Component, in particular for air springs, air spring strut, air spring damper or upper suspension housing and method for manufacturing components

Abstract

This invention relates to a component, particularly for air springs, air spring struts, air spring dampers, or upper suspension housings, wherein the component (10) has a first component part (12) with at least one groove (18), a second component part (14) with at least one tenon (20) corresponding to the groove (18), and a joining material (16), characterized in that the tenon (20) is at least partially disposed within the groove (18), wherein at least one channel (44) extends between the groove (18) and the tenon (20), and the first component part (12) and the second component part (14) are connected to each other by material joining by feeding the joining material (16) into the channel (44). With the invention, an improved component (10) is provided, wherein welds can be formed for the connection of the component parts (12, 14) from the outside.

Description

Technical Field

[0001] This invention relates to components, air spring struts, air spring dampers, or upper suspension housings and methods of manufacturing components, particularly for air springs. Background Technology

[0002] In manufacturing plastic components, injection molding can be used, for example. To manufacture a component with cavities, some parts of the component are first manufactured by injection molding. This component may have a shell structure. After its manufacture, the shells are assembled and connected to each other. The connection can be made, for example, by adhesive bonding or welding.

[0003] Both methods employ bonding materials to join the edges of the components. In the welding method, the component material at the edge surface is fused with bonding material applied to the edge at high temperature.

[0004] To create an airtight connection, it was also learned that the edges of two housings placed together are encapsulated from the outside by injection molding with a bonding material having a higher melting point than the housing materials. The housing materials and bonding materials were chosen in this way so that they can be connected to each other.

[0005] Furthermore, components with inaccessible structures that should produce connections between different individually manufactured parts are manufactured using welding methods. Summary of the Invention

[0006] The objective of this invention is therefore to provide an improved component and an improved method of manufacturing the component.

[0007] The present invention relates to a component, particularly for air springs, air spring struts, air spring dampers, or upper suspension housings, wherein the component has a first component part with at least one groove, a second component part with at least one tenon corresponding to the groove, and a joining material, wherein the tenon is at least partially disposed within the groove, wherein at least one channel extends between the groove and the tenon, and the first component part and the second component part are connected to each other by means of material joining by feeding the joining material into the channel.

[0008] Therefore, the present invention can be used to connect component parts to each other by weld in areas that were previously inaccessible. For this purpose, the first component part has at least one groove, and the second component part has at least one mating tenon. The at least one groove and at least one tenon are positioned such that the tenon is at least partially inserted into the groove when the components are joined within the frame. The component parts can thus be joined together by a groove-and-damage connection. A channel extends between the groove and the tenon. The channel can appear by only partially inserting the tenon into the groove, or it can be integrated into the tenon or the groove. The channel can have an opening or be closed on one side. After the first and second component parts are assembled, heated, flowable joining material is fed into the channel. For this purpose, the channel flows into a through-hole that can have access to the external environment of the component. The component parts can be placed in a mold and injected. The through-hole is filled with joining material, just like the channel. The joining material can flow along the channel and be distributed within the channel. It melts along with the contact surfaces with the groove and the tenon. During cooling, the joining material solidifies within the channel, creating a material joint between the groove and the tenon. Thus, the externally accessible component structures, for example, have built-in walls welded together to establish a connection between the first and second component parts. The component can be used, for example, for air springs, air spring struts, air spring dampers, or upper suspension housings. Using this invention, an improved component is provided, wherein welds can be formed for connecting component parts regardless of external accessibility.

[0009] "Available from the outside" or "accessible from the outside" means that the material used to create the weld can be delivered to the component using tools.

[0010] According to one example, the channel can be arranged at least partially between the bottom surface of the groove and the end face of the tenon.

[0011] In this example, at least one tenon can be partially inserted into at least one groove. This can be achieved, for example, by the shape of the tenon preventing it from being fully inserted into the groove. Therefore, after the component parts are assembled, a cavity is left between the end face of the tenon and the bottom face of the groove. This cavity serves as a channel through which joining materials can be introduced. This channel can be implemented simply and inexpensively in this way.

[0012] According to one example, the first component and the second component may surround at least one cavity.

