional microcellular urethane jounce bumpers and integrating with the jounce shock to reduce load inputs and eliminate external brackets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If hydraulic bump stops are mounted externally to the shock absorber's load path, then higher loads are generated due to motion ratio, but this requires additional external bracketry and increases device complexity
Solution Approach 1:
The bump stop function is merged with the existing top mount assembly of the shock absorber. The working piston is integrated into the top mount bracket, eliminating the need for separate external bump stop brackets while maintaining load damping capability. The top mount assembly now serves dual purposes: mounting the shock absorber and providing bump stop functionality.
Solution Approach 2:
The top mount assembly is designed to perform multiple functions: it serves as the mounting bracket for the shock absorber, provides structural support, and acts as the bump stop mechanism through the working piston. This multi-functional design eliminates the need for separate external bracketry while maintaining effective load damping.
2Force
If bump stops are mounted externally to maximize load damping, then load inputs are reduced, but package space is consumed and structural efficiency is reduced
Solution Approach 1:
The bump stop mechanism is combined with the existing top mount assembly structure. The working piston is housed within the top mount bracket, utilizing the same structural space already allocated for shock absorber mounting. This eliminates the need for additional external space while maintaining effective jounce load dampening.
3Device complexity
If a microcellular urethane jounce bumper is used, then the structure is simple, but it cannot dampen higher loads effectively
Solution Approach 1:
The patent replaces the urethane bumper with a hydraulic bump stop mechanism. The working piston moves within the cylinder section, utilizing hydraulic fluid to dampen jounce loads. This hydraulic system provides superior load damping capacity compared to urethane while maintaining a relatively simple integrated structure within the top mount assembly.
Solution Approach 2:
The invention changes the material and mechanism parameters from solid urethane to hydraulic fluid and piston mechanics. This parameter change enables the system to handle higher loads through hydraulic pressure and valving control while maintaining structural efficiency through integration.
4Force
If external brackets are used for bump stop mounting, then load path is optimized, but device complexity and assembly time increase
Solution Approach 1:
The bump stop mounting function is merged into the primary top mount assembly. The working piston is an integral part of the top mount bracket, eliminating the need for separate external mounting brackets. This reduces the number of components and simplifies assembly while maintaining effective load path management.
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
This solution effectively dampens jounce loads by integrating with the jounce shock, reducing load inputs and eliminating external brackets, thereby enhancing load management and freeing up package space while maintaining noise isolation and ride comfort.
Implementation Method 1
a retainer plate supported within the cylindrical metal housing by an elastomeric isolator
Implementation Method 2
an elastomeric isolator
Implementation Method 3
cylinder section of the attachment bracket includes a chamber that receives a working piston
Implementation Method 4
utilizing shock fluid and valving to dampen much higher loads
Implementation Method 5
a valve plate that separates the piston chamber from the chamber of the cylinder section and further includes a separating piston in the piston chamber
Implementation Method 6
utilizing shock fluid and valving to dampen much higher loads
Data Source
AI summary
A top mount assembly includes an attachment bracket having a flange section, a piston rod mount section, and a cylinder section, the flange section includes a plurality of apertures for receiving a plurality of fastener bolts, the piston rod mount section being configured to receive a piston rod, and the cylinder section of the attachment bracket includes an annular chamber that receives an annular working piston.