Abstract: The present disclosure provides a method of manufacturing a damper for a vehicle. The method includes forming a groove on an outer surface of a first component in a first annular region. The first component is tubular. The method further includes inducing a compressive residual stress in a second annular region. The second annular region is at least partially aligned with the first annular region along a longitudinal axis of the first component. The method further includes coupling a second component to the first component. Surfaces of the first component and the second component directly engage one another at an interface. The second component is axially aligned with and radially surrounding at least a portion of the first annular region. In some configurations, forming the groove and inducing the compressive residual stress are performed concurrently, such as by low plasticity burnishing.

Abstract: The present disclosure provides a method of manufacturing a damper for a vehicle. The method includes forming a groove on an outer surface of a first component in a first annular region. The first component is tubular. The method further includes inducing a compressive residual stress in a second annular region. The second annular region is at least partially aligned with the first annular region along a longitudinal axis of the first component. The method further includes coupling a second component to the first component. Surfaces of the first component and the second component directly engage one another at an interface. The second component is axially aligned with and radially surrounding at least a portion of the first annular region. In some configurations, forming the groove and inducing the compressive residual stress are performed concurrently, such as by low plasticity burnishing.

Abstract: A damper includes a damper tube (a pressure tube or a reserve tube for a mono-tube or a double tube damper respectively) including a first end and a second end opposite to the first end. The damper includes a base member. The base member includes a cup portion at least partially enclosing the first end of the damper tube, and a sleeve portion extending from and integral with the cup portion. The sleeve portion surrounds a length of the damper tube. The sleeve portion is attached to the damper tube. Further, the damper includes a knuckle engaged with the sleeve portion such that the sleeve portion is disposed between the knuckle and the damper tube.

Abstract: A shock absorber pressure tube defining a working chamber is provided. A piston assembly coupled to a piston rod is slidably disposed in the pressure tube and divides the working chamber into upper and lower working chambers. A reserve tube surrounds the pressure tube to define a reserve chamber. A base valve assembly, position at one end of the pressure tube, controls fluid flow between the lower working chamber and the reserve chamber. The reserve tube comprises first and second open shells that are joined together at longitudinal seams to create a substantially cylindrical shape. The first and second open shells may be made from patchwork blanks, tailor welded blanks, tailor rolled blanks, or tailor heat treated blanks to give different portions of the first and second open shells different thicknesses, strengths, properties, or characteristics.

Abstract: A method of manufacturing a damper tube is provided. The method includes providing a tube having a first end and a second end opposite to the first end. The method includes providing a reinforcing insert, at least partly, within the first end of the tube. The method includes flattening a portion of the first end of the tube. The method also includes bending at least one of the reinforcing insert and the flattened portion of the first end of the tube into a loop. The method further includes connecting an edge of the loop to the tube.

Abstract: A damper including a damper tube, a piston assembly, a piston rod attached to the piston assembly, and a monolithic base. The piston assembly is slidingly disposed within the damper tube. The monolithic base includes a closed end, an open end, a base portion at the closed end, and a wall portion. The base portion is joined to and seals one end of the damper tube. The base portion includes a concave depression that tapers inwardly from a base portion perimeter to a cup bottom. The wall portion extends longitudinally from the base portion perimeter to the open end such that the cup bottom is positioned between opposing sides of the wall portion. Integrally formed fastening eyes are provided in the opposing sides of the wall portion.

Abstract: A method of manufacturing a damper tube is provided. The method includes providing a tube having a first end and a second end opposite to the first end. The method includes providing a reinforcing insert, at least partly, within the first end of the tube. The method includes flattening a portion of the first end of the tube. The method also includes bending at least one of the reinforcing insert and the flattened portion of the first end of the tube into a loop. The method further includes connecting an edge of the loop to the tube.

Abstract: A damper includes a damper tube (a pressure tube or a reserve tube for a mono-tube or a double tube damper respectively) including a first end and a second end opposite to the first end. The damper includes a base member. The base member includes a cup portion at least partially enclosing the first end of the damper tube, and a sleeve portion extending from and integral with the cup portion. The sleeve portion surrounds a length of the damper tube. The sleeve portion is attached to the damper tube. Further, the damper includes a knuckle engaged with the sleeve portion such that the sleeve portion is disposed between the knuckle and the damper tube.

Abstract: A method of manufacturing a damper tube is provided. The method includes providing a tube having a first end and a second end opposite to the first end. The method includes providing a reinforcing insert, at least partly, within the first end of the tube. The method includes flattening a portion of the first end of the tube. The method also includes bending at least one of the reinforcing insert and the flattened portion of the first end of the tube into a loop. The method further includes connecting an edge of the loop to the tube.

Abstract: A damper including a damper tube, a piston assembly, a piston rod attached to the piston assembly, and a monolithic base. The piston assembly is slidingly disposed within the damper tube. The monolithic base includes a closed end, an open end, a base portion at the closed end, and a wall portion. The base portion is joined to and seals one end of the damper tube. The base portion includes a concave depression that tapers inwardly from a base portion perimeter to a cup bottom. The wall portion extends longitudinally from the base portion perimeter to the open end such that the cup bottom is positioned between opposing sides of the wall portion. Integrally formed fastening eyes are provided in the opposing sides of the wall portion.

Abstract: A shock absorber pressure tube defining a working chamber is provided. A piston assembly coupled to a piston rod is slidably disposed in the pressure tube and divides the working chamber into upper and lower working chambers. A reserve tube surrounds the pressure tube to define a reserve chamber. A base valve assembly, position at one end of the pressure tube, controls fluid flow between the lower working chamber and the reserve chamber. The reserve tube comprises first and second open shells that are joined together at longitudinal seams to create a substantially cylindrical shape. The first and second open shells may be made from patchwork blanks, tailor welded blanks, tailor rolled blanks, or tailor heat treated blanks to give different portions of the first and second open shells different thicknesses, strengths, properties, or characteristics.

Abstract: A method of manufacturing a damper tube is provided. The method includes providing a tube having a first end and a second end opposite to the first end. The method includes providing a reinforcing insert, at least partly, within the first end of the tube. The method includes flattening a portion of the first end of the tube. The method also includes bending at least one of the reinforcing insert and the flattened portion of the first end of the tube into a loop. The method further includes connecting an edge of the loop to the tube.