[0013] The first and second component components may at least partially enclose a cavity. It is also possible that the cavity walls can be joined by injection welding using a sprayed melt. Through a special design of the channel, particularly through the support of tenons corresponding to the channel, injection welding can be established to prevent the cavity from shrinking due to injection pressure and to ensure that the channel is equally filled.

[0014] Furthermore, the tenon can be formed, for example, with one edge narrower than the width of the groove, thus opening a channel when it is fully inserted into the groove. In this case, the channel can also be produced simply and inexpensively.

[0015] The component may also have, for example, at least one spacer retainer for retaining the tenon within the groove to a predetermined depth.

[0016] For example, spacers can be arranged within the channel between the slot and the tenon.

[0017] Furthermore, spacer retainers may be arranged on the tenon according to an example, wherein at least one sidewall of the groove is supported on the spacer retainer.

[0018] In this example, the spacer retainer protrudes from the side surface of the tenon and forms a groove for the slot. When the tenon is inserted into the slot, the sidewall of the slot rests against the spacer retainer upon reaching a predetermined insertion depth, preventing the tenon from being inserted further into the slot. Thus, a channel can be easily created between the tenon and the slot, remaining open until the joining material is fed in.

[0019] In another example, the second component may have at least one rib, wherein the tenon is arranged on the free end of the rib.

[0020] The ribs thus extend from the second component to the first component. The ribs may be arranged within the component.

[0021] It is also conceivable that the at least one rib is adjacent to at least one cavity, wherein the first component is supported on the rib in the region surrounding the cavity.

[0022] The channel may, for example, have at least one through hole, through which the channel communicates with the outer surface of the component, wherein a bonding material is disposed within the through hole.

[0023] The through-holes can be positioned for external access. Heated joining materials are fed into and distributed within the channel through these through-holes. Here, the contact surfaces with the groove and tenon are melted. Upon cooling, the joining material solidifies, joining the two components. The channel can have multiple through-holes. Therefore, joining material can be fed into the channel simultaneously from multiple locations. This prevents the joining material from experiencing excessive cooling as it flows through the channel.

[0024] In addition, the component may have at least one distribution channel on its outer surface, which is filled with a bonding material, wherein the distribution channel is connected to the channel through the bonding material and through a through hole.

[0025] The distribution channel can extend over the outer surface of one of the components and can be accessed from the outside, allowing the bonding material to be fed into it. The bonding material can flow into the channel via the distribution channel and through-holes.

[0026] In another example, the bonding material may have a lateral concave shape relative to the channel at the distribution channel.

[0027] In this example, the channel can be directly filled through a through-hole. A side recess, also known as a concave structure, can be connected to the channel through at least one other through-hole. The side recess advantageously extends on the component side opposite the groove. Therefore, a better mechanical connection between the components is achieved through the joining material. Additionally, the side recess acts as an overflow channel when the joining material is inserted. This improves venting of the channel during joining material feeding. The heated joining material flowing through the channel also preheats the channel before flowing into the area where the side recess is formed. The replenishing joining material then encounters weaker cooling and remains in the channel. This improves weld quality.

[0028] The first component may be made of a first material, and the second component may be made of a second material, wherein the bonding material has a higher melting point than the first material and the second material, and wherein the first material and the second material may be welded together with the bonding material.

[0029] The bonding material can then easily melt the material of the component when it comes into contact with it. This improves the formation and quality of the weld.

[0030] It is also conceivable that the groove and / or tenon have, for example, at least one guide bevel.

[0031] Therefore, the assembly of components becomes easier, because slots and tenons can be guided and inserted by means of guide ramps.

[0032] To compensate for the tenon position error caused by torsion, the groove can, for example, have a 0.2 mm gap on each side of the tenon. This also makes it easy to insert a groove-tenon connection structure. Thus, a gap of up to 0.4 mm can appear between the tenon and the groove under unilateral error offset. However, when the gap depth is deep enough, the melt can be retained within the gap: the channel between the groove and the tenon can therefore be filled despite the gap.

[0033] The present invention also relates to an air spring, air spring strut, air spring damper, or upper suspension housing, comprising a component as described above, wherein the component is mounted on the air spring, air spring strut, air spring damper, or upper suspension housing.

[0034] The advantages, functions, and improvements of the air spring, air spring strut, or air spring damper are derived from the advantages, functions, and improvements of the aforementioned components. Therefore, please refer to the above description.

