阅读说明：本技术 具有两件式壳体的阻尼器 (Damper with two-piece housing ) 是由 A·穆罕默迪 于 2019-10-21 设计创作，主要内容包括：本发明提供了一种限定工作室的减震器压力管。联接到活塞杆的活塞组件可滑动地设置在压力管中并将工作室分成上工作室和下工作室。储备管围绕压力管以限定储备室。位于该压力管的一个端部处的底阀组件控制下工作室与储备室之间的流体流动。该储备管包括第一开口壳体和第二开口壳体,这些开口壳体在纵向接缝处接合在一起以形成基本上圆柱形形状。该第一开口壳体和该第二开口壳体可由拼接坯件、定制焊接坯件、定制轧制坯件或定制热处理坯件制成,以赋予第一开口壳体和第二开口壳体的不同部分不同的厚度、强度、特性或特征。(The present invention provides a shock absorber pressure tube defining a working chamber. A piston assembly coupled to the piston rod is slidably disposed within the pressure tube and divides the working chamber into an upper working chamber and a lower working chamber. A reserve tube surrounds the pressure tube to define a reserve chamber. A base valve assembly at one end of the pressure tube controls fluid flow between the lower working chamber and the reserve chamber. The reserve tube includes a first open shell and a second open shell joined together at a longitudinal seam to form a substantially cylindrical shape. The first open shell and the second open shell may be made from a tailored welded blank, a tailored rolled blank, or a tailored heat-treated blank to impart different thicknesses, strengths, properties, or characteristics to different portions of the first open shell and the second open shell.)

1. A method of manufacturing a vehicle damper, the method comprising:

obtaining a pressure pipe;

slidably positioning a piston assembly within the pressure tube;

forming a first open shell from a first metal sheet;

forming a second open shell from a second metal sheet;

positioning the first and second open housings around the pressure tube;

aligning the first open housing with the second open housing;

welding the first open housing to the second open housing to sealingly engage the first open housing to the second open housing and define a reserve tube, wherein the reserve tube comprises a substantially cylindrically shaped portion and a protrusion, wherein the protrusion is at least partially defined by one of the first and second metal sheets; and

coupling the reserve tube to the pressure tube.

2. The method of claim 1, wherein the positioning of the first and second open housings occurs prior to the welding.

3. The method of claim 1, wherein the reserve tube includes a longitudinal axis, the first open housing being welded to the second open housing along the longitudinal axis.

4. The method of claim 1, wherein the first metal sheet comprises a customized blank comprising a first portion having a first set of mechanical properties and a second portion having a second set of mechanical properties different from the first set of mechanical properties.

5. The method of claim 4, wherein the first portion is manufactured separately and separately from the second portion and subsequently joined to the second portion.

6. The method of claim 4, further comprising manipulating the first portion to obtain a first thickness that is different from a second thickness of the second portion.

7. The method of claim 1, further comprising positioning a valve between the first and second split housings prior to welding the first split housing to the second split housing, wherein the protrusion at least partially retains the valve.

8. The method of claim 7, wherein the protrusion directly engages the valve within the reserve tube.

9. The method of claim 7, wherein the protrusion extends radially inward into the reserve tube.

10. The method of claim 1, further comprising securing a tubular sleeve to a first end of the reserve tube.

11. The method of claim 10, further comprising mechanically deforming a portion of the tubular sleeve to define an annular lip at the first end of the reserve tube.

12. The method of claim 10, wherein the tubular sleeve covers the first end of the reserve tube such that the tubular sleeve is positioned in abutting relation radially outward of the first end of the reserve tube.

13. The method of claim 1, wherein the step of forming the first open shell comprises forming a first flange, and the step of forming the second open shell comprises forming a second flange, the first and second flanges being secured to one another to define an end wall at a second end of the reserve tube.

14. The method of claim 13, wherein the step of forming the first open shell includes forming a third flange, and the step of forming the second open shell includes forming a fourth flange, the third and fourth flanges being secured to one another to define an annular lip at a first end of the reserve tube.

15. The method of claim 1, wherein the first and second split housings each include a semi-cylindrical shaped portion, and wherein the protrusions form a planar portion of the first split housing and a planar portion of the second split housing, the semi-cylindrical shaped portions being secured to each other to define a tube, the planar portions cooperating to define a mounting bracket.

Technical Field

The present disclosure relates to hydraulic dampers or shock absorbers suitable for use in suspension systems, such as those for motor vehicles. More particularly, the present disclosure relates to a hydraulic damper or shock absorber having a reserve tube made from a two-piece housing.

Background

The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.

Generally, dampers are mounted side-by-side with the springs (as independent shock absorbers) or inside the springs (as part of a wrap-around shock absorber and strut assembly) and placed in front and rear suspension systems. They are used to absorb and dissipate the shock and rebound motion of the vehicle suspension system and to keep the tires of the vehicle in contact with the ground. The shock absorber is mounted to the frame by an upper mount and to the suspension by a lower mount having a ring or U-shaped bracket. Components formed of different sheet metals, such as stabilizer brackets, legs, spring seats or external valve housings, may need to be welded/bonded to the seamless tube to form the exterior of the shock absorber.

