Shock absorber with metal damper tube and composite mounting attachment and spring seat

1. A shock absorber comprising:

a metal damper tube extending co-axially about a longitudinal axis between a first damper tube end and a second damper tube end;

said metal damper tube including an internal surface and an external surface;

a base assembly, fixed to said metal damper tube, that includes a composite mounting attachment made of a composite material;

said composite mounting attachment extending between a proximal end and a distal end;

said proximal end including a cavity that houses at least a portion of said metal damper tube to define an overlapping region where said composite mounting attachment and said metal damper tube are co-extensive with each other; and

at least one window in said overlapping region of said composite mounting attachment, wherein said composite mounting attachment and said metal damper tube are in contact with each other except in a region of the at least one window where said metal damper tube is left exposed and uncovered by said composite material of said composite mounting attachment to promote heat dissipation away from said metal damper tube while reducing heat transmission from said metal damper tube to said composite mounting attachment.

2. The shock absorber as set forth in claim 1 , wherein said composite mounting attachment includes a first stanchion and a second stanchion that extends longitudinally from said overlapping region of said composite mounting attachment to said distal end.

3. The shock absorber as set forth in claim 2 , wherein said base assembly includes a metal insert that is embedded in said composite material forming said composite mounting attachment, said metal insert including first and second legs that extend longitudinally within said first and second stanchions, respectively, from a flange that is attached to said second end of said metal damper tube at a fixed flange connection.

4. The shock absorber as set forth in claim 3 , wherein said base assembly includes first and second metal eyelets, wherein said first and second stanchions include first and second bores, respectively, that are positioned at said distal end of said composite mounting attachment and that cooperate to form a fastener bore that extends perpendicularly relative to said longitudinal axis, wherein said first and second legs include first and second holes, respectively, that are arranged in alignment with said first and second bores in said first and second stanchions, and wherein said first and second metal eyelets are positioned in and extend through said first and second bores in said first and second stanchions of said composite mounting attachment and said first and second holes in said first and second legs of said metal insert.

5. The shock absorber as set forth in claim 4 , wherein said first and second metal eyelets are attached to said first and second legs of said metal insert at first and second fixed connections and wherein said first and second fixed connections and said fixed flange connection are press-fit or welded.

6. The shock absorber as set forth in claim 2 , wherein said first and second stanchions extend parallel to each other on opposite sides of said longitudinal axis and are spaced apart by a transverse gap.

7. The shock absorber as set forth in claim 1 , wherein said composite mounting attachment includes a plurality of reinforcing ribs that extend across at least said overlapping region to create interstitial pockets between adjacent reinforcing ribs.

8. The shock absorber as set forth in claim 7 , wherein said interstitial pockets are filled with a filler material to give said composite mounting attachment a smooth exterior, said composite material having a first density, and said filler material having a second density that is less than said first density.

9. The shock absorber as set forth in claim 1 , wherein said metal damper tube includes an internal surface and an external surface, said external surface of said metal damper tube including a textured area adjacent said second damper tube end, and said composite material of said composite mounting attachment is bonded to said textured area of said metal damper tube.

10. The shock absorber as set forth in claim 4 , wherein said composite material of said composite mounting attachment is an overmolded composite material that covers at least portions of said metal damper tube, said metal insert, and said first and second metal eyelets.

11. The shock absorber as set forth in claim 1 , wherein said proximal end of said composite mounting attachment includes an integral spring seat that extends radially outward away from said metal damper tube and is made of said composite material.

