U.S. patent application number 09/774546 was filed with the patent office on 2001-09-06 for shock absorber.
Invention is credited to Bell, Stephen H..
Application Number | 20010019001 09/774546 |
Document ID | / |
Family ID | 25101571 |
Filed Date | 2001-09-06 |
United States Patent
Application |
20010019001 |
Kind Code |
A1 |
Bell, Stephen H. |
September 6, 2001 |
Shock absorber
Abstract
The motor vehicle shock absorber selectively enables the
selective real-time adjustments to the shock absorber damping based
on driving conditions and desired driving characteristics. The
adjustments are achieved by using a solenoid assembly to exert a
valve closing force, which is selectively adjustable, on the
compression valve and so as to control the damping characterization
of a shock absorber. The design and construction of the compression
head assembly and end cap assembly of the shock absorber permit
these assemblies to be manufactured as subassemblies and then
brought together and expeditiously assembled so as to minimize the
cost of manufacturing the shock absorber.
Inventors: |
Bell, Stephen H.; (Guelph,
CA) |
Correspondence
Address: |
McAndrews, Held & Malloy
Suite 3400
500 West Madison Street
Chicago
IL
60661
US
|
Family ID: |
25101571 |
Appl. No.: |
09/774546 |
Filed: |
January 31, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09774546 |
Jan 31, 2001 |
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09241217 |
Feb 1, 1999 |
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6213262 |
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Current U.S.
Class: |
188/280 |
Current CPC
Class: |
F16F 9/463 20130101;
B60G 2500/104 20130101; F16F 9/464 20130101; F16F 9/46
20130101 |
Class at
Publication: |
188/280 |
International
Class: |
F16F 009/49 |
Claims
What is claimed:
1. In a shock absorber capable of providing selectively adjustable
damping forces, the shock absorber including: an inner cylinder
assembly defining an internal chamber that has a rod end and a
closed end and that has a central longitudinal axis extending
between the rod and closed ends; a piston assembly that is slidably
mounted for reciprocal, axial movement within the internal chamber
in a compression stroke direction and in a recoil stroke direction
and that defines a rebound compartment adjacent the rod end of the
inner cylinder and a compression compartment adjacent the closed
end of the inner cylinder, with the volumes of the rebound and
compression compartments varying in accordance with the position of
the piston assembly in the internal chamber, with the rebound and
compression compartments being adapted to be filled with fluid, and
with the piston assembly defining one axial end of the compression
compartment; a piston rod that is connected to the piston assembly
and that extends from the rod end of the internal chamber; a
closure assembly that closes the rod end of the internal chamber
and that slidably and sealingly engages about the piston rod; a
fluid reservoir compartment that is in fluid communication with the
rebound and compression compartments; a compression head assembly
that is in the internal chamber adjacent the closed end and that
defines the other axial end of the compression compartment, the
compression assembly including a first surface adjacent to the
compression compartment, a second surface adjacent the closed end
and a compression flow passage, with the compression flow passage
having an inlet end and an outlet end, with the inlet end of the
compression flow passage being adjacent the first surface, with the
outlet end of the compression flow passage being adjacent the
second surface, with the compression flow passage extending between
the first surface and the second surface so as to permit fluid flow
from the compression compartment to the reservoir compartment when
the piston assembly moves in a compression stroke direction and
with a valve seat being defined adjacent the outlet end, the
improvement comprising: an end cap assembly including a solenoid
subassembly that has a bobbin subassembly which when energized,
creates a electromagnetic field; that has a fixed, magnetizable
core which has a first surface adjacent the second surface of the
compression head assembly and which has a second surface adjacent
the closed end of the shock absorber; that has a plunger
subassembly which is axially movable with respect to the core, and
which has a push rod which has a magnetizable plunger connected to
and movable with the push rod, with a first end of the push rod
being adapted to contact the valve seat so as to prevent fluid flow
through the compression flow passage of the compression head
assembly when the plunger subassembly is moved to a first axial
position and being adapted to be spaced from the valve seat a
predetermined distance so as to permit fluid flow through the
compression flow passage when the plunger subassembly is moved to a
second axial position; the plunger subassembly being disposed, with
respect to the bobbin subassembly and the core, so that upon
energization of the bobbin subassembly, the plunger subassembly is
moved to the first axial position and so that an air gap, having a
predetermined dimension, exists between a portion of the second
surface of the core and an axially adjacent portion of the plunger
when the plunger subassembly is in the first axial position.
2. The improved shock absorber as described in claim 1 wherein the
shock absorber includes an outer cylinder that is disposed
concentrically about the inner cylinder; and wherein the annular
volume between the inner and outer cylinders serves as the
reservoir compartment.
3. The improved shock absorber as described in claim 2 wherein the
end cap assembly includes an end cap member that is mounted on the
closed end of the outer cylinder; wherein the compression head
assembly is mounted on the closed end of the inner cylinder;
wherein the diametric dimension of the core is substantially the
same as the diameter of the outer cylinder; wherein the diametric
dimension of the compression head assembly is substantially the
same as the diameter of the inner cylinder; and wherein the end cap
member encloses the compression head assembly and the solenoid
subassembly.
4. The improved shock absorber as described in claim 1 wherein the
longitudinal axes of the pushrod, the valve seat, and the inner
cylinder are coaxial; and wherein the compression flow passage
includes a portion, which is adjacent to the first surface of the
compression head assembly, disposed at an angle with respect to the
longitudinal axis of the inner cylinder.
5. The improved shock absorber as described in claim 1 wherein the
portion of the second surface of the core and the portion of the
plunger are adjacent the push rod when the plunger subassembly is
moved to the first axial position; and wherein the portion of the
second surface of the core and the portion of the plunger are
shaped congruently so that the air gap is uniform when the plunger
subassembly is in the first axial position.
6. The improved shock absorber as described in claim 5 wherein the
air gap is approximately 0.013 inches; and wherein the spacing
between the first surface of the push rod and the valve seat when
the plunger subassembly is moved to its second axial position is
0.008 inches.
7. The improved shock absorber as described in claim 1 wherein the
bobbin subassembly, in part, encircles the plunger subassembly.