Conventional hydraulic dampers or shock absorbers include a cylinder that is adapted at one end for attachment to the sprung or unsprung mass of the vehicle. A piston is slidably disposed within the cylinder, wherein the piston divides the interior of the cylinder into two fluid chambers. A piston rod is connected to the piston and extends from one end of the cylinder where the piston rod is adapted to be attached to the other of the sprung or unsprung mass of the vehicle. A first valving system, typically incorporated within the piston, is used to generate a damping load during the extension stroke of the piston of the shock absorber relative to the cylinder. The second valve system, which is typically incorporated in a single tube design within the piston and in a double tube design within the base valve assembly, is used to generate damping loads during the compression stroke of the piston relative to the cylinder of the shock absorber.

Disclosure of Invention

This section provides a general summary of the disclosure, and is not a complete disclosure of the full scope of the invention or all of its features.

A shock absorber according to the present disclosure includes a pressure tube defining a working chamber. A piston assembly coupled to the piston rod is slidably disposed within the pressure tube and divides the working chamber into an upper working chamber and a lower working chamber. A reserve tube surrounds the pressure tube to define a reserve chamber. A base valve assembly positioned at one end of the pressure tube controls fluid flow between the lower working chamber and the reserve chamber to accommodate changes in fluid volume displaced by the length of the piston rod positioned within the upper working chamber. The base valve, alone or in combination with an externally mounted control valve, produces different pressure flow characteristics for the shock absorber, which controls the damping characteristics for the shock absorber.

According to aspects of the present disclosure, a reserve tube is comprised of a first open shell and a second open shell that are joined together at a longitudinal seam to form a substantially cylindrical shape. The first open shell and the second open shell may be made from a tailored welded blank, a tailored rolled blank, or a tailored heat-treated blank to impart different thicknesses, strengths, properties, or characteristics to different portions of the first open shell and the second open shell. The first and second open housings may optionally include various features, such as a flanged end, a cup-shaped base, a planar portion forming a support, and one or more circumferentially extending notches for supporting the base valve assembly within one end of the reserve tube.

According to other aspects of the present disclosure, a method for manufacturing a shock absorber from two open housings is provided. The method includes the steps of obtaining a pressure tube and slidably positioning a piston assembly within the pressure tube. The method further includes the steps of forming a first open shell from the first metal sheet and forming a second open shell from the second metal sheet. The method continues with the steps of: the method includes positioning a first open housing and a second open housing about the pressure tube, aligning the first open housing with the second open housing, and welding the first open housing to the second open housing to sealingly engage the first open housing to the second open housing to define a reserve tube. The method further includes the step of coupling a reserve tube to the pressure tube. According to these steps, the reserve tube is formed to comprise a substantially cylindrical shaped portion and a protrusion at least partially defined by one of the first and second metal sheets.

Further areas of applicability will become apparent from the description provided herein. It should be understood that the detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.

Drawings

The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.

FIG. 1 illustrates a motor vehicle incorporating a shock absorber according to the present disclosure;

FIG. 2 is a cross-sectional side view of one of the example shock absorbers shown in FIG. 1;

FIG. 3 is a side cross-sectional view of another example shock absorber constructed according to the present disclosure;

FIG. 4 is an exploded perspective view of an exemplary pressure tube, reserve tube and base valve subassembly constructed in accordance with the present disclosure;

FIG. 5 is a top cross-sectional view of the pressure tube and reserve tube shown in FIG. 4;

FIG. 6 is a front perspective view of an exemplary pressure tube, intermediate tube, reserve tube, and base valve subassembly constructed in accordance with the present disclosure;

FIG. 7 is an exploded perspective view of the pressure, intermediate, reserve and base valve subassemblies illustrated in FIG. 6;

FIG. 8 is a top cross-sectional view of the reserve tube and base valve shown in FIG. 6;

FIG. 9 is an enlarged side cross-sectional view of a portion of the pressure tube, intermediate tube, reserve tube and base valve subassembly illustrated in FIG. 6;

FIG. 10 is a top perspective view of the foot valve shown in FIG. 6;

FIG. 11 is a bottom perspective view of the foot valve shown in FIG. 6;

FIG. 12 is a front perspective view of another exemplary pressure tube, reserve tube, and base valve subassembly constructed in accordance with the present disclosure;

FIG. 13 is an exploded perspective view of the pressure tube, reserve tube and base valve subassembly shown in FIG. 12;

FIG. 14 is a top cross-sectional view of the reserve tube and base valve shown in FIG. 12;

FIG. 15 is an enlarged side cross-sectional view of a portion of the pressure tube, reserve tube and base valve subassembly illustrated in FIG. 12;

FIG. 16 is a top perspective view of the foot valve shown in FIG. 12;

FIG. 17 is a bottom perspective view of the foot valve shown in FIG. 12;

FIG. 18 is a side cross-sectional view of a portion of an exemplary reserve tube constructed in accordance with the present disclosure;

FIG. 19 is a side cross-sectional view of a portion of another exemplary reserve tube constructed in accordance with the present disclosure;

fig. 20A is a top perspective view illustrating an exemplary tailored blank;

FIG. 20B is a top perspective view illustrating an exemplary customized welded blank;

FIG. 20C is a top perspective view showing an exemplary customized rolled blank; and is

Fig. 20D is a top perspective view illustrating an exemplary customized heat treated blank.

Detailed Description

The foregoing description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. Referring now to the drawings, in which like numerals represent like parts throughout the several views, there is shown suspension components of a vehicle 10.

