Hydraulic damper assembly including a hydraulic compression stop

A hydraulic damper assembly comprising:

• a main tube extending along a center axis defining a fluid chamber for containing a working fluid;
• an external tube extending about said main tube defining a compensation chamber extending between said main tube and said external tube;
• a main piston located in said main tube dividing said fluid chamber into a compression chamber and a rebound chamber;
• a piston rod extending into said main tube and coupled to said main piston for moving said main piston between a compression stroke and a rebound stroke;
• a base valve located in said compression chamber and coupled to said main tube for controlling working fluid flow between said compression chamber and said compensation chamber;
• and
• a hydraulic compression stop located in said compression chamber for providing an additional damping force during said compression stroke;
• said hydraulic compression stop including an additional piston, an insert, and a fixing member, said additional piston being coupled to said main piston for movement with said main piston between said compression stroke and said rebound stroke, said fixing member located between said main tube and said base valve for coupling said base valve to said main tube, and said insert located in said compression chamber coupled to said fixing member;
• said fixing member including a head portion extending outwardly from said fixing member and along said center axis toward said main piston;
• and
• a terminal section of said insert including an internal flange extending radially inwardly toward said center axis, said internal flange defining a mounting opening for receiving said head portion to establish a press-fit engagement,
• wherein said insert has a main section and a terminal section, said terminal section being located adjacent to said fixing member and said main section being in fluid communication with said terminal section, and said terminal section having an external diameter that is less than an external diameter of said main section,
• wherein a diameter of said mounting opening satisfies the following:
• Df≤√{square root over (Dv2−0.05*[(a*Dm)2−(b*Dv)2])}, or
• Df≥√{square root over (Dd2−[(a*Dm)2−(b*Dv)2])},
• wherein Df is said diameter of said mounting opening;
• Dv is an internal diameter of said insert;
• Dm is said external diameter of said main section of said insert;
• Dd is said external diameter of said terminal section;
• a=1.1 to 1.6;
• and
• b=1.0 to 1.5, wherein b*Dv<a*Dm.

A hydraulic damper assembly comprising:

• a main tube extending along a center axis defining a fluid chamber for containing a working fluid;
• an external tube extending about said main tube defining a compensation chamber extending between said main tube and said external tube;
• a main piston located in said main tube dividing said fluid chamber into a compression chamber and a rebound chamber;
• a piston rod extending into said main tube and coupled to said main piston for moving said main piston between a compression stroke and a rebound stroke;
• a base valve located in said compression chamber and coupled to said main tube for controlling working fluid flow between said compression chamber and said compensation chamber;
• and
• a hydraulic compression stop located in said compression chamber for providing an additional damping force during said compression stroke;
• said hydraulic compression stop including an additional piston and an insert, said additional piston being coupled to said main piston for movement with said main piston between said compression stroke and said rebound stroke, said insert located in said compression chamber and being coupled to said base valve;
• said insert having a main section and a terminal section, said terminal section being located adjacent to a fixing member and said main section being in fluid communication with said terminal section, said terminal section having an external diameter that is less than an external diameter of said main section,
• wherein said hydraulic compression stop includes the fixing member, said fixing member located between said main tube and said base valve for coupling said base valve to said main tube;
• and
• wherein said insert couples to said fixing member via a press-fit engagement,
• wherein said fixing member includes a head portion extending outwardly from said fixing member and along said center axis toward said main piston,
• said terminal section of said insert includes an internal flange extending radially inwardly toward said center axis, said internal flange defining a mounting opening for receiving said head portion to establish said press-fit engagement,
• wherein said head portion has a tensile strength (Rm) greater than or equal to 300 Mpa, a yield stress (Re) greater than or equal to 250 Mpa, and hardness of at least 51 HRB in Rockwell B scale.