[0035] The present invention also relates to a method for manufacturing a component according to the above description or an air spring, air spring strut, air spring damper or upper suspension housing according to the above description, comprising the steps of: manufacturing a first component having at least one groove and a second component having at least one tenon corresponding to the groove; arranging the first component and the second component such that the tenon is at least partially inserted into the groove, wherein at least one channel is formed between the groove and the tenon; and feeding molten joining material into the channel.

[0036] The advantages, functions, and improvements of this method are derived from the advantages, functions, and improvements of the aforementioned components. Therefore, please refer to the above description.

[0037] According to one example, in the channel area, the groove and tenon can be joined by melting and attaching molten joining material.

[0038] According to another example, the first component and the second component may surround at least one cavity. Attached Figure Description

[0039] Other features, details, and advantages of the present invention are derived from the following description of embodiments in conjunction with the figures, wherein:

[0040] Figure 1 A schematic diagram of the components is shown;

[0041] Figure 2a and Figure 2b A schematic cross-sectional view of the component at the point of convergence is shown;

[0042] Figure 3a and Figure 3b A schematic diagram of the component parts is shown;

[0043] Figure 4a and Figure 4b A schematic diagram of the bonding materials is shown;

[0044] Figure 5a and Figure 5b A cross-sectional schematic diagram of the component and tool is shown when the joining material is inserted, at which point the tool has distribution channels;

[0045] Figures 6a to 6c A schematic cross-sectional view of a component with distribution channels on the component is shown;

[0046] Figure 7 A cross-sectional schematic diagram showing the details of the components; and

[0047] Figure 8 The method flowchart is shown. Detailed Implementation

[0048] The following is a summary of the components as a whole. Figure 1Refer to Figure 10 for reference.

[0049] Component 10 includes a first component 12, a second component 14, and a bonding material 16, which connects the first component 12 to the second component 14 by means of material bonding. In this example, component 10 is a component of an air spring and has a notch 11 at its center. For example, other components of the air spring or the air spring itself can be guided through the notch.

[0050] Component 10 may also be an air spring strut, an air spring damper, or a component of the upper suspension housing.

[0051] Figure 2a and Figure 2b The first component 12 and the second component 14 are shown separately before being connected to the bonding material 16.

[0052] The first component 12 includes at least one groove 18 extending along a portion of the first component 12. The groove 18 has a sidewall 40 extending away from the first component 12.

[0053] The second component 14 may have a space that forms a cavity 46 within the component 10 when the first component 12 is assembled with the second component 14. A rib 42 may be arranged within the cavity 46, supporting the cavity 46 within the component 10 and extending from the second component 14 to the first component 12 within the component 10. A tenon 20 is placed at the free end of the rib 42, which is arranged and configured to mate with a corresponding slot 18. The arrangement of the tenon 20 and the slot 18 is such that, during the assembly of the first component 12 and the second component 14, one tenon 20 is respectively assembled with one slot 18. In this example, the tenon 20 is at least partially inserted into the slot 18.

[0054] The spacer retainer 38 on the outer wall of the second component 14 determines the insertion depth of the tenon 20 into the slot 18. The sidewalls 40 of at least a few slots 18 of the first component 12 then... Figure 2b The spacer retainer 38 is abutted against the spacer. The tenon 20 can therefore not be further inserted into the slot 18. The spacer retainer 38 may also be arranged on the rib 42, which centrally supports the member components 12, 14 (not shown).

[0055] Therefore, in this example, a cavity is left between the tenon 20 and the groove 18, forming a channel 44 that extends along the tenon 20 and the groove 18. It is formed between the bottom surface of the groove 18 and the end face 21 of the tenon 20. The channel 44 preferably has a height of at least 0.5 mm, more preferably at least 2 mm.

[0056] Figure 3a Show Figure 1The first component 12. At its center, the first component 12 has a notch defined by a wall 13. In this example, a flat cover extends from wall 13 to the outer wall 19 of the first component 12, which is star-shaped by a brace 17. The brace 17 is positioned on the top side of the first component 12 and, for example, with the nozzle-side half-mold. Figure 6a The cover mold 60, together with the cover piece 12, forms a distribution channel 26 disposed on the top side of the first component 12, into which the bonding material 16 can be sprayed and distributed. Simultaneously, the diagonal brace 17, opposing each other, forms at least partially a groove 18 between the wall 13 and the outer wall 19 on the bottom side of the first component 12. The groove 18... Figure 2a As shown above.