Exemplary embodiments will now be described more fully with reference to the accompanying drawings. Exemplary embodiments are provided so that this disclosure will be thorough and will fully convey the scope to those skilled in the art. Numerous specific details are set forth, such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" may also be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Unless specifically identified as an order of execution, the method steps, processes, and operations described herein are not to be construed as necessarily requiring their execution in the particular order discussed or illustrated. It should also be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being "on," "engaged to," "connected to" or "coupled to" another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to" or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between …" versus "directly between …", "adjacent" versus "directly adjacent", etc.). As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

Although the terms "first," "second," "third," etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical values when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms (such as "inner," "outer," "lower," "below," "lower," "above," "upper," etc.) may be used herein for ease of description to describe one element or feature's relationship to another element or feature as illustrated. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as "below" or "beneath" other elements or features would then be oriented "above" the other elements or features. Thus, the exemplary term "below" can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or oriented in other directions) and the spatially relative descriptors used herein interpreted accordingly.

Fig. 1 shows a suspension system of a vehicle 10. Vehicle 10 includes a rear suspension 12, a front suspension 14, and a body 16. Rear suspension 12 has a transversely extending rear axle assembly (not shown) adapted to operatively support a pair of rear wheels 18. The rear axle is attached to body 16 by a pair of shock absorbers 20 and a pair of springs 22. Similarly, front suspension 14 includes a transversely extending front axle assembly (not shown) that operatively supports a pair of front wheels 24. The front axle assembly is attached to body 16 by a pair of shock absorbers 26 and a pair of springs 28 configured in a coiled arrangement with the pair of shock absorbers 26. Shock absorbers 20 and 26 dampen the relative movement of the unsprung portion (i.e., front and rear suspensions 12 and 14) of vehicle 10 with respect to the sprung portion (i.e., body 16). While vehicle 10 has been depicted as a passenger car having front and rear axle assemblies, shock absorbers 20 and 26 may be used with other types of vehicles or in other types of applications including, but not limited to, vehicles incorporating non-independent front and/or non-independent rear suspensions, vehicles incorporating independent front and/or independent rear suspensions, or other suspension systems known in the art. Further, as used herein, the term "shock absorber" refers to dampers in its broadest sense and thus will include McPherson struts and other damper designs known in the art.

Referring now to FIG. 2, shock absorber 20 is shown in greater detail. While FIG. 2 shows only shock absorber 20, it is to be understood that shock absorber 26 also includes the designs described below for shock absorber 20. Shock absorber 26 only differs from shock absorber 20 in the manner in which it is adapted to be connected to the sprung and unsprung masses of vehicle 10. Shock absorber 20 comprises a pressure tube 30, a piston assembly 32, a piston rod 34, a reserve tube 36, a base valve assembly 38, an intermediate tube 40 and an externally mounted control valve 42.

Pressure tube 30 defines a working chamber 44. Piston assembly 32 is slidably disposed within pressure tube 30 and divides working chamber 44 into an upper working chamber 46 and a lower working chamber 48. A seal 49 is disposed between piston assembly 32 and pressure tube 30 to permit sliding movement of piston assembly 32 with respect to pressure tube 30 without generating undue frictional forces as well as sealing upper working chamber 46 from lower working chamber 48. Piston rod 34 is attached to piston assembly 32 and extends through upper working chamber 46 and through an upper rod guide assembly 50 which closes the upper ends of pressure tube 30 and intermediate tube 40. Seal assembly 51 seals the interface between upper guide rod assembly 50 and piston rod 34. The end of piston rod 34 opposite piston assembly 32 is adapted to be secured to the sprung mass of vehicle 10. Because piston rod 34 extends only through upper working chamber 46 and not lower working chamber 48, extension and compression movements of piston assembly 32 with respect to pressure tube 30 result in a difference in the amount of fluid displaced in upper working chamber 46 and the amount of fluid displaced in lower working chamber 48. The difference in the amount of fluid displaced is referred to as the "rod volume" and during extension motion it flows through base valve assembly 38. During a compression movement of piston assembly 32 with respect to pressure tube 30, valves within piston assembly 32 allow fluid flow from lower working chamber 48 to upper working chamber 46 while a "rod volume" of fluid flow passes through control valve 42.

Reserve tube 36 surrounds pressure tube 30 to define a fluid reserve chamber 52 located between tube 36 and tube 40. The bottom end of reserve tube 36 is closed by a base 54 adapted to be connected to the unsprung mass of vehicle 10. The upper end of reserve tube 36 is attached to upper guide rod assembly 50. Reserve tube 36 includes a tubular extension 56 that extends radially outwardly away from pressure tube 30. Control valve 42 is housed within a tubular extension 56 of reserve tube 36.

Base valve assembly 38 is disposed between lower working chamber 48 and reserve chamber 52 to control the flow of fluid from reserve chamber 52 to lower working chamber 48. When shock absorber 20 extends in length, an additional volume of fluid is required in lower working chamber 48 due to the rod volume. Thus, fluid will flow from reserve chamber 52 to lower working chamber 48 through base valve assembly 38. When shock absorber 20 compresses in length, an excess of fluid must be removed from lower working chamber 48 due to the rod volume. Thus, fluid will flow from lower working chamber 48 through control valve 42 to reserve chamber 52.

