Air spring and integrated exhaust dust cover matched with same

Abstract

The invention discloses an air spring and an integrated exhaust dust cover matched with the air spring, and belongs to the technical field of air spring dust prevention. The integrated exhaust dust cover comprises a telescopic corrugated section which is of a truncated cone structure with the two ends open; the mounting base is integrally connected to the opening in the lower end of the corrugated section; a plurality of turbulence modulation flow channels protruding outwards are formed in the circumferential outer wall of the mounting base. The dust cover is provided with the exhaust outlet which is directionally arranged downwards, so that liquid water and solid particles which fall from top to bottom due to the action of gravity can be effectively prevented from invading through the air inlet, and even for splashing objects from the lower part, the splashing objects can be prevented from entering the dust cover due to the roundabout path and length of the turbulent flow modulation flow channel. Under the action of inertia and a wall attachment effect, the air is difficult to penetrate into the cover body and is finally discharged from the turbulent flow modulation flow channel under the driving of vehicle body vibration and internal airflow, so that blockage is avoided.

Description

Technical Field

[0001] This invention relates to the field of air spring dustproof technology, and specifically to an air spring and an integrated exhaust dustproof cover adapted thereto. Background Technology

[0002] An air spring is an industrial elastic element that uses compressed air sealed in a flexible air chamber as the elastic medium. It provides controllable support, vibration damping, and height adjustment by regulating the internal air pressure. An air spring dust cover is used to prevent dust, mud, rainwater, and other impurities from entering the air spring chamber, ensuring the air spring's sealing performance and service life.

[0003] Figures 1-3 The diagram shows a partial structure of an existing air spring and dust cover. The dust cover is made of thermoplastic vulcanized rubber (TPV), which has excellent elasticity, weather resistance, and moldability. However, it has the following technical defects in actual use: First, the dust cover has a corrugated telescopic structure in the middle. During the expansion and contraction of the air spring, the internal air needs to be quickly expelled or drawn in. Figure 3 As shown, existing vents are often located in the corrugated part of the dust cover, and are mostly single round holes, which are easily blocked by mud and dust, leading to internal air pressure imbalance and affecting the flexibility of expansion and contraction. Secondly, since the vents directly connect the inside and outside of the dust cover, rainwater and fine mud and sand can easily enter the interior of the dust cover through the vents, corroding the air spring support or wearing down the surface of the airbag. At the same time, during the injection molding of TPV material dust covers, the vent forming pins are prone to sticking to the melt, resulting in burrs on the edges of the vents and insufficient pore diameter precision, further increasing the risk of blockage. Summary of the Invention

[0004] This invention provides an air spring and an integrated exhaust dust cover adapted thereto. One objective is to solve the problem in existing dust covers where the exhaust vents are directly located at the corrugated section, easily leading to blockage and internal air pressure imbalance. A second objective is to solve the problem in existing dust covers where single-point exhaust vents directly penetrate the inside and outside of the dust cover, allowing rainwater and fine sand to easily enter the dust cover. A third objective is to solve the problem in existing dust covers where, during injection molding, the exhaust vent forming pin easily adheres to the melt, resulting in burrs on the exhaust vent edges and insufficient vent diameter accuracy.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: An integrated exhaust dust cover includes: a retractable corrugated section, which has a truncated conical shape with open ends; and a mounting base integrally connected to the lower open end of the corrugated section; wherein, the circumferential outer wall of the mounting base is formed with a plurality of outwardly protruding turbulence modulation channels, and the inner wall of each turbulence modulation channel is formed with a cavity, the upper end of which is provided with an exhaust inlet communicating with the interior of the corrugated section, and the lower end is provided with an exhaust outlet communicating with the outside.

[0006] The above technical solution further includes: The upper opening of the corrugated section is configured to engage with the piston of the air spring, and the mounting base is configured to be interference-fitted with the guide tube of the air spring.

[0007] The turbulence modulation channel is S-shaped or has a meandering path.

[0008] The exhaust outlet faces downwards.