[0057] Distribution channels 26 are shown along the diagonal brace 17, which are in fluid communication with the groove 18 on the other side of the first component 12 via through holes 22. Other diagonal braces 17 have a concave shape 24, which are also in fluid communication with the corresponding groove 18 on the other side of the first component 12 via through holes 22.

[0058] The diagonal brace 17 may include other through holes 22, which are arranged in a portion of the member 10 that can be accessed from the outside.

[0059] Figure 3b Show Figure 1 The second component 14 has a notch 11 defined by a sleeve-shaped wall. At least one rib 42 extends from the notch 11 to the outer wall 15. In this example, multiple ribs 42 are provided. In the assembled component 10, the ribs 42 define cavities 46 within the component 10. A tenon 20 is provided on the free end of at least one rib 42, which can be inserted into a corresponding slot 18 of the first component 12 when the first component 12 and the second component 14 are assembled.

[0060] When the tenon 20 is inserted into the groove 18, a channel 44 is formed between the tenon 20 and the groove 18. The channel 44 can be arranged between the side wall of the groove 18 and the end face 21 of the tenon 20 and the bottom surface of the groove 18.

[0061] Figure 4a and Figure 4b This illustrates how the joining material 16 extends between the first component 12 and the second component 14 or on the two component components 12, 14.

[0062] Figure 4aThis is shown a bonding material 16, which has a ring 23 that welds the first component 12 and the second component 14 together at its outer wall. The first component 12 is made of a first material that can be welded to the bonding material 16. The second component 14 is made of a second material that can be welded to the bonding material 16. The first and second materials can be the same. In addition, the first and second materials preferably have a lower melting point than the bonding material 16.

[0063] The first and second materials may, for example, have polyamide 6, and the bonding material 16 may, for example, have polyamide 66.

[0064] Within component 10, weld 32 extends from ring 23 along channel 44. It either extends directly from ring 23 into channel 44 or extends through distribution structure 30, which is arranged in distribution channel 26 within component 10. The connection between distribution structure 30 and weld 32 is established by connectors 34 or 36, which are arranged in through-hole 22 within component 10.

[0065] The through-hole 22 can have different shapes, so the connectors 34 and 36 can also be formed differently. Therefore, connector 34 can be designed as circular or cylindrical, and connector 36 as rectangular or square. Correspondingly, through-holes 22 are formed, and connectors 34 and 36 are disposed within these through-holes. Furthermore, connector 36 extends a longer distance along or parallel to the weld 32 that serves as connector 34, while connector 34 is formed only along a short distance of weld 32.

[0066] It is also possible that welds 32 are not joined to distribution channels 26 via connectors 34 or 36. Instead, they are joined directly to ring 23 and thereby filled.

[0067] Figure 4b Also shown is the bonding material 16, which has another ring 25, which is circular in this example. It... Figure 1 In the example, the first component 12 is arranged at the gap 11 and the connection point at the gap 11 connects the first component 12 to the second component 14.

[0068] Weld 32 is also connected to another ring 25 via distribution structure 30. Two other welds 32 are directly connected to another ring 25. They have connection structures 36 that connect weld 32 to the side recess 28.

[0069] Figure 5a and Figure 5b The component 10 is shown being placed in the forming tool.

[0070] according to Figure 5aThe mold 49 has a lower mold 48, an intermediate mold 50, and an upper mold 52. The lower mold 48 houses a portion of the second component 14. The first component 12 is placed on the second component 14. It is surrounded from the outside by the intermediate mold 50. The upper mold 52 is placed on the intermediate mold 50. A through channel 56 extends through the upper mold 52 and the intermediate mold 50 and connects to the channel 44 of the component 10 through a through hole 22. The through channel 56 is filled with a bonding material 16. The bonding material 16 is fed in through an inlet 57 on the upper mold 52. In this example, the distribution gate of the bonding material 16 extends between the upper mold 52 and the intermediate mold 50, opening into the through hole 22 of the component 10. In a liquid state, the bonding material 16 can therefore flow from the inlet 57 to the through hole 22 and be distributed along the channel 44 between the groove 18 and the tenon 20. In particular, the wall structure arranged within the member 10, such as the rib 42 adjacent to the cavity 46 within the member 10, forms a connection between the member components 12 and 14 by weld.