Piston assembly 32 includes a piston body 60, a first compression valve assembly 62 and a first extension valve assembly 64. Nut 66 is threaded onto piston rod 34 to secure first compression valve assembly 62, piston body 60, and first extension valve assembly 64 to piston rod 34. Piston body 60 defines a first plurality of compression passages 68 and a first plurality of extension passages 70. Base valve assembly 38 includes a valve body 72, a second extension valve assembly 74, and a second compression valve assembly 76. Valve body 72 defines a second plurality of extension passages 78 and a second plurality of compression passages 80.

During a compression stroke, fluid in lower working chamber 48 is pressurized causing fluid pressure to react against first compression valve assembly 62. First compression valve assembly 62, therefore, acts as a check valve between lower working chamber 48 and upper working chamber 46. The damping characteristics for shock absorber 20 during a compression stroke are controlled by control valve 42 alone or by control valve 42 operating in parallel with base valve assembly 38. Second compression valve assembly 76 controls the flow of fluid from lower working chamber 48 to reserve chamber 52 during a compression stroke. Second compression valve assembly 76 may be designed as a safety hydraulic relief valve, a damping valve working in parallel with control valve 42, or second compression valve assembly 76 may be completely removable from base valve assembly 38. During an extension stroke, first plurality of compression passages 68 are closed by first compression valve assembly 62.

During an extension stroke, fluid in upper working chamber 46 is pressurized causing fluid pressure to react against first extension valve assembly 64. First extension valve assembly 64 is designed as a safety hydraulic relief valve that will open when the fluid pressure within upper working chamber 46 exceeds a predetermined limit, or as a pressure valve that operates in parallel with control valve 42 to change the shape of the damping curve. The damping characteristics for shock absorber 20 during an extension stroke are controlled by control valve 42 alone or by control valve 42 operating in parallel with first extension valve assembly 64. Fluid displaced into lower working chamber 48 during an extension stroke flows through base valve assembly 38. The pressure of the fluid in lower working chamber 48 decreases causing the fluid pressure in reserve chamber 52 to open second extension valve assembly 74 which allows fluid to flow from reserve chamber 52 to lower working chamber 48 through second plurality of extension passages 78. Thus, second extension valve assembly 74 acts as a check valve between reserve chamber 52 and lower working chamber 48. The damping characteristics for shock absorber 20 during an extension stroke are controlled by control valve 42 alone or by first extension valve assembly 64 working in parallel with control valve 42.

Intermediate tube 40 engages upper guide rod assembly 50 on an upper end and bottom valve assembly 38 on a lower end. Intermediate chamber 82 is defined between intermediate tube 40 and pressure tube 30. A passage 84 is formed in upper guide rod assembly 50 for fluidly connecting upper working chamber 46 and intermediate chamber 82. Control valve 42 controls the flow of fluid between intermediate chamber 82 and reserve chamber 52. During a compression stroke of shock absorber 20, fluid in upper working chamber 46 may flow through passage 84 into intermediate chamber 82 and then into reserve chamber 52 as permitted by control valve 42 to accommodate the increase in rod volume in upper working chamber 46. During an extension stroke of shock absorber 20, fluid in reserve chamber 52 flows through base valve assembly 38 and into lower working chamber 44 to replace the lost rod volume.

FIG. 3 shows another shock absorber 20' wherein control valve 42 of shock absorber 20 has been deleted. Shock absorber 20 'is the same as shock absorber 20 and operates in the same manner as described above except that shock absorber 20' lacks intermediate tube 40, control valve 42 and intermediate chamber 82 of shock absorber 20. As a result of these variations, shock absorber 20 'includes reserve tube 36' which does not include tubular extension 56 that houses control valve 42 within shock absorber 20.

In accordance with the subject disclosure, reserve tubes 36, 36 'of shock absorbers 20 and 20' are configured to have a clamshell arrangement with various internal and external features. Examples of these configurations are shown in fig. 4-19.

Referring to fig. 4 and 5, a shock absorber subassembly 100 is shown that includes a pressure tube 102, a reserve tube 104, and a base valve 106. The pressure tube 102 extends coaxially along a longitudinal axis 111 between the upper end 108 and the lower end 110. The upper end 108 of pressure tube 102 is configured to mate with upper guide rod assembly 50 of shock absorber 20' shown in FIG. 3, and base valve 106 is press fit into the lower end 110 of pressure tube 102. Reserve tube 104 is formed of a first open housing 112a and a second open housing 112b that are held together in a clamshell arrangement to surround pressure tube 102 and base valve 106. Thus, pressure tube 102 and reserve tube 104 are concentrically arranged about longitudinal axis 111.

In the illustrated example, the first and second open housings 112a, 112b are joined together at two longitudinally extending seams 116a, 116b that extend parallel to the longitudinal axis 111. The first and second open housings 112a, 112b may be attached at the seams 116a, 116b in a variety of different ways. By way of example and not limitation, the first open housing 112a may be welded to the second open housing 112b along longitudinally extending seams 116a, 116 b.

Reserve tube 104 extends longitudinally between first end 118 and second end 120. The first open housing 112a includes a first flange 122a and the second open housing 112b includes a second flange 122 b. First flange 122a and second flange 122b are secured to one another to define an end wall 124 at second end 120 of reserve tube 104. End wall 124 is concave or cup-shaped to help center and support lower end 110 of pressure tube 102 and base valve 106 within reserve tube 104. The first open housing 112a also includes a third flange 126a and the second open housing 112b includes a fourth flange 126 b. Third flange 126a and fourth flange 126b cooperate with one another to define an annular lip 128 at first end 118 of reserve tube 104. Annular lip 128 is configured to retain upper guide rod assembly 50 of shock absorber 20' shown in FIG. 3, which extends longitudinally between annular lip 128 of reserve tube 104 and upper end 108 of pressure tube 102.