[0009] The plurality of the turbulence modulation channels are evenly distributed along the circumference of the mounting base.

[0010] The integrated exhaust dust cover is integrally formed using a blow molding process with thermoplastic dynamic vulcanized elastomer material, resulting in a uniform wall thickness with a wall thickness deviation of ≤0.2mm.

[0011] During the blow molding process, a forming needle with a segmented tapered structure is used to form the turbulent modulation channel, and the aperture accuracy error of the exhaust inlet and exhaust outlet is controlled within ±0.05mm.

[0012] An air spring is provided with an annular buckle at the upper part for engaging with a piston and a guide cylinder at the lower part; the upper end of the retractable corrugated section of the dust cover is connected to the piston connection part, and the mounting base of the dust cover is sleeved on the guide cylinder.

[0013] The upper end of the guide cylinder is provided with a radial flange for axially limiting the mounting base sleeved below it.

[0014] The beneficial effects of this invention are: 1. This invention features a downward-oriented exhaust outlet on the dust cover, effectively preventing liquid water and solid particles falling from above due to gravity from entering through the air inlet. Even when faced with splashes from below, the tortuous path and length of the turbulent flow modulation channel prevent them from penetrating deep into the cover due to inertia and wall adhesion effects. The debris is ultimately discharged from the turbulent flow modulation channel under the influence of vehicle vibration and internal airflow, thus preventing blockage.

[0015] 2. The multiple circumferentially distributed turbulent modulation channels of this invention form a parallel, highly efficient aerodynamic compensation network, enabling rapid exchange of internal gases during the compression and expansion of the air spring, thus avoiding operational lag caused by pressure imbalance. Compared to traditional single-point exhaust ports, both steady-state and dynamic exhaust efficiency are improved. Simultaneously, the exhaust structure is integrated into the lower mounting base, occupying no additional space and not interfering with the movement of the dust cover and piston, thus having no negative impact on guiding and sealing functions.

[0016] 3. The integrated design of the dust cover of this invention reduces the use of components such as brackets and clamps, thereby reducing material costs; its assembly process requires no tools, simplifying the production line operation process and thus saving manpower and equipment investment.

[0017] 4. This invention's dust cover uses a thermoplastic dynamic vulcanized elastomer material and is manufactured using hollow blow molding. This material system combines the elastomer properties of vulcanized rubber with the processing characteristics of thermoplastic plastics, exhibiting excellent weather resistance, wear resistance, and fatigue resistance, matching the operating requirements of air springs. During the molding process, a molding needle with segmented tapers is used. This structure is adapted to the rheological characteristics of the material melt, ensuring uniform filling of the mold cavity, smooth and flash-free edges of the vent holes, and pore diameter tolerances that can be controlled within ±0.05mm. Compared to traditional injection molding, the process yield is improved.

[0018] 5. The blow molding process of this invention ensures the uniformity of the product wall thickness, with a wall thickness deviation of no more than 0.2mm. This provides a guarantee for the structural integrity of the expandable corrugated section under long-term alternating stress, meets the application scenarios of high-frequency expansion and contraction, and extends the service life. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of an air spring and dust cover in the prior art; Figure 2 This is a schematic diagram of the structure of a dust cover bracket in the prior art; Figure 3 This is a three-dimensional structural diagram of a dust cover and exhaust vent in the prior art; Figure 4 This is a schematic diagram of the structure of the air spring and dust cover in this invention; Figure 5 yes Figure 4 Cross-sectional view at point AA; Figure 6 yes Figure 5 A magnified view of a section at point A in the middle; Figure 7 This is a perspective view of the dust cover in this invention; Figure 8 This is a bottom view of the dust cover in this invention.

