U.S. patent application number 09/813704 was filed with the patent office on 2002-09-26 for vehicle suspension monotube strut base cup assembly.
This patent application is currently assigned to DELPHI TECHNOLOGIES INC.. Invention is credited to Hopkins, Patrick N., Lisenker, Ilya.
Application Number | 20020134627 09/813704 |
Document ID | / |
Family ID | 27663652 |
Filed Date | 2002-09-26 |
United States Patent
Application |
20020134627 |
Kind Code |
A1 |
Lisenker, Ilya ; et
al. |
September 26, 2002 |
VEHICLE SUSPENSION MONOTUBE STRUT BASE CUP ASSEMBLY
Abstract
A vehicle suspension damper assembly is provided which includes
a cup member with a threaded opening formed therein. A piston rod
includes a threaded portion, which is engaged in the threaded
opening. An electrical connector including a terminal portion is
received in an opening formed in the piston rod. The threaded
engagement between the piston rod and the cup member is a
predetermined length that reduces deflection of the cup member to
reduce transfer of load to the terminal portion of the electrical
connector.
Inventors: |
Lisenker, Ilya; (Miamisburg,
OH) ; Hopkins, Patrick N.; (West Carrollton,
OH) |
Correspondence
Address: |
DELPHI TECHNOLOGIES, INC.
Legal Staff Mail Code: 482-204-450
1450 W. Long Lake
P.O. Box 5052
Troy
MI
48098
US
|
Assignee: |
DELPHI TECHNOLOGIES INC.
|
Family ID: |
27663652 |
Appl. No.: |
09/813704 |
Filed: |
March 21, 2001 |
Current U.S.
Class: |
188/266.1 ;
188/322.12 |
Current CPC
Class: |
F16F 9/53 20130101; F16F
9/463 20130101 |
Class at
Publication: |
188/266.1 ;
188/322.12 |
International
Class: |
F16F 009/512 |
Claims
1. A vehicle suspension damper assembly comprising: a cup member
including a threaded opening formed therein; a piston rod including
a threaded portion, the threaded portion engaged in the threaded
opening; and an electrical connector including a terminal portion
received in an opening formed in the piston rod, wherein the
threaded engagement has a predetermined length that reduces
deflection of the cup member to reduce transfer of load to the
terminal portion of the electrical connector.
2. The assembly of claim 1 wherein the cup member includes a first
portion adapted to be fitted to a reservoir tube.
3. The assembly of claim 2 wherein the threaded opening is formed
in the first portion.
4. The assembly of claim 2 wherein the cup member includes a second
portion having a first seat formed therein for receiving the
electrical connector.
5. The assembly of claim 4 wherein the cup member includes a slot
formed in the second portion to allow the electrical connector to
extend therethrough.
6. The assembly of claim 5 wherein a socket portion of the
electrical connector extends through the slot in the second portion
of the cup member.
7. The assembly of claim 4 wherein the cup member includes a second
seat adjacent the first seat for receiving a cap, and wherein the
cap when fitted to the second seat, retains the electrical
connector to the cup member.
8. The assembly of claim 7 wherein the electrical connector
includes a concave portion.
9. The assembly of claim 8 wherein the cap includes a convex
portion, the concave portion being in contact with the convex
portion of the electrical connector when the electrical connector
and cap are assembled to the cup member.
10. The assembly of claim 1 wherein a ground terminal of the
electrical connector contacts the cup member.
11. The assembly of claim 1 further comprising a ring member
disposed between the piston rod and cup member.
12. The assembly of claim 10 wherein the ring member contacts a
shoulder formed about the piston rod and a groove formed in the cup
member.
13. The assembly of claim 1 wherein the piston rod includes a bore
extending in the axial direction.
14. The assembly of claim 13 wherein the rod includes a first
countersunk portion of the axial bore for receiving the terminal
portion of the electrical connector.
15. The assembly of claim 14 wherein the rod includes a second
countersunk portion relatively distally formed with respect to the
first countersunk portion, the second countersunk portion including
a driving feature.