The first and second open housings 112a, 112b each include a semi-cylindrical shaped portion 130a, 130b and a planar portion 132a, 132 b. The semi-cylindrical shaped portions 130a, 130b are secured to each other to define a tube. In the illustrated embodiment, each of the semi-cylindrical shaped portions 130a, 130b of the first and second open housings 112a, 112b extends in an arch spanning about 180 degrees such that the first and second open housings 112a, 112b mirror each other and form about half (i.e., 50%) of the reserve tube 104. However, it should be understood that other configurations are possible in which one of the first and second open housings 112a, 112b forms more than 50% of the reserve tube 104 and the other of the first and second open housings 112a, 112b forms less than 50% of the reserve tube 104.

Planar portions 132a, 132b of first and second open housings 112a, 112b cooperate to define a clevis-shaped mounting bracket 134 for coupling reserve tube 104 to an unsprung portion of vehicle 10. However, it should be understood that shock absorbers 20, 20' may be mounted in a reverse orientation, wherein mounting bracket 134 couples reserve tube 104 to body 16 of vehicle 10. Each of the planar portions 132a, 132b may include one or more mounting holes 136 configured to receive a fastener, such as a bolt (not shown).

The first and second open housings 112a, 112b each include a first portion 138a, 138b and a second portion 140a, 140 b. The planar portions 132a, 132b are part of the second portions 140a, 140b of the first and second open housings 112a, 112b, and the first portions 138a, 138b of the first and second open housings 112a, 112b extend longitudinally between the second portions 140a, 140b and the first end 118 of the reserve tube 104. In the illustrated example, the first portions 138a, 138b of the first and second open housings 112a, 112b have a first thickness 142, and the second portions 140a, 140b of the first and second open housings 112a, 112b have a second thickness 144 that is greater than the first thickness 142. This increases the strength of reserve tube 104 in the area of mounting bracket 134.

Referring to fig. 6-11, another shock absorber subassembly 200 is shown that includes a pressure tube 202, a reserve tube 204, an intermediate tube 205, and a base valve 206. The pressure tube 202 extends coaxially along a longitudinal axis 211 between an upper end 208 and a lower end 210. An intermediate tube 205 extends coaxially around the pressure tube 202 and longitudinally between the rod side end 207 and the valve side end 209. The upper end 208 of pressure tube 202 and rod side end 207 of intermediate tube 205 are configured to mate with upper rod guide assembly 50 of shock absorber 20 as shown in FIG. 2. The base valve 206 is press fit into the lower end 210 of the pressure tube 202 and the valve side end 209 of the intermediate tube 205. The reserve tube 204 is formed of a first open housing 212a and a second open housing 212b that are held together in a clamshell arrangement to surround the pressure tube 202, the intermediate tube 205, and the base valve 206. Accordingly, pressure tube 202, intermediate tube 205, and reserve tube 204 are concentrically arranged about longitudinal axis 211.

In the illustrated example, the first and second open housings 212a, 212b are joined together at two longitudinally extending seams 216a, 216b that extend parallel to the longitudinal axis 211. The first and second open housings 212a, 212b may be attached at the seams 216a, 216b in a variety of different ways. By way of example and not limitation, the first open housing 212a may be welded to the second open housing 212b along longitudinally extending seams 216a, 216 b.

Reserve tube 204 extends longitudinally between a first end 218 and a second end 220. The first open housing 212a includes a first flange 222a and the second open housing 212b includes a second flange 222 b. First flange 222a and second flange 222b are secured to one another to define an end wall 224 at second end 220 of reserve tube 204.

The first and second split housings 212a, 212b each include a semi-cylindrical shaped portion 230a, 230 b. The semi-cylindrical shaped portions 230a, 230b are secured to each other to define a tube. In the illustrated embodiment, each of the semi-cylindrical shaped portions 230a, 230b of the first and second open housings 212a, 212b extends in an arch spanning about 180 degrees such that the first and second open housings 212a, 212b mirror each other and form about half (i.e., 50%) of the reserve tube 204. However, it should be understood that other configurations are possible in which one of the first and second open housings 212a, 212b forms more than 50% of the reserve tube 204 and the other of the first and second open housings 212a, 212b forms less than 50% of the reserve tube 204.

Each of the first and second open housings 212a, 212b includes one or more protrusions 232 extending radially inward toward the longitudinal axis 211. The projections 232 are circumferentially spaced from one another such that fluid flow channels 234 are defined between the spaced apart projections 232. Each protrusion 232 has a first inclined surface 236a and a second inclined surface 236b that converge at a circular inner edge 238 in the illustrated example. First inclined surface 236a of projection 232 directly engages base valve 206 and supports base valve 206 within reserve tube 204 at a location longitudinally spaced from end wall 224 of reserve tube 204.