[0020] In the diagram: 1. Air spring; 2. Ring-shaped fastener; 3. Guide cylinder section; 4. Dust cover; 401. Corrugated section; 402. Mounting base; 403. Turbulence modulation channel; 404. Exhaust inlet; 405. Exhaust outlet; 5. Flanged edge. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] This embodiment provides an air spring. Combined with... Figures 4 to 6 As shown, the air spring 1 includes a main body, an annular buckle 2 for engaging with a piston is provided on the upper part of the main body, and a guide cylinder 3 is provided on the lower part of the main body, wherein the top end of the guide cylinder 3 is provided with a horizontal radial flange 5.

[0023] Please see Figures 4-5 As shown, this embodiment also discloses an integrated exhaust dust cover 4 adapted to the air spring 1 described above. The dust cover 4 is made of thermoplastic dynamic vulcanized elastomer material and is manufactured in one piece by hollow blow molding process. Structurally, it is divided into a retractable corrugated section 401 and an annular mounting base 402 with an air guiding structure.

[0024] Please refer to it again. Figure 5 For details, please refer to Figure 7 The retractable corrugated section 401 has open ports at both ends along its axis. Its shape is a truncated cone with a cross-sectional diameter that gradually decreases from bottom to top along the axis. This gives the corrugated section 401 the freedom to generate follow-up elastic deformation when the air spring 1 is extended or retracted, thereby obtaining a larger deformation stroke.

[0025] Please refer to it again. Figure 6 , Figure 7 as well as Figure 8 As shown, the mounting base 402 is integrated at the lower open port of the corrugated section 401; a plurality of turbulence modulation channels 403 with specific curvatures are formed on the circumferential outer wall of the mounting base 402. Each turbulence modulation channel 403 forms a concave cavity in the region corresponding to the inner wall of the mounting base 402, and an exhaust outlet 405 is opened at the lower end of each cavity and an exhaust inlet 404 is opened at the upper end.

[0026] In this embodiment, during installation, the upper edge of the corrugated section 401 is fastened to the annular buckle 2 of the air spring 1; the mounting base 402 and the guide cylinder 3 are interference-fitted, and axial positioning is achieved by the radial flange 5 at the top of the guide cylinder 3. This connection scheme eliminates the dust cover 4 bracket and mechanical fasteners (such as clamps) in the traditional structure, achieving direct assembly and functional integration through the integrated structure of the dust cover 4 itself. Its advantages are: no special tools are required for assembly; during maintenance, the interference fit between the mounting base 402 and the guide cylinder 3 can be manually released, achieving non-destructive and rapid disassembly. It effectively solves the drawback of the need for destructive removal after traditional mechanical fasteners are locked, significantly reducing the disassembly complexity and maintenance time cost of the air spring 1 assembly. In addition, the integrated design of parts reduces the number of components, eliminates the cumulative tolerances that may occur in the assembly of multiple components, and reduces the probability of sealing or connection failure due to wear and aging of connecting parts.

[0027] In terms of dust cover performance, no dust cover bracket is required (such as...). Figure 2 As shown, the air spring 1 has no radial space occupied, which increases the effective volume of the inner bladder of the air spring 1. The stiffness fluctuation of the air spring 1 during movement is reduced, and the driving comfort of the vehicle is significantly improved. At the same time, the interference risk between the dust cover 4 and the surrounding connecting rods is reduced, and the design adjustment range of the air spring 1 is expanded. Multiple sets of turbulence modulation channels 403 are adapted to the full stroke extension and retraction, further stabilizing the stiffness characteristics of the air spring 1.

[0028] In terms of anti-intrusion performance, this structure excels. Specifically, the downward-facing layout of its exhaust outlet 405 effectively blocks liquid water and solid particles falling from above due to gravity from entering through the air inlet. Even when faced with splashes from below, the meandering path and length of the turbulence modulation channel 403 prevent them from penetrating deep into the enclosure due to inertia and wall adhesion effects. The debris is ultimately discharged from the turbulence modulation channel 403 under the influence of vehicle vibration and internal airflow, preventing blockage. Multiple circumferentially distributed turbulence modulation channels 403 form a parallel, highly efficient aerodynamic compensation network, enabling rapid exchange of internal gases during the compression and extension of the air spring 1, avoiding sluggish operation caused by pressure imbalance. Compared to traditional single-point exhaust ports, both steady-state and dynamic exhaust efficiency are improved. Furthermore, the exhaust structure is integrated into the lower mounting base 402, without occupying additional space or interfering with the movement of the dust cover 4 and piston, and has no negative impact on guiding and sealing functions.

