Patent Publication Number: US-2023150328-A1

Title: Hydraulic Jounce Bumper with Improved Installation

Description:
TECHNICAL FIELD 
     Example embodiments generally relate to vehicle suspension and, more particularly, relate to a suspension system with an easy to install jounce bumper for a suspension damper or shock absorber. 
     BACKGROUND 
     Vehicles commonly employ independent suspension systems that allow each wheel to move relative to the vehicle chassis independent of the other wheels. The components and geometries used for independent suspension designs can vary to some degree. However, a typical independent suspension system will employ dampers or shock absorbers (or simply “shocks”) that are designed to provide damping for pitch (i.e., oscillation about a lateral axis of the vehicle). The shocks generally resist compression and rebound with damping forces that are applied over a range of travel of a piston rod. The shocks selected for a particular vehicle are generally chosen based on the expectation of normal pitch scenarios that are encountered during routine driving conditions. Some typical suspension components that may be considered for selection include springs and dampers (e.g., gas shocks). 
     In addition to shocks, many independent suspension systems also employ jounce bumpers (i.e. bump stops). Jounce bumpers are known to reduce the impact on the suspension components when under full compression from abrupt changes in driving conditions. In some cases, jounce bumpers are embodied as blocks of rubber or some other shock absorbent material that are placed somewhere between the axle tube that connects to the wheel and the body of the vehicle to prevent damage therebetween. These jounce bumpers, although useful, typically require an additional bracket assembly or weldment to be employed for installation, which adds complication and reduces efficiency. 
     BRIEF SUMMARY OF SOME EXAMPLES 
     In accordance with an example embodiment, a damping assembly for a vehicle suspension system may be provided. The damping assembly may include a spring including a first end operably coupled to a body of a vehicle and a second end operably coupled to a wheel assembly of the vehicle, a spring isolator operably coupling the body of the vehicle to the first end of the spring, a hydraulic jounce bumper to dampen jounce forces on the vehicle, and a reinforcement member operably coupled to the hydraulic jounce bumper at a proximal end of the reinforcement member and to the spring isolator at a distal end of the reinforcement member. The reinforcement member may be integrated with the spring isolator at the distal end of the reinforcement member. 
     In another example embodiment, a suspension system for a vehicle may be provided. The suspension system may include a wheel assembly of the vehicle, a body of the vehicle, and a damping assembly operably coupling the wheel assembly and the body to dampen impacts on the body of the vehicle responsive to jounce and rebound events experienced at the wheel assembly. The damping assembly may include a spring including a first end operably coupled to the body of a vehicle and a second end operably coupled to the wheel assembly of the vehicle, a spring isolator operably coupling the body of the vehicle to the first end of the spring, a hydraulic jounce bumper to dampen jounce forces on the vehicle, and a reinforcement member operably coupled to the hydraulic jounce bumper at a proximal end of the reinforcement member and to the spring isolator at a distal end of the reinforcement member. The reinforcement member may be integrated with the spring isolator at the distal end of the reinforcement member. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
       Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein: 
         FIG.  1    illustrates a block diagram of a vehicle suspension system in accordance with an example embodiment; 
         FIG.  2    illustrates a side view of a damping assembly in accordance with an example embodiment; 
         FIG.  3 A  illustrates a section view of the damping assembly with the jounce bumper extended in accordance with an example embodiment; 
         FIG.  3 B  illustrates a section view of the damping assembly with the jounce bumper compressed in accordance with an example embodiment; and 
         FIG.  4    illustrates a perspective view of the damping assembly in accordance with an example embodiment. 
     
    
    
     DETAILED DESCRIPTION 
     Some example embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all example embodiments are shown. Indeed, the examples described and pictured herein should not be construed as being limiting as to the scope, applicability or configuration of the present disclosure. Rather, these example embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like reference numerals refer to like elements throughout. Furthermore, as used herein, the term “or” is to be interpreted as a logical operator that results in true whenever one or more of its operands are true. As used herein, operable coupling should be understood to relate to direct or indirect connection that, in either case, enables functional interconnection of components that are operably coupled to each other. 