Each of the first and second open housings 112a, 112b includes semi-cylindrical projections 240a, 240b that extend radially outward away from the longitudinal axis 211 at a location adjacent one of the seams 216a, 216 b. When the first and second open housings 112a, 112b are joined together, the semi-cylindrical projections 240a, 240b cooperate to form a tubular extension 242 configured to receive the control valve 42 shown in fig. 2. The intermediate tube 205 includes a through bore 244 aligned with the tubular extension 242 such that the through bore 244 may be connected in fluid communication with the control valve 42 shown in fig. 2.

Base valve 206 includes a base valve disc 246, a compression disc stack 248, an extension disc stack 250, and a valve pin 252. Bottom valve disc 246 includes valve pin hole 254, a plurality of compression passages 256, and a plurality of extension passages 258 positioned circumferentially between a plurality of valve disc legs 260. Valve pin hole 254 receives a valve pin 252 that retains the compressed disk stack 248 and the extended disk stack 250 on the bottom valve disk 246. Base valve disc 246 has a proximal face 262 facing downward working chamber 44 and a distal face 264 facing end wall 224 of reserve tube 204. The extension disc stack 250 is positioned on at least a portion of the proximal face 262 of the base valve disc 246 to control fluid flow through the extension passages 258. The compression disc stack 248 is positioned on at least a portion of the distal face 264 of the base valve disc 246 to control fluid flow through the compression passages 256.

The proximal face 262 of the disc 246 includes an annular shoulder 268 that is configured to be inserted into the lower end 210 of the pressure tube 202 in a press-fit manner. The base valve disk 246 includes an outer diameter 270 that is configured to be inserted into the valve side end 209 of the intermediate tube 205 in a press fit manner. The inner edge 238 of the protrusion 232 in the reserve tube 204 defines an inner diameter 272 that is smaller than the outer diameter 270 of the base valve disc 246 and the distal face 264 of the base valve disc 246 includes a tapered portion 274 configured to abut the first angled surface 236a of the protrusion 232. Thus, protrusion 232 supports base valve 206 in a centered position within reserve tube 204.

Referring to fig. 12-17, another shock absorber subassembly 300 is shown and includes a pressure tube 302, a reserve tube 304, and a base valve 306. Pressure tube 302 extends coaxially along a longitudinal axis 311 between an upper end 308 and a lower end 310. The upper end 308 of pressure tube 302 is configured to mate with upper guide rod assembly 50 of shock absorber 20' as shown in FIG. 3. Base valve 306 is press fit into the lower end 310 of pressure tube 302. Reserve tube 304 is formed from a first open housing 312a and a second open housing 312b that are held together in a clamshell arrangement to surround pressure tube 302 and base valve 306. Accordingly, pressure tube 302 and reserve tube 304 are concentrically arranged about longitudinal axis 311.

In the illustrated example, the first and second open housings 312a, 312b are joined together at two longitudinally extending seams 316a, 316b that extend parallel to the longitudinal axis 311. The first and second open housings 312a, 312b may be attached at the seams 316a, 316b in a variety of different ways. By way of example and not limitation, the first open housing 312a may be welded to the second open housing 312b along longitudinally extending seams 316a, 316 b.

Reserve tube 304 extends longitudinally between first end 318 and second end 320. The first open housing 312a includes a first flange 322a and the second open housing 312b includes a second flange 322 b. First flange 322a and second flange 322b are secured to one another to define an end wall 324 at second end 320 of reserve tube 304.

The first and second split housings 312a, 312b each include a semi-cylindrical shaped portion 330a, 330 b. The semi-cylindrical shaped portions 330a, 330b are secured to each other to define a tube. In the illustrated embodiment, each of the semi-cylindrical shaped portions 330a, 330b of the first and second open housings 312a, 312b extends in an arch spanning about 180 degrees such that the first and second open housings 312a, 312b form about half (i.e., 50%) of the reserve tube 304. However, it should be understood that other configurations are possible in which one of the first and second open housings 312a, 312b forms more than 50% of the reserve tube 304 and the other of the first and second open housings 312a, 312b forms less than 50% of the reserve tube 304. Optionally, one of the first and second open housings 312a, 312b may include a tire recess 331. In the example shown in fig. 12-17, the tire indentation 331 is a depression that is stamped into the second open housing 312 b. The tire indentation 331 is longitudinally positioned at a location aligned with a tire sidewall mounted on one of the wheels 18, 24 of the vehicle 10 to provide improved clearance between the tire and the reserve tube 304. It should be appreciated that the tire recess 331 is easier to manufacture because the reserve tube 304 is formed from the first and second open housings 312a, 312b, rather than from a preformed tube. The tire indentation 331 can be formed during the same stamping operation that forms the first and second open housings 312a, 312b, thus eliminating the need for a separate manufacturing step for forming the tire indentation 331.

Each of the first and second open housings 312a, 312b includes an arcuate projection 332 extending radially inward toward the longitudinal axis 311. Arcuate projections 332 cooperate to form a continuous annular recess 334 that extends 360 degrees around reserve tube 304. Each arcuate projection 332 has a first sloping surface 336a and a second sloping surface 336b that converge at a circular inner edge 338 in the illustrated example. First inclined surface 336a of arcuate projection 332 directly engages base valve 306 and supports base valve 306 within reserve tube 304 at a location longitudinally spaced from end wall 324 of reserve tube 304.