16. A method of assembling a vehicle suspension damper assembly
comprising: fitting a cup member into a reservoir tube of the
damper; threading a piston rod into the cup member a predetermined
distance; positioning an electrical connector into the cup member;
forming an electrical connection between the electrical connector
and a component within the piston rod; and securing a cap in the
cup member to encapsulate the electrical connector in the cup
member.
17. The method of claim 16 wherein threading the piston rod into
the cup member includes engaging a driving feature of the piston
rod with a driving device and rotating the piston rod.
18. The method of claim 17 further comprising: contacting a stop
feature of the piston rod to the cup member.
19. A vehicle suspension damper assembly comprising: means for
fitting a cup member into a reservoir tube of the damper; means for
threading a piston rod into the cup member a predetermined
distance; means for positioning an electrical connector into the
cup member; means for forming an electrical connection between the
electrical connector and a component within the piston rod; and
means for securing the electrical connector in the cup member.
20. The vehicle suspension damper assembly of claim 19 further
comprising means to stop the threading of the piston rod into the
cup member.
Description
TECHNICAL FIELD
[0001] In general, the invention relates to damper assemblies for
use in vehicle suspension systems, and more particularly, to a
monotube strut and base cup assembly.
BACKGROUND OF THE INVENTION
[0002] Current vehicle suspensions frequently incorporate strut
assemblies as both a damping device and, in some applications, part
of the suspension's load bearing structure. Monotube struts or
dampers are conventionally known which include a piston with a
connected piston rod. The piston is slidably contained in a fluid
filled tube or chamber.
[0003] Typically, in prior designs, an end of the piston rod
opposite the piston is held in a hole formed through a base cup of
the strut by a threaded nut on a side of the cup outside the fluid
chamber. Typically, an opposing nut is fastened to the piston rod
on an opposite side of the base cup in order to provide an
anti-rotation feature for the piston rod that allows the connection
to be tightened. This conventional design requires a relatively
thin base cup in order to minimize dead length for the design.
However, a thin cup increases the chances of fatigue failure of the
cup by permitting the cup and associated members to deflect in
response to loads from the strut.
[0004] Controlled dampers require an electrical connection to be
made with the piston rod. Typically, the connector includes a
terminal portion inserted into the piston rod and a ground portion
in contact with the strut. The piston rod can be provided with
sensors that sense the relative position between the sprung and
unsprung masses (body and wheel assembly) of a vehicle. Another
example discloses electrical components extending into the rod to
control the magnetic flux in the damper to effect changes in a MR
fluid and thus, effects damping characteristics of the damper unit.
These electrically controlled dampers had been provided with an
electrical connection to the rod, introducing a potential
electrical failure point between the electrical connector and the
nut. The electrical connector cannot be made integral with the nut
because the connector needs to be oriented whereas the nut can
tighten at any angular position. Finally, the prior art dampers
have retained the connector within the cup assembly and a cap has
been press fit to the cup for that purpose. However, the cap can be
dislodged when the relatively thin base cup deflects under heavy
damping loads.
[0005] It is an object of the present invention to provide a strut
assembly that overcomes these disadvantages.
SUMMARY OF THE INVENTION
[0006] One aspect of the present invention provides a vehicle
suspension damper assembly configured to be arranged between a
wheel assembly and a body of a vehicle the vehicle suspension
damper assembly including a cup member with a threaded opening
formed therein. A piston rod is provided, which includes a threaded
portion, the threaded portion of the piston engaged in the threaded
opening of the cup. An electrical connector is provided that
includes a terminal portion received in an opening formed in the
piston rod. The threaded engagement between the cup member and
piston rod is a predetermined length that reduces deflection of the
cup member to reduce transfer of load to the terminal portion of
the electrical connector.
[0007] Other aspects of the present invention provide a cup member,
which includes a first portion adapted to be fitted to a reservoir
tube. The threaded opening of the cup member can be formed in the
first portion. The cup member can include a second portion having a
first seat formed therein for receiving the electrical connector.
The cup member can include a slot formed in the second portion to
allow the electrical connector to extend therethrough. A socket
portion of the electrical connector can extend through the slot in
the second portion of the cup member. The cup member can include a
second seat adjacent the first seat for receiving a cap, and
wherein the cap when fitted to the second seat, retains the
electrical connector to the cup member.