8. In a shock absorber capable of providing selectively adjustable
damping forces, the shock absorber including: an inner cylinder
assembly defining an internal chamber that has a rod end and a
closed end and that has a central longitudinal axis extending
between the rod and closed ends; a piston assembly that is slidably
mounted for reciprocal, axial movement within the internal chamber
in a compression stroke direction and in a recoil stroke direction
and that defines a rebound compartment adjacent the rod end of the
inner cylinder and a compression compartment adjacent the closed
end of the inner cylinder, with the volumes of the rebound and
compression compartments varying in accordance with the position of
the piston assembly in the internal chamber, with the rebound and
compression compartments being adapted to be filled with fluid, and
with the piston assembly defining one axial end of the compression
compartment; a piston rod that is connected to the piston assembly
and that extends from the rod end of the internal chamber; a
closure assembly that closes the rod end of the internal chamber
and that slidably and sealingly engages about the piston rod; a
fluid reservoir compartment that is in fluid communication with the
rebound and compression compartments; a compression head assembly
that is in the internal chamber adjacent the closed end and that
defines the other axial end of the compression compartment, the
compression head assembly including a first surface adjacent to the
compression compartment, a second surface adjacent the closed end
and a compression flow passage, with the compression flow passage
having an inlet end and an outlet end, with the inlet end of the
compression flow passage being adjacent the first surface, with the
outlet end of the compression flow passage being adjacent the
second surface, with the compression flow passage extending between
the first surface and the second surface so as to permit fluid flow
from the compression compartment to the reservoir compartment when
the piston assembly moves in a compression stroke direction, and
with a valve seat being defined adjacent the outlet end, the
improvement comprising: an end cap assembly including an end cap
member and a solenoid subassembly that has a bobbin subassembly
which when energized, creates a electromagnetic field; that has a
fixed, magnetizable core; that has a plunger subassembly which is
axially movable with respect to the core, and which has a push rod
which has a magnetizable plunger connected to and movable with the
push rod, with a first end of the push rod being adapted to contact
the valve seat so as to prevent fluid flow through the compression
flow passage of the compression head assembly when the plunger
subassembly is moved to a first axial position and being adapted to
be spaced from the valve seat a predetermined distance when the
plunger subassembly is moved to a second axial position, with the
power of the electromagnetic field being determined by a
controller, with the bobbin subassembly having a coil electrically
connected with a pair of electrically conductive spring clip
terminals which are adjacent the end cap member, and with the end
cap member having a pair of spaced openings therethrough, with each
of the openings having therein an electrical connector which
extends through the end cap member and which serve to provide a
portion of the electrical connection between the controller and the
spring clips.
9. The improved shock absorber as described in claim 8 wherein the
end cap member includes an exterior facing surface; wherein means
for connecting the shock absorber to selectively one of a vehicle
body or a vehicle suspension system is connected with exterior
facing surface; and wherein the electrical connectors are spaced a
predetermined radial distance from the longitudinal axes of the
inner cylinder and at a predetermined angle with respect to each
other to facilitate properly locating the connecting means on the
exterior surface.
10. The improved shock absorber as described in claim 8 wherein the
plunger subassembly is disposed, with respect to the bobbin
subassembly and the core, so that upon energization of the bobbin
subassembly, the plunger subassembly is moved to the first axial
position and so that an air gap, having a predetermined dimension,
exists between a portion of the second surface of the core and an
axially adjacent portion of the plunger when the plunger
subassembly is in the first axial position.
11. The improved shock absorber as described in claim 8 wherein the
bobbin subassembly includes a flux washer so as to increase the
power of the electromagnetic field.
12. The improved shock absorber as described in claim 9 wherein the
electrical connectors are made from a heat resistant material so as
to permit welding of the connecting means and the outer cylinder to
the end cap member.
13. The improved shock absorber of claim 9 wherein the spring clip
terminals are disposed and oriented on the end cap member so as to
maximize the distance that the spring clip terminals are from the
area of weld heat related to the connection of the connecting means
and the outer cylinder to the end cap assembly and so as to prevent
rotation of the bobbin subassembly during the manufacture of the
shock absorber.
14. In a shock absorber capable of providing selectively adjustable
damping forces, the shock absorber including: an inner cylinder
assembly defining an internal chamber that has a rod end and a
closed end and that has a central longitudinal axis extending
between the rod and closed ends; a piston assembly that is slidably
mounted for reciprocal, axial movement within the internal chamber
in a compression stroke direction and in a recoil stroke direction
and that defines a rebound compartment adjacent the rod end of the
inner cylinder and a compression compartment adjacent the closed
end of the inner cylinder, with the volumes of the rebound and
compression compartments varying in accordance with the position of
the piston assembly in the internal chamber, with the rebound and
compression compartments being adapted to be filled with fluid, and
with the piston assembly defining one axial end of the compression
compartment; a piston rod that is connected to the piston assembly
and that extends from the rod end of the internal chamber; a
closure assembly that closes the rod end of the internal chamber
and that slidably and sealingly engages about the piston rod; a
fluid reservoir compartment that is in fluid communication with the
rebound and compression compartments, the improvement comprising: a
compression head assembly that is in the internal chamber adjacent
the closed end; that closes the compression end of the inner
cylinder; that defines the other axial end of the compression
compartment; that has a compression head member which has a first
surface adjacent to the compression compartment, a second surface
adjacent the closed end, a first opening therein, and a
replenishing flow passage extending between the first and second
surfaces and defining a first valve seat adjacent the first
surface; that has a replenishing valve which is movable between a
first position where the replenishing valve contacts the first
valve seat and blocks fluid flow through the replenishing passage
and a second position where the fluid may flow through the
replenishing passage; that has a retaining member which is
connected within the first opening, which has a neck portion
extending into the compression compartment, which includes a
compression flow passage extending between the first surface and
the second surface so as to permit fluid flow from the compression
compartment to the reservoir compartment when the piston assembly
moves in a compression stroke direction, with the compression flow
passage having an inlet end and an outlet end, with the inlet end
of the compression flow passage being adjacent the first surface,
with the outlet end of the compression flow passage being adjacent
the second surface of the compression head, with a compression
valve seat being defined adjacent the outlet end, and with the
portion of the compression flow passage being in the neck portion
and being disposed at an angle with respect to the longitudinal
axis of the inner cylinder; and a spring extending between the neck
portion and the replenishing valve and biasing the replenishing
valve to the first position; and an end cap assembly including a
solenoid subassembly that has a bobbin subassembly which when
energized, creates a electromagnetic field; that has a fixed,
magnetizable core which has a first surface adjacent and spaced
from the second surface of the compression head assembly and which
has a second surface adjacent the closed end of the shock absorber;
that has a plunger subassembly which is axially movable with
respect to the core, which has a push rod and which has a
magnetizable plunger connected to and movable with the push rod,
with a first end of the push rod being adapted to contact the
compression valve seat so as to prevent fluid flow through the
compression flow passage of the compression head assembly when the
plunger subassembly is moved to a first axial position and being
adapted to be spaced from the compression valve seat a
predetermined distance so as to permit fluid flow through the
compression flow passage when the plunger subassembly is moved to a
second axial position; the plunger subassembly being disposed, with
respect to the bobbin subassembly and the core, so that upon
energization of the bobbin subassembly, the plunger subassembly is
moved to the first axial position.