Base valve 306 includes a base valve disc 346, a compression disc stack 348, an extension disc stack 350, and a valve pin 352. Bottom valve disc 346 includes a valve pin hole 354, a plurality of compression passages 356 and a plurality of extension passages 358 positioned circumferentially between a plurality of disc legs 360. Valve pin holes 354 receive valve pins 352 that hold the compressed disk stack 348 and the extended disk stack 350 on the bottom valve disk 346. Base valve disc 346 has a proximal face 362 facing downward working chamber 44 and a distal face 364 facing end wall 324 of reserve tube 304. An extension disc stack 350 is positioned on at least a portion of a proximal face 362 of the base valve disc 346 to control fluid flow through the extension passages 358. A compression disc stack 348 is positioned on at least a portion of distal face 364 of base valve disc 346 to control fluid flow through compression passages 356.

Proximal face 362 of the undercut disk 346 includes an annular shoulder 368 that is configured to be inserted into the lower end 310 of pressure tube 302 in a press-fit manner. Bottom valve disc 346 includes an outer diameter 370 and inner edge 338 of arcuate projection 332 in reserve tube 304 defines an inner diameter 372 that is smaller than outer diameter 370 of bottom valve disc 346. The distal face 364 of the base valve disc 246 includes a plurality of longitudinal legs 374 that extend longitudinally toward the end wall 324 of the reserve tube 304. The plurality of longitudinal legs 374 are circumferentially spaced apart by the channel 376. The longitudinal leg 374 has a tapered end 378 configured to abut the first inclined surface 336a of the arcuate projection 332. Thus, arcuate projection 332 supports base valve 306 in a centered position within reserve tube 304.

The number, radial thickness, and circumferential width of longitudinal legs 374 may vary depending on the desired fluid flow rate through passages 376 and the amount of preload applied to bottom valve disc 346 during assembly of shock absorber subassembly 300. For example, when pressure tube 302 is installed in reserve tube 304, a preload of 10 kilonewtons to 15 kilonewtons (kN) may be applied to base valve disk 346. Base valve disc 346 must be designed such that longitudinal leg 374 does not break under the preload force.

The shock absorber subassemblies 100, 200, 300 described above may be manufactured according to the exemplary methods set forth below.

The method comprises the following steps: obtaining a pressure tube 102, 202, 302; slidably positioning the piston assembly 32 within the pressure tube 102, 202, 302; forming the first open shell 112a, 212a, 312a from a first metal sheet; forming the second open housing 112b, 212b, 312b from a second sheet of metal, and positioning the first open housing 112a, 212a, 312a and the second open housing 112b, 212b, 312b around the pressure tube 102, 202, 302. The method continues with the steps of: aligning the first open housing 112a, 212a, 312a with the second open housing 112b, 212b, 312b, welding the first open housing 112a, 212a, 312a to the second open housing 112b, 212b, 312b to sealingly engage the first open housing 112a, 212a, 312a to the second open housing 112b, 212b, 312b and thereby define the reserve tube 104, 204, 304, and coupling the reserve tube 104, 204, 304 to the pressure tube 102, 202, 302.

As described above, reserve tubes 202 and 302 include substantially cylindrically shaped portions 230a, 230b, 230a, 230b and one or more protrusions 232, 332. The protrusions 232, 332 are at least partially defined by one of the first and second sheets. According to the method described above, the step of positioning the first and second open housings 112a, 212a, 312a, 112b, 212b, 312b occurs before the welding step. The method may further include the step of positioning the base valve 106, 206, 306 between the first open housing 112a, 212a, 312a and the second open housing 112b, 212b, 312b prior to the step of welding the first open housing 112a, 212a, 312a to the second open housing 112b, 212b, 312 b. According to this step of the method, one or more protrusions 232, 332 retain base valve 206, 306 at least partially within reserve tube 104, 204, 304.

The annular lip 128, 228, 328 at the first end 118, 218, 318 of the reserve tube 104, 204, 304 may be manufactured in a number of different ways. In the example shown in fig. 3 and 4, the annular lip 128 is formed by flanges 126a, 126b that may be stamped or otherwise formed in the first and second open housings 112a, 112 b. Fig. 18 and 19 illustrate other examples in which the annular lips 428, 528 are formed by method steps of securing a tubular sleeve 480, 580 to the first end 418, 518 of the reserve tube 404, 504 and mechanically deforming a portion of the tubular sleeve 480, 580 to define the annular lips 428, 528 at the first end 418, 518 of the reserve tube 404, 504. The mechanical deformation process used in the above method steps may be a process known as spinning, in which tubular sleeves 480, 580 are pushed longitudinally against an angled die while tubular sleeves 480, 580 are rotated about longitudinal axes 411, 511 to bend a portion of tubular sleeves 480, 580 inward to form annular lips 428, 528. If a spinning process is applied to first end 118 of reserve tube 104 shown in fig. 3 and 4 to form annular lip 128, the weld at seams 116a, 116b may break. By attaching the tubular sleeves 480, 580 to the first ends 418, 518 of the reserve tubes 404, 504 shown in fig. 18 and 19, a spinning process may be used without compromising the integrity of the weld. In fig. 18, tubular sleeve 480 is welded to first end 418 of reserve tube 404 at joint 482. In fig. 19, a tubular sleeve 580 is configured to cover the first end 518 of the reserve tube 504 and is welded to the reserve tube 504 at location 582.

