Metal working – Method of mechanical manufacture – Assembling or joining
Reexamination Certificate
2000-05-16
2001-11-13
Hughes, S. Thomas (Department: 3726)
Metal working
Method of mechanical manufacture
Assembling or joining
C029S445000, C029S897200, C029S512000
Reexamination Certificate
active
06314633
ABSTRACT:
FIELD OF THE INVENTION
The present invention relates to an automotive suspension system, and more particularly to a jounce bumper assembly for cushioning the impact between two components of an automotive suspension system. In another aspect, the present invention relates to a method of manufacturing such a jounce bumper assembly.
BACKGROUND OF THE INVENTION
Jounce bumpers for use in motor vehicle suspension systems are well known. Such devices have long been used for cushioning the impact between two suspension system components, such as the axle and a portion of the frame. To this end the jounce bumper, which includes a resilient material, is attached to the suspension system at a point where impact is likely to occur when the shock absorber fails to absorb the forces created by extraordinary driving conditions. The jounce bumper serves to cushion the impact, thereby reducing noise, the feel of the impact by the driver, and possible damage to the suspension system. However, although such devices are known, certain deficiencies in the prior art exist.
Referring to
FIG. 1
, an example of a prior art jounce bumper assembly is shown. The jounce bumper assembly
100
comprises a mounting cup
102
sized and shaped to receive a resilient bumper
104
. A plurality of stamped fingers
106
in the side waits
108
of mounting cup
102
are pressed into bumper
104
to retain bumper
104
in mounting cup
102
. A disadvantage of such a design is that side walls
108
of mounting cup
102
must have a depth great enough to provide fingers
106
of a sufficient length to retain bumper
104
in mounting cup
102
. There may not, however, be enough space available between the suspension system components to allow for the use of such a deep mounting cup. Another disadvantage of this prior art design is the stresses on jounce bumper assembly
100
caused by repeated impacts may cause bumper
104
to deform and eventually pull out of mounting cup
102
. This is particularly true when the depth of mounting cup
102
is shallow relative to its width.
What is desired, therefore, is a jounce bumper assembly for cushioning the impact between two components of an automotive suspension system, which can be disposed between suspension system components even when little space is provided therebetween, and which can withstand the stresses associated with repeated impacts.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a jounce bumper assembly which cushions the impact between two components of an automotive suspension system.
Another object of the present invention to provide a jounce bumper assembly having the above characteristics and which can be disposed between suspension system components even when little space is provided therebetween.
A further object of the present invention is to provide a jounce bumper assembly having the above characteristics and which can withstand the stresses associated with repeated impacts.
These and other objects of the present invention are achieved by provision of a jounce bumper assembly having a mounting plate with at least one, but preferably two, substantially tubular proturbances protruding from a face thereof. A bumper is molded from a microcellular polymeric material around the mounting plate such that the ends of the proturbances extend out from the bumper. The bumper is disposed within a mounting cup having a recess sized and shaped to receive the bumper. The recess has holes passing therethrough corresponding to the proturbances such that the ends of the proturbances pass through the holes. The ends of the proturbances passing through the holes are deformed radially outwardly such that the bumper is fixed within the recess of the mounting cup.
Preferably the mounting plate has a plurality of holes passing therethrough, which aid in molding the bumper therearound and which act to strengthen the attachment between the bumper and the mounting plate. The mounting plate also preferably has a plurality of protrusions on the face thereof, the plurality of protrusions being encased within the bumper to further strengthen the attachment. Also preferably, the microcellular polymeric material of which the bumper is formed is microcellular urethane. The preferred methods for deforming the ends of the proturbances radially outwardly are orbital spinning or cold staking.
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patent: 3694895 (1972-10-01), Werner
patent: 3809427 (1974-05-01), Bennett
patent: 4536116 (1985-08-01), Murray
patent: 5240233 (1993-08-01), Kato et al.
patent: 5397112 (1995-03-01), Roth et al.
patent: 5415443 (1995-05-01), Hayashi
patent: 5656353 (1997-08-01), Butler
patent: 5672405 (1997-09-01), Plank, Jr. et al.
patent: 5911936 (1999-06-01), Hanazaki et al.
patent: 6096256 (2000-08-01), Aretz
patent: 6159417 (1994-06-01), None
Curley, Jr. William J.
Norkus James F.
Hughes S. Thomas
Illinois Tool Works Inc.
Nguyen T.
St. Onge Steward Johnston & Reens LLC
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