15. The improved shock absorber as described in claim 14 wherein
the plunger subassembly is disposed, with respect to the bobbin
subassembly and the core, so that upon energization of the bobbin
subassembly, the plunger subassembly is moved to the first axial
position and so that an air gap, having a predetermined dimension,
exists between a portion of the second surface of the core and an
axially adjacent portion of the plunger when the plunger
subassembly is in the first axial position.
16. The improved shock absorber as described in claim 14 wherein
the shock absorber includes an outer cylinder that is disposed
concentrically about the inner cylinder; and wherein the annular
volume between the inner and outer cylinders serves as the
reservoir compartment.
17. The improved shock absorber as described in claim 16 wherein
the end cap assembly includes an end cap member that is mounted on
the closed end of the outer cylinder; wherein the compression head
assembly is mounted on the closed end of the inner cylinder;
wherein the diametric dimension of the core is substantially the
same as the diameter of the outer cylinder; wherein the diametric
dimension of the compression head assembly is substantially the
same as the diameter of the inner cylinder; and wherein the end cap
member encloses the compression head assembly and the solenoid
subassembly.
18. The improved shock absorber as described in claim 14 wherein
the longitudinal axes of the pushrod, the valve seat, and the inner
cylinder are coaxial; and wherein the compression flow passage
includes a portion, which is adjacent to the first surface of the
compression head assembly, disposed at an angle with respect to the
longitudinal axis of the inner cylinder.
19. The improved shock absorber as described in claim 15 wherein
the portion of the second surface of the core and the portion of
the plunger are adjacent the push rod when the plunger subassembly
is moved to the first axial position; and wherein the portion of
the second surface of the core and the portion of the plunger are
shaped congruently so that the air gap between the portions is
uniform when the plunger subassembly is in the first axial
position.
20. The improved shock absorber as described in claim 19 wherein
the air gap is approximately 0.013 inches; and wherein the spacing
between the first surface of the push rod and the valve seat when
the plunger subassembly is moved to its second axial position is
0.008 inches.
21. A method for manufacturing a shock absorber where the shock
absorber includes: an inner cylinder defining an internal chamber
that has a rod end and a closed end and that has a central
longitudinal axis extending between the rod and closed ends; an
outer cylinder that is disposed concentrically about the inner
cylinder, with the inner and outer cylinders defining an annular
volume therebetween that serves as a fluid reservoir compartment; a
piston assembly that is slidably mounted for reciprocal, axial
movement within the internal chamber in a compression stroke
direction and in a recoil stroke direction and that defines a
rebound compartment adjacent the rod end of the inner cylinder and
a compression compartment adjacent the closed end of the inner
cylinder, with the volumes of the rebound and compression
compartments varying in accordance with the position of the piston
assembly in the internal chamber, with the rebound and compression
compartments being adapted to be filled with fluid, and being in
fluid communication with the reservoir compartment, and with the
piston assembly defining one axial end of the compression
compartment; a piston rod that is connected to the piston assembly
and that extends from the rod end of the internal chamber; a
closure assembly that closes the rod end of the internal chamber
and that slidably and sealingly engages about the piston rod; a
compression head assembly that is in the internal chamber adjacent
the closed end and that defines the other axial end of the
compression compartment, the compression head assembly including a
first surface, a second surface and a compression flow passage,
with the compression flow passage having an inlet end and an outlet
end, and extending between the first surface and the second surface
with the inlet end of the compression flow passage being adjacent
the first surface, with the outlet end of the compression flow
passage being adjacent the second surface of the compression head,
and with a valve seat being defined adjacent the outlet end; an end
cap assembly including an end cap member; and a solenoid
subassembly that has a bobbin subassembly which when energized,
creates a electromagnetic field; that has a fixed, magnetizable
core which has a first surface and a second surface; that has a
plunger subassembly which is adjacent the second surface of the
core, which is axially movable with respect to the core, and which
has a push rod which has a magnetizable plunger connected to and
movable with the push rod, with a first end of the push rod being
adapted to contact the valve seat so as to prevent fluid flow
through the compression flow passage of the compression head
assembly when the plunger subassembly is moved to a first axial
position and being adapted to be spaced from the valve seat a
predetermined distance when the plunger subassembly is moved to a
second axial position, with the bobbin subassembly having a coil
electrically connected with a pair of electrically conductive
spring clip terminals which are adjacent the end cap member, and
with the end cap member having a pair of spaced openings
therethrough, with each of the openings having therein an
electrical connector which extends through the end cap member and
which serve to provide a portion of the electrical connection
between a controller and the spring clips, the improvement
comprising: placing the end cap assembly in the closed end of the
outer cylinder and without regard to orienting the end cap assembly
laterally with respect to the outer cylinder: securing the end cap
assembly to the closed end of the outer cylinder placing the
compression head assembly in the closed end of the inner cylinder
so that the first surface of the compression head assembly will
face the piston assembly and without regard to orienting the
compression head assembly laterally with respect to the inner
cylinder; securing the compression head assembly to the closed end
of the inner cylinder; placing the compression head assembly and
inner cylinder as assembled together into the outer cylinder and
end cap assembly as assembled together so that the second surface
of the compression head assembly is adjacent to the first surface
of the core and without regard to orienting the compression head
assembly and inner cylinder as assembled laterally with respect to
the outer cylinder and end cap assembly as assembled; and placing
and securing all other components into the rod ends of the inner
and outer cylinders without regard to laterally orienting those
components to the inner cylinder, compression head assembly, outer
cylinder, or end cap assembly.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to hydraulic shock absorbers
for motor vehicles, for example, including snowmobiles. More
specifically, the present invention relates to motor vehicle
hydraulic shock absorbers that because of their design and
construction are adapted for facile and relatively inexpensive
manufacture while affording real time, selectively variable damping
characteristics.