Advantageously, constructing the reserve tube 104, 204, 304 from first and second open housings 112a, 112b, 212a, 212b, 312a, 312b rather than from drawn tube provides great flexibility in applying various internal and external features to the reserve tube 104, 204, 304 in a more accurate and less costly manner, which is easier to manufacture and requires fewer welds. According to the above method, the first and second open housings 112a, 112b, 212a, 212b, 312a, 312b are formed of first and second metal sheets. The first metal sheet may be a mirror image of the second metal sheet and may have a non-rectangular perimeter shape.

Referring to fig. 20A-D, the first and second metal sheets may be made from metal blanks 600A, 600b, 600c, 600D. Referring to fig. 20A, each of the first and second metal sheets may include a tailored blank 600A including a first portion 602a having a first set of mechanical properties and a second portion 604a having a second set of mechanical properties different from the first set of mechanical properties. For example, the first portion 602a has a first thickness 606a that is different than a second thickness 608a of the second portion 604a that is greater than the first thickness 606 a. In another example shown in fig. 20B, each of the first and second metal sheets can include a custom weld blank 600B that includes first and second portions 602a, 604B made of different materials and/or having different thicknesses. In both examples shown in fig. 20A-B, the first portions 602a, 602B are manufactured separately and separately from the second portions 604a, 604B, and then joined to the second portions 604a, 604B by welding or another attachment mechanism. In another example shown in fig. 20C, each of the first and second metal sheets may comprise a tailored rolled blank 600C comprising a first portion 602C having a first thickness 606C and a second portion 604C having a second thickness 608C greater than the first thickness 606C. According to this example, the rolling operation is used to impart different thicknesses 606c, 608c and other mechanical properties to the customized rolled blank 600c in the first portion 602c and the second portion 604 c. In another example shown in fig. 20D, each of the first and second metal sheets can comprise a customized heat treatment blank 600D comprising a first portion 602D and a second portion 604D that have been subjected to different levels of heat treatment to impart different mechanical properties (e.g., strength) to the first portion 602D as compared to the second portion 604D.

The blanks 600A, 600b, 600c, 600D shown in fig. 20A-D may be used to create a variety of different features. By way of non-limiting example, the portions 140A, 140b of reserve tube 104 shown in fig. 4 and 5 adjacent to mounting bracket 134 may be formed using one of the blanks 600A, 600b, 600C shown in fig. 20A-C.

It should be understood that the first and second metal sheets described herein may be made from ferrous or non-ferrous flat metal sheets in the form of blanks or coils. More specifically, the first and second open housings 112a, 112b, 212a, 212b, 312a, 312b may be stamped using a pressurized medium

(i.e., sheet hydroforming with a die (SHF-D) or a punch (SHF-P)), stamping, rubber forming, incremental forming, or other similar sheet metal forming methods. This allows for integration of attachment components such as mounting bracket 134, stabilizing bracket, legs, spring seats, and tubular extension 242 (i.e., the outer valve housing) into the plastically deformed sheet metal forming reserve tubes 104, 204, 304. This eliminates the need to manufacture tubes with external attachments and eliminates the need for multiple joining and welding operations. The use of first and second open housings 112a, 112b, 212a, 212b, 312a, 312b to manufacture reserve tubes 104, 204, 304 minimizes the generation of sheet metal scrap, reduces cycle time, and reduces production costs. In addition, potential cost reductions are realized as part complexity is shifted to sheet manufacturing processes (e.g., tooling and mold costs).

The deformation of the blanks 600a, 600b, 600c, 600d may be performed in a single forming operation or in multiple simultaneous forming operations, such as progressive stamping. The cutting of the deformed sheet metal part may be integrated into the forming operation or may be performed separately using a laser, water jet, plasma or other cutting operation. During the manufacture of the first and second split housings 112a, 112b, 212a, 212b, 312a, 312b, bracket and fastener like value added features may be integrated into the plastically deformed sheet.

The pressure tube 202, 302, base valve 206, 306, and/or intermediate tube 305 may be supported within the reserve tube 204, 304 by stamping or otherwise forming one or more protrusions 232, 332 of the first and second open housings 212a, 212b, 312a, 312 b. In this way, the manufacture of the base/cover or the thermal closing of the end of the reserve tube can be eliminated. Instead, the top closure may be formed during the housing forming process.

In accordance with the above method, the welding process that applies a relatively small amount of heat to the reserve tubes 104, 204, 304 is selected so as to reduce possible deformation of the first and second open housings 112a, 112b, 212a, 212b, 312a, 312 b. As a non-limiting example, laser welding may be used. The tailored blanks 600a, 600b, 600c, 600d (e.g., sheets having different alloys, thicknesses, coatings, or material properties) may be used as initial blanks for sheet metal forming operations to achieve different mechanical properties (e.g., different strengths and stiffnesses) at different portions of the reserve tubes 104, 204, 304. For example, greater thickness is desired in portions of reserve tube 104 near mounting bracket 134 or at locations of high stress concentration (e.g., rings and tube attachments).

For less ductile materials, such as high strength steel sheets, the forming/stamping operations described herein may occur at elevated temperatures to improve formability and reduce spring back. For example, sheet metal blank 600d may be locally softened (e.g., locally annealed using laser or induction heating) in areas where higher strain is desired to enhance formability.

Many other modifications and variations of the present disclosure are possible in light of the above teachings and may be practiced otherwise than as specifically described within the scope of the appended claims. Further, the steps of the methods set forth above and in the appended claims may be performed in parallel, sequentially, or in a different order than those described herein without departing from the scope of the disclosure.