     Some example embodiments described herein may address the problems described above. In this regard, for example, some embodiments may provide an improved damping assembly or suspension system design that is also easy to install. In particular, example embodiments may be installed without any requirement for additional bracket assemblies or weldments to be employed. 
       FIG.  1    illustrates a block diagram of a vehicle suspension system  100  employing a damping assembly  110 . The damping assembly  110  may be used to dampen jounce and rebound forces that may be initiated between a body or chassis  120  of the vehicle and a wheel assembly  130  (which may include each individual wheel and other suspension system components that support the corresponding wheels). Bumps or obstacles in a terrain over which a vehicle is being operated may cause the wheel and wheel assembly  130  to articulate varying amounts depending on how the vehicle is driven and the size of the obstacle in the terrain. Thus, the vehicle&#39;s suspension system  100  may reach full compression at certain points depending on the articulation distance the wheel assembly  130  may be required to travel. In other words, the wheel assembly  130  may be forced towards the body  120  and at this point the suspension system  100  may be at full compression. Thus there may be potential for the wheel assembly  130  to impart a significant jounce force on other components in the suspension system  100 . The wheel assembly  130  making forceful contact with other elements of the suspension system  100  may lead to the components of the suspension system  100  impacting each other. In this regard, the damping assembly  110  may be prevent or mitigate any such impact occurring to components of the suspension system  100  as a result of jounce forces from the wheel assembly  130 . 
     In some embodiments, the damping assembly  110  operably couples the chassis  120  to the wheel assembly  130 . The damping assembly  110  may include a spring  140 , a hydraulic jounce bumper  150 , a reinforcement member  160 , and a spring isolator  170 . In some embodiments, the vehicle suspension system  100  may also include a shock absorber (not pictured) that may be separate from the damping assembly  110 , and may also operably couple the body  120  to the wheel assembly  130 . The spring  140  may be configured to compress or decompress responsive to the wheel assembly  130  articulation as the vehicle traverses uneven terrain. The spring  140  may therefore be disposed such that a first end of the spring  140  is operably coupled to the body  120  (via a spring isolator  170 ), and a second end of the spring is operably coupled to the wheel assembly  130 . Spring seats or other intermediate components may therefore also be understood to be provided at the first and second ends of the spring  140  in some cases. The spring  140  may also be disposed around the hydraulic jounce bumper  150  such that the hydraulic jounce bumper  150  is disposed inside and at a center of the spring  140 . In some embodiments, the spring  140  may be designed to compress a predetermined amount before the wheel assembly  130  comes into contact with the hydraulic jounce bumper  150 . In this regard, the hydraulic jounce bumper  150  may extend to a total length that is less than the distance between the first end and the second end of the spring  140 . Accordingly, the hydraulic jounce bumper  150  may not be engaged as a result of the wheel assembly  130  articulating a small amount due to the vehicle traversing a small obstacle. In other words, the hydraulic jounce bumper  150  may only make contact with the wheel assembly  130  when the wheel assembly  130  articulates a large amount with great force. In this regard, the hydraulic jounce bumper  150  is more of a backup feature to be used as protection for extreme jounce events, and is different from a shock absorber designed to provide a smoother ride for the vehicle during normal ride conditions. 
     The hydraulic jounce bumper  150  may further include a sleeve  152 , a rod  154  and an bump member  156 . The hydraulic jounce bumper sleeve  152  may be configured to slidably fit over the hydraulic jounce bumper rod  154 . In this regard, the rod  154  may be configured to slide into and out of the sleeve  152  as a result of the external jounce forces imparted on the hydraulic jounce bumper  150  by the wheel assembly  130 . In some embodiments, the sleeve  152  may be filled with a fluid, e.g., of gaseous or liquid nature, to aid in resisting sudden forceful movements of the hydraulic jounce bumper rod  154  and thus dampen the jounce forces of the wheel assembly  130 . The bump member  156  of the hydraulic jounce bumper  150  may be fixedly operably coupled to the rod  154  such that the bump member  156  and the rod  154  move together. The bump member  156  of the hydraulic jounce bumper  150  may be where the wheel assembly  130  (or a portion of the suspension system  100  operably coupled thereto) makes contact with the hydraulic jounce bumper  150  in the event that the spring  140  has compressed beyond the predetermined amount. Responsive to the wheel assembly  130  (or the portion of the suspension system  100  operably coupled thereto) imparting a jounce force on the bump member  156  of the hydraulic jounce bumper  150 , the rod  154  may slide into the sleeve  152  filled with a compressible fluid in order to dampen the force felt on the body  120 . 