[0002] Shock absorbers are commonly used in vehicle suspension
systems to absorb unwanted vibrations that occur during driving.
Specifically, shock absorbers are generally connected between the
body (sprung mass) and the suspension (unsprung mass) of the
vehicle to dampen the vibrations transmitted from the suspension to
the body.
[0003] Motor vehicle shock absorbers usually have a hollow cylinder
defining an internal chamber or cavity that is filled with fluid
and that is divided into working compartments (viz., a compression
compartment and a rebound compartment) by a piston assembly
slidably positioned in the internal chamber. The compression and
rebound compartments are usually in fluid communication with a
reservoir compartment. Shock absorbers also usually include
internal valving that permits fluid to flow between the
compression, rebound and reservoir compartments as the piston
assembly moves within the internal chamber.
[0004] One end of the shock absorber cylinder is closed and is
typically connected to the vehicle suspension by a suitable
linkage. A piston rod extends through a seal assembly mounted in
the other end of the cylinder. The piston rod has its inner end
connected to the piston assembly and its outer end connected to the
vehicle body by a suitable connector.
[0005] A shock absorber usually also includes a compression valve,
a replenishing valve and valving in the piston assembly to control
or restrict the flow of damping fluid within the shock absorber
during the compression and extension strokes of the shock absorber,
thereby providing a damping force, which "smooths" or "dampens"
vibrations transmitted from the suspension to the body. The damping
characteristics of a shock absorber are determined by the fluid
pressure differential across the piston assembly required to drive
the fluid between the compression, rebound and reservoir
compartments. This pressure differential and the resulting flow
rate, in turn, control the speed at which the piston assembly may
move in the cylinder responsive to the external forces applied to
the shock absorber. The greater the degree to which the flow of
damping fluid is restricted, the greater the damping forces that
are provided by the shock absorber. Accordingly, a "soft"
compression and rebound stroke is afforded when the flow of damping
fluid between the working compartments is relatively unrestricted.
By contrast, a "firm" compression and rebound stroke is afforded
when there is an increased restriction in the flow of fluid between
the working compartments.
[0006] Different desired driving characteristics, such as ride
comfort, vehicle handling, and vehicle ground holding ability,
depend on the amount of damping force provided by the motor
vehicle's shock absorbers. The amount of damping force required to
meet a particular set of driving characteristics is, in turn,
dependent on driving surface conditions including, for instance,
the terrain over which the vehicle travels, and the manner in which
a vehicle is being driven. Because driving conditions and desired
characteristics may change, often even within the scope of a single
journey, the damping force required to meet the desired driving
characteristics needs also to change often. This is particularly so
when the vehicle being driven is a snowmobile.
[0007] A need has long existed for a motor vehicle shock absorber
that provides for selective real-time damping characteristics in
response to changing driving conditions and/or changes in desired
driving "feel." Additionally, a need also exists for such a shock
absorber that additionally may be reliably mass-produced on a
relatively inexpensive basis.
SUMMARY OF THE INVENTION
[0008] Accordingly, it is an object of the present invention to
provide an improved motor vehicle shock absorber that permits
selective, real-time adjustment of the shock absorber damping
characteristics.
[0009] Another object of the present invention is to provide an
improved shock absorber of the type described that may be used in
rugged, changeable driving conditions, such as those frequently
encountered by a snowmobile, and that may be reliable and
relatively inexpensively mass-produced.
[0010] Still another object of the present invention is to provide
an improved shock absorber, as described, where a novel solenoid
subassembly, which is part of a novel end cap assembly, is utilized
to selectively and variably control the force required to unseat
the shock absorber's compression valve, which is part of a novel
compression head assembly, during movement of the piston assembly
in the compression stroke direction or motion. A related object of
the present invention is to provide an improved shock absorber, as
described, where the design and construction of the novel end cap
and compression head assemblies enable these assemblies to be
separately manufactured, as sub-assemblies, and to be relatively
inexpensively assembled together, in the shock absorber
manufacturing facility.
[0011] The foregoing objects are met, in whole or in part, by the
improved shock absorber of the present invention that includes
novel compression head and end cap assemblies, and that provides
desired changeable damping force characteristics through selective,
real-time adjustable damping by using a solenoid subassembly, which
is part of the novel end cap assembly, to variably control the
force required to unseat the compression valve, which is a part of
the novel end cap assembly and which is clamped against a valve
seat on the novel compression head assembly, during movement of the
shock absorber's piston assembly in the compression stroke
direction. The design and construction of the novel compression
head assembly and the novel end cap assembly facilitates their
expeditious and sure assembly, as components of the shock absorber.
Fluid flow past the compression valve during the compression stroke
of the piston assembly is selectively controlled in a real-time
adjustable manner by a solenoid subassembly, which is used to apply
a selectively variable valve closure force to the compression
valve, thereby regulating fluid flow between the compression
compartment and the reservoir compartment during the compression
stroke. The valve closure force applied by the solenoid subassembly
may be controlled directly by the vehicle operator, or optionally
by an autonomous shock absorption control system. Through the use
of the present invention, shock absorption damping may be
selectively adjusted in real-time in response to changing driving
conditions or changes in desired driving characteristics. The
advantages of real-time adjustable damping include increased safety
and rider comfort.
[0012] These and other objects, advantages and benefits of the
present invention will become apparent to those skilled in the art
from the following detailed description of the preferred embodiment
of the present invention with reference to the accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is an axial, cross-sectional view of a preferred
embodiment of the shock absorber of the present invention.
[0014] FIG. 2 is an axial, cross-sectional view of the end cap
assembly of the present invention.
[0015] FIG. 3 is an axial, cross-sectional view of the compression
head assembly of the present invention.
[0016] FIG. 4 is an end view of the closed end of the shock
absorber of the present invention and illustrates the orientation
of the solenoid terminals with respect to the lower shock mounting
connector.