[0008] The assembly can further include an electrical connector
including a concave portion. The cap can include a convex portion,
the concave portion being in contact with the convex portion of the
electrical connector when the electrical connector and cap are
assembled to the cup member. A ground terminal of the electrical
connector can be provided to contact the cup member.
[0009] A ring member can be provided, the ring member being
disposed between the piston rod and cup member. The ring member can
contact a shoulder formed about the piston rod and a groove formed
in the cup member.
[0010] The piston rod includes a bore extending in the axial
direction. The rod can include a first countersunk portion of the
axial bore for receiving the terminal portion of the electrical
connector. The rod can include a second countersunk portion
relatively distally formed with respect to the first countersunk
portion, the second countersunk portion including a driving
feature.
[0011] Another aspect of the present invention provides a method of
assembling a vehicle suspension damper assembly. The method
includes fitting a cup member into a reservoir tube of the damper,
threading a piston rod into the cup member a predetermined
distance, positioning an electrical connector into the cup member,
forming an electrical connection between the electrical connector
and a component within the piston rod and securing a cap in the cup
member to encapsulate the electrical connector in the cup member.
The method can further include threading the piston rod into the
cup member includes engaging a driving feature of the piston rod
with a driving device and rotating the piston rod. The method can
further include contacting a stop feature of the piston rod to the
cup member.
[0012] Another aspect of the present invention provides a vehicle
suspension damper assembly including a means for fitting a cup
member into a reservoir tube of the damper, means for threading a
piston rod into the cup member a predetermined distance, means for
positioning an electrical connector into the cup member, means for
forming an electrical connection between the electrical connector
and a component within the piston rod and means for securing the
electrical connector in the cup member. The vehicle suspension
damper assembly can further include means to stop the threading of
the piston rod into the cup member.
[0013] The foregoing and other features and advantages of the
invention will become further apparent from the following detailed
description of the presently preferred embodiments, read in
conjunction with the accompanying drawings. The detailed
description and drawings are merely illustrative of the invention
rather than limiting, the scope of the invention being defined by
the appended claims and equivalents thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an exploded perspective view of one embodiment of
the damper base cup and rod assembly of the present invention.
[0015] FIG. 2 is a top view of the embodiment shown in FIG. 1.
[0016] FIG. 3 is a cross-sectional view of the embodiment shown in
FIG. 2 along lines 3-3.
[0017] FIG. 4 is a cross-sectional view of the embodiment shown in
FIG. 2 along lines 4-4.
[0018] FIG. 5 is an exploded view of another embodiment of the base
cup and rod assembly of the present invention.
[0019] FIG. 6 is a cross-sectional view of the assembly shown in
FIG. 5.
[0020] FIG. 7 is a cross-sectional view of another embodiment of
the base cup of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] Referring to FIGS. 1-4, one embodiment of a vehicle damper
cup assembly of the present invention is shown generally at 10. As
shown in FIG. 1, in the expanded or exploded view, the assembly 10
can generally include a piston rod 12, a wire-retaining ring 14, a
base cup 16, an electrical connector 18 and a cap 20.
[0022] The piston rod 12 can be a slender cylindrical rod that
extends in an axial direction. Adjacent a first end of the rod 12 a
piston can be affixed in a known manner (not shown). Adjacent a
second end 22, which is located at an end opposite the first end,
is a threaded portion 24. Adjacent the threaded portion 24, a
shoulder 26 can be formed. The shoulder 26 can be formed with a
flare, land, concavity, or like configuration, to provide a seat or
stop. The rod 12 can further include an axial bore or chamber 28.