     The reinforcement member  160  may be operably coupled to the hydraulic jounce bumper  150 . The reinforcement member  160  may be structured to further distribute and dampen jounce forces from the hydraulic jounce bumper  150 . The reinforcement member  160  may also be configured to secure the hydraulic jounce bumper  150  in a proper functioning position at the center of the spring  140 . In some embodiments, the reinforcement member  160  may be conical in shape. The reinforcement member  160  may be operably coupled to the hydraulic jounce bumper  150  at a narrow end, and may get wider moving away from the operable coupling with the hydraulic jounce bumper  150  and towards the body  120  at a wide end of the reinforcement member  160 . Additionally, the reinforcement member  160  may be formed from a metallic material in order to provide adequate rigidity and strength to ensure the hydraulic jounce bumper  150  can withstand large repeated jounce forces. 
     The reinforcement member  160  may be operably coupled to a spring isolator  170  at the wide end of the reinforcement member  160 . In this regard, a portion of the reinforcement member  160  may extend into, and may be integrated with, the spring isolator  170  which will be discussed in greater detail below in reference to later figures. In some embodiments, the spring isolator  170  may be disposed between the body  120  and the first end of the spring  140 . As such, the spring isolator  170  may be fixedly operably coupled to the spring  140  such that the spring isolator  170  isolates the body  120  from the spring  140 . In this regard, the forces generated by the compression of the spring  140  may not be directly transferred to the body  120 , but rather may be transferred indirectly via the spring isolator  170 . In some embodiments, the spring isolator  170  may comprise a rubber or composite material that is compressible, or some other type of shock absorbent material, which may help isolate the body  120  from the forces and vibrations transferred through the spring  140  from the wheel assembly  130 . In some embodiments, the spring isolator  170  may be shaped like a ring, where the center of the spring isolator  170  may be open. On the outer edge of the spring isolator  170 , where the spring isolator  170  contacts the spring  140 , there may be a lip configured to operably couple to the first end of the spring  140 . The lip may be formed so that the spring  140  naturally seats itself within the lip of the spring isolator  170 . The hydraulic jounce bumper  150  may extend through the center of the reinforcement member  160 , and in some embodiments, at least part of the spring isolator  170 . In this regard, the hydraulic jounce bumper  150  may not extend all the way through the spring isolator  170 , leaving some room between the end of the hydraulic jounce bumper  150  and an end of the spring isolator  170 . 
     In some embodiments, the open space inside the ring of the spring isolator  170 , and between the hydraulic jounce bumper  150  and the body  120 , may operably couple with a locator  180 . The locator  180  may provide a secure connection between the damping assembly  110  and the body  120 . In this regard, the locator  180  may be operably coupled to the body  120  to provide a consistent location for, and retention of, the spring isolator  170 . In some embodiments, the locator  180  may be fixedly operably coupled with a portion of the body  120  (e.g., via bolts, welds, or other fixing means). Additionally, as previously mentioned, the locator  180  may provide a seat that is configured to relatively tightly fit inside the center of the spring isolator  170  so that lateral motion of the spring isolator  170  is prevented. Therefore, the damping assembly  110  may be placed into position over the locator  180  by hand and without the need for further fastening via welding or bolting between the damping assembly  110  and the body  120  or wheel assembly  130 . In some embodiments, the force of the spring  140  against the spring isolator  170  may be sufficient to keep the damping assembly  110  in the correct orientation on the locator  180 , and the locator  180  may extend far enough into the spring isolator  170  to prevent unseating of the spring isolator  170  from the locator  180  even in the event of a significant rebound event. Accordingly, the use of the spring isolator  170  with the locator  180  may offer numerous improvements to the vehicle manufacturing process. Namely, it may reduce the time and effort required to install the damping assembly  110 , the total number of parts needed to produce the vehicle, and it may also increase efficiency of producing the vehicle as a function of reducing the time and number of parts needed for installation. 