[0017] In the following detailed description of the preferred
embodiment of the present invention, spatially descriptive
orienting terms such as "upper," "lower," "inner," "outer," "left,"
"right," "left-hand," "right-hand," "vertical," "horizontal," and
the like, are utilized. It is to be understood that these terms are
used for convenience of describing the preferred embodiment with
reference to the foregoing drawings. These terms do not necessarily
describe the absolute location in space that a component or part so
described will assume when the shock absorber is in actual
usage.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] As illustrated in FIG. 1, the shock absorber 100 of the
present invention is especially adapted for use with snowmobiles
where the terrain over which the snowmobiles travel can vary
significantly from one moment to the next and where the snowmobiles
may be exposed to relatively wide ranges of temperatures.
[0019] The shock absorber 100 incorporates a number of assemblies,
subassemblies and component parts that are of conventional design
and construction. Except as otherwise noted below, these assemblies
and parts, as utilized with the shock absorber 100, are as
disclosed in U.S. Pat. Nos. 4,310,077 and 5,234,084, and the
disclosures of these patents are hereby incorporated by reference.
More specifically, and referring now to FIGS. 1-4, the shock
absorber 100 includes inner and outer cylinders 116, 118 that
extend coaxially and concentrically in a conventional manner. The
inner cylinder 116 defines an internal chamber or cavity 120, and
the annular space between the inner and outer cylinders 116, 118
defines an annular reservoir compartment 122.
[0020] A conventional piston or, more specifically, piston assembly
126, is slidably mounted within the internal chamber 120 and
divides the internal chamber 120 into a rebound working compartment
128 and a compression working compartment 130. The volumes of the
working compartments 128 and 130 vary in accordance with the
position of the piston assembly 126 in the chamber 120.
[0021] As is conventional, the end of the shock absorber 100
adjacent the rebound compartment 128 (that is, the left-hand end as
shown in FIG. 1) is sometimes referred to as the open end or rod
end. The end adjacent the compression compartment 130 (that is, the
right-hand end as shown in FIG. 1) is commonly referred to as the
closed end. The ends of the cylinders 116, 118, adjacent the closed
end of the shock absorber 100, are closed by a novel end cap
assembly 134. The ends of the cylinders 116, 118, adjacent the rod
end, are closed by a conventional rod end closure assembly 136.
[0022] A piston rod 138 has an inner end 140 connected with the
piston 126. The outer end 142 of the rod 138 slidably and sealably
projects through the closure assembly 136 in a conventional
manner.
[0023] The shock absorber 100 is adapted to be connected between
two masses, for instance, between the vehicle's body and the
vehicle's suspension. For this purpose, an eye connector 132 (as
shown in FIG. 4) is typically secured to the center of the exterior
surface of the end cap assembly 134 so that the connector 132 is
aligned with the longitudinal axes of the piston rod 138 and the
chamber 120 and so that the connector 132 may be used to secure the
shock absorber 100 to the vehicle's suspension. Similarly, the
outer end 142 of the piston rod 138 is typically threaded to permit
it to be secured to a mounting aperture on the vehicle's body by,
for example, by a reciprocal nut. Alternatively, the outer end 142
of the piston rod 138 could also include an eye connector.
[0024] The end cap assembly 134 includes a cap member 150 whose
distal annular wall portion 151 faces the rod end and is connected,
by welding, to the right-hand end of the outer cylinder 118 so as
to seal and close the right end of the outer cylinder 118. The end
cap assembly 134 is disposed adjacent a novel compression head
assembly 154 that is connected, by a press fit, with the right-hand
end of the inner cylinder 116 and that extends partially into the
interior volume defined in the left-hand or rod end facing end of
the end cap assembly 134. The assembly 154 provides fluid passages,
not shown, which permit unrestricted fluid communication between
the reservoir compartment 122 and the space or volume defined
between the assembly 154 and the assembly 134.
[0025] The rod end closure assembly 136 includes a conventional
inner head member 160 that closes the left-hand or rod end of the
inner cylinder 116. The inner head 160 has a reduced diameter lower
portion 164, which is press fit into the inner cylinder 116, and a
central aperture sized to slidably engage the piston rod 138. A
conventional seal 165 is disposed within the central aperture and
seals about the outer surface of the piston rod 138. The inner head
160 further includes an increased diameter upper flange 166 that
extends radially towards the outer cylinder 118.
[0026] The rod end closure assembly 136 further includes a
conventional seal subassembly 170 comprising a metallic outer cap
172 and an elastomeric seal member 174. Both the cap 172 and the
member 174 have a respective central aperture sized to slidably
engage about the piston rod 138. The cap 172 also includes a lower
leg 178, which is fixedly jointed to the outer cylinder 118, to
secure the seal subassembly 170 in the rod end of the shock
absorber 100. A spring 180 is positioned between the inner head 160
and the seal member 174 to bias the seal member 174 against the
inner face of the outer cap 172. A spring seat 182 is positioned
between the spring 180 and the seal member 174 to prevent
degradation of the seal member 174 by the spring 180. The central
aperture of the seal member 174 includes a plurality of lips or
ridges 184 which scrape against the outer diameter of the piston
rod 138 to remove excess shock absorber fluid from the piston rod
as it moves out of the internal chamber 120.
[0027] The rod end of the shock absorber 100 also includes a
conventional retainer 190. Its upper end is connected with and
moves with the piston rod 138. More specifically, the outer end 142
of the piston rod 138 includes a reduced diameter portion 192
defining a shoulder 194. The retainer 190 has a center bore 196
sized to fit around the reduced diameter portion 192 of the piston
rod 138. The retainer 190 may be secured against the shoulder 194
by a hex nut which threads onto the reduced diameter portion 192
above the retainer 190. Alternately, the retainer 190 can be welded
to the shoulder 194.