12. A shock absorber comprising:

a metal damper tube extending co-axially about a longitudinal axis between a first damper tube end and a second damper tube end;

said metal damper tube including an internal surface and an external surface;

a piston slideably disposed inside said metal damper tube;

a piston rod, fixably coupled to said piston, that extends co-axially along said longitudinal axis and protrudes out from said first damper tube end;

a base assembly that is fixed to said metal damper tube at a location adjacent said second damper tube end;

said base assembly including a composite mounting attachment that extends longitudinally between a proximal end and a distal end;

said proximal end of said composite mounting attachment including a cavity that houses at least a portion of said metal damper tube to define an overlapping region adjacent to said proximal end of said composite mounting attachment where said composite mounting attachment and said metal damper tube are co-extensive with each other;

said composite mounting attachment is made of a composite material that is bonded to said external surface of said metal damper tube; and

at least one window in said overlapping region of said composite mounting attachment, wherein said composite mounting attachment and said metal damper tube are in contact with each other except in a region of the at least one window where said metal damper tube is left exposed and uncovered by said composite material of said composite mounting attachment to promote heat dissipation away from said metal damper tube while reducing heat transmission from said metal damper tube to said composite mounting attachment to reduce overheating said composite material.

13. The shock absorber as set forth in claim 12 , wherein said composite mounting attachment includes a plurality of reinforcing ribs and interstitial pockets between adjacent reinforcing ribs.

14. The shock absorber as set forth in claim 13 , wherein said interstitial pockets are filled with a filler material to give said composite mounting attachment a smooth exterior, said composite material having a first density, and said filler material having a second density that is less than said first density.

15. The shock absorber as set forth in claim 12 , wherein said proximal end of said composite mounting attachment includes an integral spring seat that extends radially outward away from said metal damper tube and said distal end of said composite mounting attachment includes first and second stanchions that extend longitudinally from said overlapping region of said composite mounting attachment.

16. The shock absorber as set forth in claim 12 , wherein said external surface of said metal damper tube including a textured area adjacent said second damper tube end and said composite material of said composite mounting attachment is bonded to said textured area of said metal damper tube.

17. The shock absorber as set forth in claim 12 , wherein said composite material of said composite mounting attachment is a reinforced thermoplastic that is overmolded onto at least portions of said metal damper tube by an injection molding or three-dimensional printing process.

18. A shock absorber comprising:

a metal damper tube extending co-axially about a longitudinal axis between a first damper tube end and a second damper tube end;

a base assembly that is fixed to said metal damper tube at a location adjacent said second damper tube end;

said base assembly including a composite mounting attachment, made of a composite material, that extends longitudinally between a proximal end and a distal end;

said proximal end of said composite mounting attachment including a cavity that houses at least a portion of said metal damper tube to define an overlapping region adjacent to said proximal end of said composite mounting attachment where said composite mounting attachment and said metal damper tube are co-extensive with each other;

said composite mounting attachment including one or more windows, wherein said composite mounting attachment and said metal damper tube are in contact with each other except in a region of said one or more windows where said outer surface of said metal damper tube is left exposed and uncovered to promote heat dissipation away from said metal damper tube while decreasing heat transmission from said metal damper tube to said composite mounting attachment to reduce overheating said composite material;

said composite mounting attachment including a first stanchion and a second stanchion that extend longitudinally from said overlapping region of said composite mounting attachment to said distal end;

said first and second stanchions extending substantially parallel to each other on opposite sides of said longitudinal axis and being spaced apart by a transverse gap; and

said first and second stanchions including first and second bores, respectively, that are positioned at said distal end of said composite mounting attachment and that cooperate to form a fastener bore that extends perpendicularly relative to said longitudinal axis.

19. The shock absorber as set forth in claim 18 , wherein said base assembly includes a metal insert that is embedded in said composite material forming said composite mounting attachment, said metal insert including first and second legs that extend longitudinally within said first and second stanchions, respectively, from a flange that is attached to said second end of said metal damper tube at a fixed flange connection.

20. The shock absorber as set forth in claim 19 , wherein said base assembly includes first and second metal eyelets, wherein said first and second stanchions include first and second bores, respectively, that are positioned at said distal end of said composite mounting attachment and that cooperate to form a fastener bore that extends perpendicularly relative to said longitudinal axis, wherein said first and second legs include first and second holes, respectively, that are arranged in alignment with said first and second bores in said first and second stanchions, and wherein said first and second metal eyelets are positioned in and extend through said first and second bores in said first and second stanchions of said composite mounting attachment and said first and second holes in said first and second legs of said metal insert.