       FIG.  2    shows a specific example of some structures that may be employed to instantiate the components described above. In this regard, a damping assembly  210 , which is illustrated in  FIG.  2   , may include spring  240  and hydraulic jounce bumper  250 . The hydraulic jounce bumper  250  may include a sleeve  252 , rod  254  and bump member  256  that correspond to similarly named (but differently numbered) items described above in reference to  FIG.  1   . The damping assembly  210  may further include a reinforcement member  260 , and spring isolator  270 . In this embodiment, it should be appreciated that the spring  240  may extend further down than is shown in  FIG.  2    so that it extends beyond the bump member  256  of the hydraulic jounce bumper  250 . In some embodiments, the spring  240 , the hydraulic jounce bumper  250 , the reinforcement member  260  and the spring isolator  270  may all be coaxial about a longitudinal axis  290 . As such, the spring  240  and the hydraulic jounce bumper  250  may both compress and decompress in the same direction parallel to axis  290 . In some embodiments, the reinforcement member  260  may be adjustably operably coupled to the hydraulic jounce bumper  250 . In this regard, a threaded connection  265  may be provided on the outer surface of the sleeve  252  of the hydraulic jounce bumper  250 . The threaded connection  265  may define an adjustable point at which the reinforcement member  260  contacts the hydraulic jounce bumper  250 . In this regard, the hydraulic jounce bumper  250  may be threaded to a desired position with respect to the reinforcement member  260 , effectively altering the predetermined amount of compression that the spring  240  must experience before the wheel assembly  130  engages bump member  256  of the hydraulic jounce bumper  250 . Furthermore, the threaded connection  265  may allow for the hydraulic jounce bumper  250  to be fine-tuned to achieve acceptable noise, vibrations and harshness (NVH) levels. In some embodiments, the threaded connection  265  may include a locking nut that may also operably couple to the threaded connection  265  on the sleeve  252  and which may secure the hydraulic jounce bumper  250  in place on the reinforcement member  260  at the desired adjustable point. In some other embodiments, the reinforcement member  260  may be fixedly operably coupled to the hydraulic jounce bumper  250  (e.g., to the sleeve  252  of the hydraulic jounce bumper  250 ). In this regard, the threaded connection  265  may not be provided, and as such, the position of the hydraulic jounce bumper  250  relative to the reinforcement member  260  may not be adjustable. 
       FIGS.  3 A and  3 B , show respective cross section views of the damping assembly  210  shown in  FIG.  2   . In particular,  FIG.  3 A  depicts the damping assembly  210  in an uncompressed state, or in other words, the rod  254  of the hydraulic jounce bumper  250  is shown at full extension rather than full compression.  FIG.  3 B , on the other hand, depicts the damping assembly  210  in a compressed state, or in other words, the rod  254  of the hydraulic jounce bumper  250  is shown at full compression rather than full extension. In the section views provided by  FIGS.  3 A and  3 B , the reinforcement member  260  is shown to extend into, and be integrated within, the spring isolator  270 . In this regard, the spring isolator  270  may comprise solid rubber or some other shock absorbing material, and the reinforcement member  260  may be integrally formed inside of the solid rubber spring isolator  270 . The integration of the reinforcement member  260  with the spring isolator  270  may allow the reinforcement member  260  to act as the fastening method for the damping assembly  210 . In an example embodiment, the spring isolator  270  may be molded around the reinforcement member  260  to integrate the components together in a tight coupling. In this regard, the reinforcement member  260 , although generally conical in shape, includes a flared end portion  262  that is completely surrounded by the spring isolator  270 , and which is captured within the spring isolator  270 . The flared end portion  262 , which is at the distal end of the reinforcement member  260  relative to the threaded connection  265  in some examples, is therefore provided to enable the fixing of the reinforcement member  260  to the spring isolator  270  in a consistent orientation, and without any other fixing means provided therebetween. In some cases, a thickness of rubber or other material forming the spring isolator  270  is consistent at all point relative to the flared end portion  262 . However, a thickness of the rubber or other material forming the spring isolator below the flared end portion  262  changes to conform to the shape of the spring  240 . Accordingly, integrating the reinforcement member  260  with the spring isolator  270  may simplify the installation process of the damping assembly  210  and thus cut down on vehicle production time while improving efficiency. Additionally, integrating the reinforcement member  260  with the spring isolator  270  may enhance the jounce force distribution of the damping assembly  110  as well as reduce NVH levels between the reinforcement member  260  and the spring isolator  270 . 