[0028] As is conventional, the shock absorber 100 is filled with
fluid, such as hydraulic oil, pressurized air and/or a combination
of both. As is explained below, the shock absorber 100 includes
fluid control valving--some conventional and some novel--for
permitting controlled fluid flow between the reservoir, compression
and rebound compartments 122, 128 and 130 as the piston 126 moves
within the internal chamber 120 thereby providing the desired
selected damping force. In summary, the shock absorber 100 includes
a fluid flow control system for providing controlled fluid flow
between the rebound and compression compartments 128, 130 as the
piston 126 moves within the internal chamber 120. This flow control
system preferably includes by-pass means for permitting the
controlled by-pass flow of fluid through the piston 126 from the
rebound compartment 128 to the compression compartment 130 during
the rebound stroke and from the compression compartment 130 to the
rebound compartment 128 during the compression stroke. In this
regard, the shock absorber 100 incorporates a disk-valved piston
126 such as is commonly used in the industry. The rebound by-pass
means typically includes at least one rebound flow passage
extending through the piston 126 between the rebound and
compression compartments 128, 130. Likewise, the compression
by-pass means typically includes at least one compression flow
passage extending through the piston 126 between the compression
and rebound compartments 130, 128. Each flow passage is
conventionally valved so as to govern fluid flow between the
rebound and compression compartments during rebound and compression
strokes.
[0029] It will be understood that except for the assemblies 134 and
154, the construction of the shock absorber 100 as thus far
described is similar to the shock absorbers described in the
aforementioned patents. It will also be understood that the
assemblies, subassemblies, and components thus far described may
assume other designs, constructions or configurations without
departing from the scope of the present invention.
[0030] As illustrated in FIGS. 1 and 2, the end cap assembly 134 of
the present invention includes a novel solenoid assembly or
subassembly 300. This subassembly is used for selectively
controllably damping the movement of the piston rod 138, with
respect to the internal chamber 120, during the compression stroke
of the piston 126. More specifically, the solenoid subassembly 300
includes a ferrous core 303 and a non-magnetizable, stainless steel
pushrod 302 that slidably extends through the axial central portion
of the fixed ferrous core 303 and is then press fit through a
movable ferrous magnetizable plunger 304. The core 303 has a
diameter greater than that of the compression head assembly 154 and
also greater than that of the inner cylinder 116. The core 303
defines the left-hand end of the assembly 134.
[0031] The pushrod 302 is press fit with the plunger 304 after
being passed through the core 303 and together the pushrod 302 and
plunger 304 move, as a unit, axially. The pushrod 302 and plunger
304 constitute a plunger subassembly or assembly 305. A compression
valve contact face or surface 311 is defined on the upper or
left-hand end of the push rod 302. The plane of the surface 311 is
perpendicular to the longitudinal axis of the push rod 302.
[0032] An annular bobbin subassembly or assembly 306 comprises a
conductive wire coil 307, flux washer halves 318 and spring clip
terminals 314. The flux washer halves 318 are adjacent to the lower
or right-hand end of assembly 306. When installed into bobbin
assembly 306 these washer halves form a complete washer. These
washer halves increase the closed loop magnetic current so as to
make the solenoid subassembly 300 more efficient.
[0033] Assembly 306 is connected with the core 303 and is mounted
about the plunger subassembly 305. The left-hand end of the bobbin
subassembly 306 abuts the right-end side of the core 303 so that,
together, they form a fixed core subassembly or subassembly
309.
[0034] The longitudinal central axes of the plunger subassembly 305
and the fixed core subassembly 309 are aligned and are coaxial with
the longitudinal central axis of the piston rod 138. The axial
central opening of the fixed core subassembly 309, and more
particularly of the core 303, is sized so that the plunger
subassembly 305 may move axially with respect to the subassembly
309 and with respect to the bobbin subassembly 306. More
specifically, a left-hand facing recess 308 in the member 150 and a
central aperture 310 in the core 303 receive the push rod 302 and
maintain the longitudinal alignment between the plunger subassembly
305 and the fixed core subassembly 309 while allowing the plunger
subassembly 305 to move longitudinally or axially with respect to
the fixed core subassembly 309.
[0035] As is conventional, when electrical current is driven
through the coil 307, an electromagnetic field is formed. This
electromagnetic field, in turn, asserts a closing force on the
plunger 304 in that the field draws the plunger subassembly 305
upwardly (leftwardly) towards the compression head assembly 154.
The magnitude of this closing force is a function of the electrical
current flowing through the coil 307, which may be readily
controlled by a conventional controller 315 shown in FIG. 2, such
as those manufactured by Trombelta Motion Technologies, 13901 Main
Street, Menomonee Falls, Wis. 53051. A controller for use with
snowmobile shock absorbers is Trombelta Part No. D03297. A
prototype controller for use with truck cab shock absorbers is
Trombelta Part No. SK797-A. The electrical power is provided to the
coil 307 preferably from the vehicle alternator. The AC voltage
from the alternator is rectified to a DC voltage, which is then
controllably applied to the coil 307.
[0036] A pair of electrical connectors 312 are mounted in the end
cap member 150. Their outer ends protrude from the right-hand or
outwardly facing surface of the end cap member 150. These
connectors provide means for conveniently connecting the coil 307
with a source of electrical power. Each of the connectors 312
includes an annular plastic, externally threaded member 313 so that
the connectors 312 can be threaded into the end cap member 150. An
O-ring seal, not shown, may be disposed between the connector 312
and its associated threaded member 313. A flanged sealing gasket,
also not shown, may be disposed between the member 313 and the end
cap member 150. The connectors 312 (and their associated parts) are
made from a heat resistant material so as to withstand heat from
the welding required to attach the outer cylinder 118 and the eye
connector 132 to the end cap member 150.
[0037] Each inner end of the connectors 312 conductively engages a
spring clip terminal 314 (only one of which being shown in FIG. 2).
The spring clip terminals 314 are, in turn, conductivity coupled to
the coil 307. The spring clip terminals 314 have two functions.
First, they provide an improved electrical connection between the
bobbin subassembly 306 and the outside source of electrical power.
Second, the engagement of the connectors 312 and terminal clips 314
prevents the bobbin subassembly 306 from rotating inside the
solenoid subassembly 300 during the high speed rotation of the
shock absorber 100 during the "spin" closing of the upper end of
the shock absorber, that is, the end adjacent to where the piston
rod 138 comes out of the assembly 136.
[0038] The bobbin subassembly 306 is conventional in most aspects.