The chamber 28 can extend longitudinally along part or all of the
rod length. The chamber 28 can be provided to house sensors or
devices (not shown) for the purpose of sensing or effecting changes
in the strut properties. Other devices can be positioned within the
chamber 28. The rod chamber or bore 28 can include a first
countersunk portion 30 (See FIG. 4) to allow insertion of a
terminal portion 32 of the electrical connector 18. A second
countersunk portion 34 can be formed in a relatively distal section
of the bore with respect to the first countersunk portion 30. The
second countersunk portion 34 can include a driving feature such as
a "Torx" socket or hexagonal, or like, configuration or feature
incorporated therein. In this manner, the rod 12 can be
mechanically driven or rotated by engaging the second countersunk
portion 34 with a mechanical device, such as, for example, an
electrical motor with a male portion that cooperates with the
second countersunk portion 34.
[0023] The wire retaining ring 14 can be a completely or partially
closed ring made of steel or any suitable material. The ring 14 can
be positioned on or contacted to the rod shoulder 26 to provide a
positive stop feature between the rod 12 and base cup 16. In this
manner, the rod 12 can be threaded a predetermined distance into
the base cup 16 when the ring 14 contacts both the rod shoulder 2
and the base cup 16.
[0024] The base cup 16 can include a generally cylindrical body or
overall shape. The base cup 16 can be made of any suitable
material. In one embodiment, the base cup 16 is formed of a metal
material. Casting, forging, stamping or any suitable process can be
used to form the base cup 16. A first portion 36 of the base cup
body 16 can be cylindrical for insertion into a cylindrical strut
reservoir tube 70. The body of the base cup 16 can include a second
collar portion 38 adjacent the first portion 36. The base cup first
portion 36 can include a threaded axial bore or opening 40. In
another embodiment, the threaded portion 40 can extend through the
body 16 through both the first and second portions 36, 38. The
opening 40 can include an annular groove or portion 42 to contact
the wire retaining ring 14. The axial thickness of the base cup 16
at the threaded opening 40 can be, for example, from about 1/4
inches to about 3/4 inches. It will be understood that the
thickness of the base cup 16 can be a predetermined thickness that
resists or reduces deflection or deformation of the cup member 16
and the overall assembly 10 from stresses or loads. In this manner,
the base cup 16 resists fatigue failures related to loads placed on
the base cup 16 and associated elements of the assembly 10.
[0025] The base cup body 16 can include a connector seat area 44,
which can be formed in the second portion of the body 38. The
connector seat area 44 can be a chamber or countersunk area formed
adjacent and opening to the axial bore 40 and allows the connector
18 to be received therein. The connector seat area 44 can open or
extend through a slot 46 formed through a sidewall portion of the
second or collar portion 38 of the body 16 (so that a socket
portion 50 of the electrical connector 18 extends out of the base
cup body 16). A second countersunk area or cap seat area 52 can be
formed outwardly from the connector seat area 44 to receive the cap
20 in the collar portion 38 of the body 16.
[0026] The electrical connector 18 can include a connector body
portion 54. The connector body portion 54 can be formed of a
non-metallic material, for example, plastic. The body 54, which can
be of a generally elongate shape, can include a socket portion 50
adjacent one end of the body for receiving an electrical plug,
jack, connector or the like (not shown). The socket portion 50 can
include a pair of socket terminals 56. Opposite the socket portion
50 is an extending terminal portion 32 for electrically connecting
one of the socket terminals 56 to an electrical component (not
shown) in the rod 12. The other socket terminal can be electrically
connected to a ground terminal 60 positioned along the connector
body 54 (see FIG. 4). The ground terminal 60 is positioned along
the connector body 54 to contact the base cup 16 when the two
components 16, 18 are assembled. The terminal portion 32 can
include a sheath 62. The sheath 62 surrounds the terminal portion
32 outside of the connector body 54 and can be made of a plastic
material including electrical insulating properties. A gasket 64
can be positioned about the sheath 62 to form a seal between the
base cup 16 and the connector body 54 when the two components are
assembled. The gasket 64 can be made of any suitable gasket
material, for example, silicone. The electrical connector 16 can
include a concavity 66 for contacting a retaining surface 68 of the
cap 20.