[0071] After the joined components 12 and 14 are demolded, the distribution gate located between the upper mold 52 and the intermediate mold 50 is discarded from the joined material 16, so a new cycle can be performed.

[0072] Figure 5b This is shown Figure 5a Detailed diagram. The groove 18, with tenon 20 and channel 44, is shown in detail here. The groove 18 has an inlet ramp 54 on its sidewall 40, which facilitates insertion of the tenon 20 into the groove 18. The distribution gate disconnects from the through-hole 22 filled with the joining material 16 after demolding from the injection mold, leaving no gate residue standing upright; no further processing is required, thus enabling low-cost connection of components 12, 14, including low-cost distribution gate demolding.

[0073] Figures 6a to 6c Another embodiment of component 10 and its associated mold is shown.

[0074] according to Figure 6a Mold 49 includes a lower mold 48 and a cover mold 60, with the cover mold directly connected to the lower mold 48. (As per...) Figure 5a As in the example, the lower mold 48 accommodates at least a portion of the second component 14. A distribution channel 26 is provided between the cover mold 60 and the first component 12. In this example, the distribution channel 26 runs along the outward-pointing surface of the first component 12. Figure 3a The diagonal brace 17 shown extends all the way to the through hole 22. The distribution channel 26 is filled with bonding material 16 and connected to the first component 12 by material bonding. It does not need to be like in Figure 5aIn contrast, the bonding material attached to the component 12 along the diagonal brace 17 by a material bonding method can help strengthen the component. An inlet 57 is also arranged on the cover mold 60. Heated, flowable bonding material 16 can be fed into the distribution channel 26 through the inlet 57. The heated bonding material 16 can flow into the channel 44 along the distribution channel 26 via the through-hole 22.

[0075] Figure 6b The demolded component 10 is shown here. The distribution channel 26 now has solidified bonding material 16 filling the distribution channel 26. Solidified bonding material 16 is also provided in the channel 44, which is at least partially fused to the surfaces of the groove 18 and the tenon 20.

[0076] Figure 6c Show Figure 6b A detailed view of the illustration is shown here. A channel 44 with a groove 18 and a tenon 20 is shown, the channel being filled with a joining material 16. The material 16 extends along a distribution channel 26 on the outer surface of the first member 12 through a through-hole 22.

[0077] It should be noted that the distribution channel 26 can also be located within component parts 12 and 14.

[0078] In this example, the sidewall 40 of the groove 18 has an inlet ramp 54.

[0079] like Figure 7 As shown, the guide bevel 54 can also be arranged on the tenon 20. In this case, the guide bevel 54 also makes it easier for the tenon 20 to be inserted into the groove 18.

[0080] Figure 8 A method 100 for manufacturing component 10 is shown.

[0081] In the first step 102, a first component and a second component are manufactured. The first component is manufactured to have at least one groove, and the second component is manufactured to have at least one tenon. The groove and the tenon correspond to each other, so that the tenon can be at least partially inserted into the groove when the first component and the second component are assembled.

[0082] In another step 104, the first component and the second component are arranged together such that the tenon is at least partially inserted into the groove. Thus, the component is assembled. At least one channel is left between the groove and the tenon. Furthermore, the first and second component may enclose at least one cavity.

[0083] In another step 106, molten bonding material is fed into the channel. The molten bonding material also melts the contact surfaces with the groove and tenon. As the bonding material solidifies, a weld is formed between the first and second component parts. An adhesion connection occurs between the groove and tenon within the channel area.

[0084] This invention is not limited to one of the foregoing embodiments, but can be modified in a variety of ways. All features and advantages derived from the specification and figures, including structural details, spatial arrangements, and method steps, are important to the invention not only individually but also in various combinations.