However, it is uniquely designed to hold the coil 307, which is
needed to produce the electromagnetic field or magnetic flux, the
two spring clip terminals 314 and the flux washer halves 318. The
concept of using the spring clip terminals is novel and allows for
the efficient assembly of the bobbin subassembly 306 and the other
parts of the end cap assembly 134. The spring clip terminals 314
are novel in that they take the electrical power from the wire
leads (not shown) attached to the connectors 312 into the bobbin
subassembly 306 without the need to pull wires through the end cap
member 150. Wires protruding from the member 150 would not be
compatible with welding of the end mount 132 to the member 150, the
seam welding of the outer cylinder 118 to the member 150, the
aforementioned upper, spin closing used to close the rod end of the
shock absorber adjacent to the rod 138, or the shock absorber
painting processes. After the bobbin subassembly 306, which
includes the spring clip terminals 314, is dropped into and
properly oriented to the connector holes in the member 150, the
connectors 312 may be easily screwed into the member 150 so as to,
in turn, engage the spring clip terminals 314.
[0039] As illustrated in FIG. 4, the connectors 312 are disposed at
predetermined angles (at 30 degrees in the preferred embodiment)
with respect to the transverse axis of the opening of the eye
connector 132 so as to minimize the risk of the connectors 312 (and
their associated parts) being damaged during the welding
operations. These protruding connectors 312 are also used as
locators to orient the end cap member 150 to the eye connector 132
during the welding connection of the end cap member 150 to the eye
connector 132. The orientation of the connectors 312 to the eye
connector 132 transverse axis is necessary to allow the vehicle
manufacturer to route the leads from the controller 315 properly to
the connectors 312. In particular, in a snowmobile suspension space
is limited, and the leads from the controller must be brought into
the connectors 312 at a specific lateral orientation to avoid
damage to the leads from the snowmobile suspension members.
[0040] As noted, a controller 315 controls the power applied to the
coil 307. The controller 315 may act to control either the voltage
across the coil 307 or the current through the coil 307. Where the
voltage is controlled or adjusted, the controller may adjust the
voltage between 3 volts (soft ride) and 14 volts (firm ride). Where
the current is controlled or adjusted, the adjustment may be
between 0.35 amps (soft ride) and 2.1 amps (firm ride).
[0041] A voltage controller 315 is a little less expensive to
manufacture. However the shock absorber temperature, and thus the
coil temperature, can change due to changes in ambient temperature
or due to the shock absorber heating up from severe use. And a
voltage controller has no way of compensating for coil resistance
changes due to such shock absorber coil temperature changes. In
other words, the voltage is held constant by a voltage controller
regardless of the temperature of the coil 307, and the solenoid
assembly's clamping force, and thus the shock absorber damping
force varies with changes to the shock absorber coil
resistance.
[0042] In contrast, a current controller 315 has an advantage in
that when the shock absorber's coil temperature changes, the
current controller adjusts the current to the previously set value.
This helps keep the damping forces from changing with the changing
temperatures. If the ambient temperature were to get colder from
the time when the coil current was set for a particular damping
adjustment, without the current controller's compensating effect,
the shock damping would increase due to increased coil current flow
resulting from the reduced coil resistance that lowered
temperatures caused. An ambient warming of the shock absorber, or
heating up of the shock due to severe use, will have the opposite
effect without compensation. In other words, without compensation
if shock temperature increases, the damping force will decrease due
to resistance of the coil 307 increasing with increased shock coil
temperature. In the absence of current compensation the increased
coil resistance/temperature reduces the amount of coil current
flow, which controls the amount of magnetic flux generated in the
coil. In the absence of current compensation the reduced flux would
thereby reduce the clamping force that controls the damping
level.
[0043] The controller 315 may be, for example, mounted on the
handle bars of the snowmobile where it can be selectively actuated
by the driver to reflect changes in the terrain and/or the driver's
desire to change the damping characteristics. Alternatively, the
controller 315 could be positioned at other locations on the
vehicle.
[0044] Referring now to FIG. 3, the compression head assembly 154
includes a compression head member 405 that closes the inner
cylinder 116. More specifically, the periphery of the upper-facing
end is connected with the lower-facing end of the cylinder 116, and
the periphery of the lower-facing end abuts the upper-facing end of
the core 303. A replenishing valve disk 402 regulates the flow of
fluid through the replenishing flow passage 404 in the member 405.
A spring 406 normally biases the valve disk 402 to a flow blocking
position by having the disk contact a replenishing valve seat,
which surrounds the upper or left end of the passage 404. The upper
end of the spring 406 is held in place by a retaining member 408
that is threaded into an axial, central opening in the member
405.
[0045] A compression flow passage 410 passes through the retaining
member 408 and connects the compression compartment 130 to the
reservoir compartment 122. The flow passage 410 preferably contains
an axial portion and a right angle portion 411 that is adjacent the
compartment 130 and that serves to break up fluid flow and prevent
the relatively heavy plunger subassembly 305 from resonating at
higher vehicle speeds. A compression valve seat 414 is located at
the lower or right-hand end of the retaining member 408, that is,
the end adjacent to the assembly 134. The compression valve contact
surface 311 of the plunger subassembly 305 is normally biased
against the valve seat 414, that is, to a fluid flow blocking
position, with the electromagnetically induced closing force of the
solenoid subassembly.
[0046] The longitudinal axes of the plunger subassembly 305 and the
compression valve seat 414 are aligned so that the longitudinal or
axial motion of the subassembly 305, relative to the fixed core
subassembly 309, increases and decreases the distance between the
contact surface 311 and the compression valve seat 414. The flow of
fluid from the compression compartment 130 to the reservoir
compartment 122 is regulated by the interaction or spacial
relationship between the surface 311 of the pushrod 302 and the
compression valve seat 414.
[0047] When the electromagnetic field is formed, the plunger
subassembly 305 is moved to a position where the upper or left-hand
end of the pushrod 302 contacts the assembly 154, as described
below, and where the upwardly (leftwardly) facing surface of the
plunger 304 is spaced or gapped from the adjacent rearwardly
(rightwardly) facing congruent surface of the core 303 by a
predetermined distance; in the preferred embodiment, 0.013 inches.
This 0.013 inch air gap is maintained between the plunger
subassembly 305 and the core 303 when the compression valve surface
311 is pressed against the compression valve seat 414 so as to
block flow through the passage 410.