[0027] The cap 20 can be disc shaped and can be inserted into the
cap seat area 52. The cap 20 can be provided with a central convex
portion 68 that contacts the concavity 66 in the electrical
connector body 54 to secure the connector 18 in place in the base
cup 16. Any suitable means can be used to secure the cap 20 in the
base cup 16. In one embodiment, the cap 20 can be secured in place
by staking. Staking involves moving by deforming or displacing an
adjacent portion 72 of the base cup 16 over the peripheral edge of
the cap 20 after the cap 20 has been seated in the cap seat area
52.
[0028] The assembly of one embodiment of the present invention
proceeds by securing the base cup 16 in the bottom of the strut
(not shown). The base cup 16 can be secured by press fitting the
cup 16 into the end of the reservoir tube 70 and welding the cup in
place. The piston rod 12 can be provided with the wire retaining
ring 14. The threading of the rod 12 can be initiated by hand into
engagement with the threaded opening 40 of the base cup 16. In one
embodiment, the assembly of the rod 12 to the base cup 16 includes
starting the threaded end 24 of the rod 12 into the base cup 16 by
hand. The completion of the coupling of the rod 12 to the base cup
16 can be performed by rotating the rod 12 mechanically through the
engagement of a mechanical device in the rod-driving feature 34. If
a wire retaining ring 14 is used, the assembly of the piston rod 12
to the base cup 16 seats the ring 14 to the rod shoulder 26 and the
groove 42 of the base cup 16. This ensures the proper insertion
depth of the rod 12 in the cup 16. The proper insertion depth
ensures a proper connection between the rod 12 and the cup 16 and a
proper connection between the terminal 32 of the electrical
connector 18 and the electrical component (not shown) in the rod
12.
[0029] After assembly of the rod 12 and the cup 16, the electrical
connector 18 can be inserted into the provided seat 44. Insertion
of the terminal portion 32 allows electrical connection of the
connector 18 terminals 56 with the electrical component in the rod
12. Also, the ground terminal 60 contacts the cup 16, providing
means for a completed circuit. The cap 20 is fitted to the base cup
16 and secured in place, in one embodiment by a staking process.
Briefly, in the present embodiment, staking involves contacting the
body of the base cup 60 at a peripheral portion 72 adjacent the cap
20 such that body material is deformed over the cap 20, and thus
holding the cap in place.
[0030] Referring to FIGS. 5-6, another embodiment of a vehicle
damper cup assembly of the present invention is shown generally at
100, where like elements are referred to with like reference
characters. In this embodiment, the base cup 160 can include a body
formed using powder metal, which can be fused or processed by
sintering, or the like. Forming the body of powder metal can
provide a less expensive and lighter weight base cup 160 that still
retains the rigid properties desired.
[0031] The assembly 100 can generally include a piston rod 12, a
wire-retaining ring 14, a base cup 160, an electrical connector 18
and a cap 20. The assembly 100 is arranged and fitted together in a
fashion like that of the previous embodiment. However, the base cup
160 shown in FIGS. 5 and 6 can include features that differ from
that of the previous embodiment. The base cup 160 can include a
plurality of voids 180, 182, 184 formed therein for further
reducing weight. In addition, the base cup 160 can include an
extension or housing 186 for the socket portion 50 of the
electrical connector 18, which in the illustrated embodiment
includes a U-shaped radial extension of the base cup 160. The
extension 186 can provide protection for the socket 50 and
electrical connector 18 from damage and the like.
[0032] Referring to FIG. 7, another embodiment of a base cup of the
present invention is shown generally at 260. In this embodiment,
the base cup 260 can include a body formed of powder metal, which
can be processed into a unitary element by processes known in the
art. While similar to the base cup shown in FIGS. 5-6, the present
base cup 260 can include a sleeve 290 of metal, for example, steel,
provided about the periphery of the first portion 236. The sleeve
290 can be attached to the powder metal base cup by brazing or the
like. In this manner, the sleeve 290 can provide a substrate
suitable for welding into the reservoir tube (not shown).
[0033] While the embodiments of the invention disclosed herein are
presently considered to be preferred, various changes and
modifications can be made without departing from the spirit and
scope of the invention. The scope of the invention is indicated in
the appended claims, and all changes that come within the meaning
and range of equivalents are intended to be embraced therein.
* * * * *