[0085] List of reference numerals

[0086] 10 components

[0087] 11 gaps

[0088] 12 First component parts

[0089] 13 walls

[0090] 14 Second component parts

[0091] 15 outer wall

[0092] 16. Bonding materials

[0093] 17. Diagonal brace

[0094] 18 slotted parts

[0095] 19 outer wall

[0096] 20 Tenons

[0097] 21 End face

[0098] 22 Through Holes

[0099] 23 rings

[0100] 24 Laterally concave shape

[0101] 25 Another ring

[0102] 26 distribution channels

[0103] 28 Lateral concave

[0104] 30 Distribution Structure

[0105] 32 Weld

[0106] 34 Connectors

[0107] 36 Connectors

[0108] 38 Spacer retainer

[0109] 40 sidewalls

[0110] 42 ribs

[0111] 44 channels

[0112] 46. ​​Cavity

[0113] 48 Lower mold

[0114] 49 Molds

[0115] 50 intermediate mold

[0116] 52 upper mold

[0117] 54 Importing the inclined plane

[0118] 56 Distribution Channels

[0119] Entrance 57

[0120] 60 Cover mold

Claims

1. A component for use in an air spring, air spring strut, air spring damper, or upper suspension housing, wherein, The component (10) has a first component part (12) with at least one groove (18), a second component part (14) with at least one tenon (20) corresponding to the groove (18), and a joining material (16), characterized in that the tenon (20) is at least partially disposed within the groove (18), wherein at least one channel (44) extends between the groove (18) and the tenon (20), and the first component part (12) and the second component part (14) are connected to each other by material joining by feeding the joining material (16) into the channel (44). The second component (14) has at least one rib (42), wherein the tenon (20) is mounted on the free end of the rib (42). The components are interconnected via a tenon-and-groove connection by inserting the tenon into the corresponding groove element. The first component has at least one groove, and the second component has at least one matching tenon.

2. The component according to claim 1, characterized in that, The channel (44) is at least partially arranged between the bottom surface of the groove (18), the side surface of the groove (18), and the end face (21) of the tenon (20).

3. The component according to claim 1 or 2, characterized in that, The first component (12) and the second component (14) surround at least one cavity (46).

4. The component according to claim 1, characterized in that, The spacer retainer is mounted on the tenon (20), wherein at least one sidewall of the groove (18) is supported on the spacer retainer.

5. The component according to claim 1, characterized in that, The at least one rib (42) is adjacent to the at least one cavity (46), wherein the first component (12) is supported on the rib (42) in the area surrounding the cavity (46).

6. The component according to claim 1, characterized in that, The channel (44) has at least one through hole (22), wherein the channel (44) is connected to the outer surface of the component (10) through the through hole (22), wherein a bonding material (16) is provided in the through hole (22).

7. The component according to claim 6, characterized in that, The component (10) has at least one distribution channel (26) on its outer surface, the distribution channel (26) being filled with a bonding material (16), wherein the distribution channel (26) communicates with the channel (44) through the bonding material (16) and through the through hole (22).

8. The component according to claim 6 or 7, characterized in that, The bonding material (16) has a lateral recess relative to the channel (44) at the distribution channel (26).

9. The component according to claim 1, characterized in that, The first component (12) is made of a first material, and the second component (14) is made of a second material, wherein the bonding material (16) has a melting point higher than that of the first material and the second material.

10. The component according to claim 1, characterized in that, The groove (18) and / or the tenon (20) have at least one guide bevel (54).

11. The component according to claim 9, characterized in that, The first material and the second material can be welded to the bonding material (16) respectively.

12. An air spring, air spring strut, air spring damper, or upper suspension housing, comprising the component (10) according to any one of claims 1 to 11, wherein, The component (10) is mounted on the air spring, the air spring support, the air spring damper, or the upper suspension housing.

13. A method for manufacturing a component according to any one of claims 1 to 11 or an air spring, air spring strut, air spring damper, or upper suspension housing according to claim 12, the method comprising the following steps: - Manufacture (102) a first component part having at least one groove and a second component part having at least one tenon corresponding to the groove; - The first component and the second component are arranged (104) such that the tenon is at least partially inserted into the groove, wherein at least one channel is formed between the groove and the tenon; - The molten bonding material is fed into the channel (106).

14. The method according to claim 13, characterized in that, Within the area of ​​the channel, the groove and the tenon are melted and attached together by the molten joining material.

15. The method according to claim 13 or 14, characterized in that, The first component and the second component surround at least one cavity.

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