[0029] At the manufacturing level, this dust cover 4 is made of thermoplastic dynamic vulcanized elastomer material and is manufactured using hollow blow molding. This material system combines the elastomer properties of vulcanized rubber with the processing characteristics of thermoplastic plastics, exhibiting excellent performance in weather resistance, wear resistance, and fatigue resistance, matching the working requirements of the air spring 1. During the molding process, a molding needle with segmented tapers is used. This structure is adapted to the rheological characteristics of the material melt, ensuring uniform filling of the mold cavity, smooth and flash-free edges of the vent holes, and pore diameter tolerances that can be controlled within ±0.05mm. Compared with traditional injection molding, the process yield is improved. The blow molding process ensures the uniformity of the product wall thickness, with a wall thickness deviation of no more than 0.2mm. This provides a guarantee for the structural integrity of the expandable corrugated section 401 under long-term alternating stress, meeting the application scenarios of high-frequency expansion and contraction, and extending service life. From a cost and assembly perspective, the integrated design reduces the use of components such as brackets and clamps, reducing material costs; its assembly process requires no tools, simplifying the production line operation process, thereby saving manpower and equipment investment.

[0030] It should be noted that, in this document, terms such as “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0031] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention.

Claims

1. An integrated exhaust dust cover, characterized in that: include: The expandable corrugated section (401) has a truncated cone shape with open ends; as well as, Mounting base (402), which is integrally connected to the lower opening of the corrugated section (401); The mounting base (402) has multiple outwardly protruding turbulence modulation channels (403) formed on its circumferential outer wall. Each turbulence modulation channel (403) has a cavity formed on its inner wall. The upper end of the cavity is provided with an exhaust inlet (404) that communicates with the interior of the corrugated section (401), and the lower end is provided with an exhaust outlet (405) that communicates with the outside.

2. The integrated exhaust dust cover according to claim 1, characterized in that: The upper end of the corrugated section (401) is open and configured to engage with the piston of the air spring (1), and the mounting base (402) is configured to be interference-fitted with the guide tube of the air spring (1).

3. The integrated exhaust dust cover according to claim 1, characterized in that: The turbulence modulation channel (403) is S-shaped or has a meandering path.

4. The integrated exhaust dust cover according to claim 1, characterized in that: The exhaust outlet (405) has an opening facing downwards.

5. The integrated exhaust dust cover according to claim 1, characterized in that: The plurality of the turbulence modulation channels (403) are uniformly distributed along the circumference of the mounting base (402).

6. The integrated exhaust dust cover according to claim 1, characterized in that: The integrated exhaust dust cover (4) is integrally formed by blow molding of thermoplastic dynamic vulcanized elastomer material, so that the wall thickness of the dust cover (4) is uniform and the wall thickness deviation is ≤0.2mm.

7. The integrated exhaust dust cover according to claim 1, characterized in that: During the blow molding process, a molding needle with a segmented tapered structure is used to form the turbulent modulation channel (403), and the aperture accuracy error of the exhaust inlet (404) and exhaust outlet (405) is controlled within ±0.05mm.

8. An air spring, suitable for the integrated exhaust dust cover as described in any one of claims 1-6, characterized in that: The air spring (1) has an annular buckle (2) for engaging with the piston on the upper part and a guide cylinder (3) on the lower part; the upper end of the retractable corrugated section (401) of the dust cover (4) is connected to the piston connection part, and the mounting base (402) of the dust cover (4) is sleeved on the guide cylinder (3).

9. An air spring according to claim 8, characterized in that: The upper end of the guide cylinder (3) is provided with a radial flange (5) for axially limiting the mounting base (402) sleeved below it.

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