       FIG.  4    illustrates a perspective view of the damping assembly  210  in accordance with an example embodiment. The perspective shown in  FIG.  4    shows how the spring isolator  270  may be ring or annular shaped. In this regard, the spring isolator  270  may comprise a circular or cup shaped reception region  300  at the center of the spring isolator  270  which the locator  280  may operably couple with during installation of the damping assembly  210 . As such, the locator  280  may be configured to not interfere with the hydraulic jounce bumper  250  that may also reside at the center of the damping assembly  210  and along the longitudinal axis  290 . In other words, the locator  280  may contact the spring isolator  270  around a perimeter of the reception region  300  so as to leave space for the hydraulic jounce bumper  250  to be fit into operable coupling with the frame or body  120 , without any need for additional brackets or weldments. 
     A damping assembly for a vehicle suspension system may therefore be provided. The damping assembly may include a spring including a first end operably coupled to a body of a vehicle and a second end operably coupled to a wheel of the vehicle, a spring isolator operably coupling the body of the vehicle to the first end of the spring, a hydraulic jounce bumper to dampen jounce forces on the vehicle, and a reinforcement member operably coupled to the hydraulic jounce bumper at a proximal end of the reinforcement member and to the spring isolator at a distal end of the reinforcement member. The reinforcement member may be integrated with the spring isolator at the distal end of the reinforcement member. 
     The damping assembly (or a suspension system including the same) of some embodiments may include additional features, modifications, augmentations and/or the like to achieve further objectives or enhance performance of the device. The additional features, modifications, augmentations and/or the like may be added in any combination with each other. Below is a list of various additional features, modifications, and augmentations that can each be added individually or in any combination with each other. For example, the reinforcement member may be adjustably operably coupled to a sleeve of the hydraulic jounce bumper. In an example embodiment, reinforcement member may be operably coupled to the sleeve of the hydraulic jounce bumper via a threaded connection. In some cases, a locking nut may be used to lock the threaded connection between the reinforcement member and the hydraulic jounce bumper. In an example embodiment, the reinforcement member may be fixed to a sleeve of the hydraulic jounce bumper. In some cases, the spring isolator may be operably coupled to a locator operably coupled to the body, and the locator may extend into the spring isolator to prevent separation of the spring isolator from the locator during a rebound event. In an example embodiment, the spring isolator may be operably coupled to the body without welds or brackets. In some cases, reinforcement member may be integrated with the spring isolator via shock absorbent material of the spring isolator being molded over a distal end of the reinforcement member. In an example embodiment, a flared end portion may be disposed at the distal end of the reinforcement member, and the flared end portion may be entirely surrounded by and captured within the spring isolator. In some cases, an amount of material of the spring isolator between the flared end portion and the body may be substantially consistent at all portions of a periphery of the flared end portion, and an amount of material of the spring isolator between the flared end portion and the spring may change at least at some portions of the periphery of the flared end portion. 
     Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although the foregoing descriptions and the associated drawings describe exemplary embodiments in the context of certain exemplary combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative embodiments without departing from the scope of the appended claims. In this regard, for example, different combinations of elements and/or functions than those explicitly described above are also contemplated as may be set forth in some of the appended claims. In cases where advantages, benefits or solutions to problems are described herein, it should be appreciated that such advantages, benefits and/or solutions may be applicable to some example embodiments, but not necessarily all example embodiments. Thus, any advantages, benefits or solutions described herein should not be thought of as being critical, required or essential to all embodiments or to that which is claimed herein. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.