[0048] When the fluid pressure in the compression compartment 130
increases so as to overcome the electromagnetic closing force, the
plunger subassembly 305 is pushed away (or pushed open) from the
valve seat 414, by as much as 0.008 inch, so that the rate of flow
out of the passage 410 is equal to the rate of flow coming into the
passage 410. The solenoid assembly 300 maintains its force on the
plunger at this maximum spacing between the surface 311 and the
seat 414. When the subassembly 305 is moved away from contact with
the valve seat 414, due to the flow, there is a spacing of 0.021
inches (0.013 inch air gap plus 0.008 inch deflection) between the
core 303 and plunger 304.
[0049] There is an important advantage to having an air gap of some
dimension between the core 303 and the plunger 304. If there was no
air gap at all, the force required to move the compression valve
open, as described above, would be too high. Also, if there was no
air gap at all when the high force required to open the valve was
met, the valve would open uncontrollably. If the air gap was too
large, then the force of the solenoid assembly 300 would be too
weak instead of too strong. If the solenoid force was too weak due
to too a large a gap, then there would be inadequate clamping force
and hence inadequate damping adjustment available. So the 0.013
inch air gap in the preferred embodiment is the correct air gap, so
that the force of the solenoid assembly 300 is neither too strong
nor weak and so the opening force is in a controllable range.
[0050] The 0.008 inch opening spacing between the seat 414 and
surface 311 is also important. If the compression valve moved away
from the seat 414 much more than the 0.008 inch, in the preferred
embodiment, the force of the solenoid assembly 300 would become too
weak due to an excessive air gap at this maximum valve open
position. Therefore, with an air gap much larger than the 0.013
inch plus the 0.008 inch gap at the valve full open position, the
solenoid assembly would not have the force to close the compression
valve (that is, have the surface 311 press against the seat 414)
even when the oil flow through passage 410 had stopped.
[0051] The closing force between the fixed core assembly 309 and
the plunger assembly 305 effectively provides an adjustable
compression valve closing force that acts to inhibit the flow of
fluid through the compression flow passage 410. By controlling the
controller 315, the closing force may be selectively adjusted to
achieve desired damping characteristics. In summary, during the
compression stroke of the shock absorber 100, the fluid pressure in
the compression compartment 130, and thus in the flow passage 410,
acts on the compression valve surface 311. Thus the fluid pressure
in the compression compartment 130 creates an opening force on the
plunger assembly 305 opposing the electromagnetically induced
closing force applied to the plunger subassembly 305. When this
opening force exceeds this closing force, the plunger assembly 305
is unseated from the compression valve seat 414, which enables
fluid to flow from the compression compartment 130 to the reservoir
compartment 122 through the passage 410.
[0052] When the present invention is incorporated into a motor
vehicle shock absorption system, selective manual or autonomous
control of shock absorber damping is possible. A vehicle operator
may selectively add stiffness or compliance to the vehicle shock
absorption system, or an autonomous control system may act, in
real-time, to adjust shock absorption damping in response to
detected changes in driving conditions. For example, in this latter
regard, acceleration or position sensors may, for example, be
located at various places on the vehicle or the shock absorbers to
provide acceleration or position information to the controller 315
that, in turn, makes damping magnitude decisions and provides the
appropriate electrical stimulus to the plunger subassembly 305
through the coil 307. Vehicle speed information may also be
collected and used to make damping decisions. More specifically,
the present invention provides real-time shock absorption damping
control that, in turn, allows vehicle operators or autonomous
control systems to make damping adjustments in response to changing
driving conditions and/or changes in desired driving
characteristics. An operator may choose to sacrifice ride comfort
for handling in poor driving conditions resulting in safer travel.
Similarly, a less comfortable, better handling ride may be chosen
in an emergency situation. Conversely, in good driving conditions,
an operator may chose a more comfortable ride resulting in a more
relaxed driving environment and less mechanical stress on the
vehicle.
[0053] Another commercially advantageous feature of the present
invention is the facility by which the novel compression head
assembly 154 and the end cap assembly 134 may be preassembled,
preferably before the final manufacture of the shock absorber 100,
and then assembled, with the other shock absorber components, when
the shock absorber 100 is manufactured in an assembly line
manufacturing operation. As noted, the assembly 154 comprises four
parts: the compression head member 405, the disk 402, the spring
406, and the retaining member 408. These parts can be readily
assembled together because they do not have to be oriented,
relative to each other, regarding a specific reference point. For
instance, the member 408 can be threaded into the member 405
without regard to the radial direction the portion 411 of the
passage 410 points.
[0054] Similarly, the assembly 154 can be mated within the
right-hand end of the inner cylinder 116 without having to
laterally orient the assembly with respect to other parts of the
cylinder or even the shock absorber. Again, for instance, without
having to direct the axial portion 411 of the passage 410 in any
particular radial direction. Thus placing the assembly 154 in the
inner cylinder 116 is a relative quick and trouble-free
operation.
[0055] Like the assembly 154, the subassemblies and components of
the assembly 134 may be put together with a minimum of time and
effort. First, the core 303 including the plunger subassembly 305
is put together with the bobbin subassembly 306. Then the assembler
need only orient the openings for the connectors 312 with the clips
314 and then fit those subassemblies and parts within the member
150. The assembly 134 is next mated within the right-hand end of
the outer cylinder 118, again without regard to the lateral
orientation of the assembly 134 with respect to the cylinder 118.
As noted above, the connector 132 can be welded to the member 150
prior to the weld attachment of the outer cylinder 118 using the
connectors 312 as guides to facilitate the proper location of the
connector 132 on the member 150.
[0056] Once the inner cylinder 116 is press fit onto the novel
compression head assembly 154 it can be lowered without lateral
orientation into the outer cylinder 118 welded onto the novel end
cap assembly 134. This is an important benefit in a manufacturing
environment where cycle time for assembly of parts is
important.
[0057] As will be appreciated by those skilled in the art, the
present invention could also be used with a monotube having a
remote fluid reservoir. The solenoid assembly could then be
disposed in the reservoir, preferably near the reservoir entrance,
or in the line connecting the reservoir with the monotube.
[0058] While particular elements, embodiments and applications of
the present invention have been shown and described, it will be
understood, of course, that the invention is not limited thereto
since modifications may be made by those skilled in the art,
particularly in light of the foregoing teachings. It is therefore
contemplated by the appended claims to cover such modifications as
incorporate those features, which come within the spirit and scope
of the invention.
* * * * *