An air suspension air chamber

Abstract

The utility model discloses an air suspension air chamber relates to the technical field of automobile air suspension, and this device includes: the plastic shell is composed of upper casing and lower casing, and the upper casing includes the integrated fixed ring of upper, upper casing cover and upper stiffener subassembly, and upper stiffener subassembly is connected between the outer ring of upper fixed ring and upper casing cover inner wall, and the lower casing includes the integrated fixed ring of lower, lower casing cover, lower stiffener subassembly, air inlet, assembly port, mounting and gas guide, and lower stiffener subassembly is connected between the lower fixed ring and lower casing cover, and assembly port sets up at lower casing cover bottom, and it is communicated with lower fixed ring. The utility model discloses a plastic shell and integrated structure realize light weight and corrosion resistance, and the internal stiffener and cavity design guarantee structural strength and gas flowability, and the modular integrated interface improves the sealing property and assembly efficiency, and the manufacturing cost is reduced significantly and the suspension performance is optimized.

Description

Technical Field

[0001] This utility model belongs to the field of automotive air suspension technology, specifically an air suspension chamber. Background Technology

[0002] Air suspension systems are a key component of modern automotive chassis. They replace traditional steel springs with compressed air chambers as elastic elements, providing superior ride comfort and handling stability. As the core actuator of this system, the structural design and material properties of the air chamber directly determine the overall performance of the suspension. With technological advancements, dual-chamber structures have emerged, where primary and secondary chambers work in tandem. By controlling the opening and closing of the two chambers with solenoid valves, the total volume is altered to achieve multi-level adjustment of suspension stiffness, meeting the diverse comfort and handling needs of vehicles under different operating conditions.

[0003] Currently, air suspension chambers on the market, especially those involving complex cavity structures, generally use metal materials such as aluminum alloys or steel for their outer shells, and are manufactured using traditional processes such as casting and machining. For the aforementioned dual-chamber air chambers, the manufacturing process is usually more complicated, requiring the production of multiple metal parts before assembly and connection.

[0004] However, this existing air chamber solution based on metal materials and traditional processes has several obvious drawbacks: First, the metal shell is relatively heavy, significantly increasing the unsprung mass of the vehicle, which is detrimental to improving handling sensitivity and also increases vehicle energy consumption, negatively impacting the driving range of new energy vehicles; second, the cost of metal raw materials is high, and its manufacturing processes such as casting, cutting, and grinding are complex, resulting in high production costs and hindering the popularization of air suspension technology; third, metal materials are susceptible to corrosion from rainwater, acids, and alkalis, affecting the structural integrity and sealing reliability of the air chamber; finally, metal forming processes have many design limitations, making it difficult to economically and efficiently achieve more complex or integrated functional structures, limiting further optimization of air chamber performance and layout flexibility in a compact space. Utility Model Content

[0005] This invention provides an air suspension chamber that can solve the problems of large weight, high energy consumption, high manufacturing cost, poor corrosion resistance, and limited design flexibility of existing metal air chambers.

[0006] To achieve the above objectives, an air suspension chamber is provided according to an embodiment of the first aspect of this utility model, comprising a plastic shell, the plastic shell being composed of an upper shell and a lower shell. The upper shell includes an integrally formed upper fixing ring, an upper shell cover, and an upper reinforcing rib assembly, the upper reinforcing rib assembly being connected between the outer ring of the upper fixing ring and the inner wall of the upper shell cover. The lower shell includes an integrally formed lower fixing ring, a lower shell cover, a lower reinforcing rib assembly, an air inlet, an assembly port, an installation port, and an air guide port. The lower reinforcing rib assembly is connected between the lower fixing ring and the lower shell cover. The assembly port is located at the bottom of the lower shell cover and communicates with the lower fixing ring. The air guide port is located through the top side wall of the assembly port and communicates with the inner cavity of the lower shell cover. The air inlet is located at the bottom of the lower shell cover and communicates with its inner cavity. One end of the installation port penetrates the side wall of the lower shell cover and extends into its inner cavity, and the installation port is used to install a solenoid valve.

[0007] As a further technical solution of this utility model, the upper housing also includes an insert installed on the top of the upper housing cover, the top end of the insert being flush with the top end of the upper housing cover, and the bottom end of the insert extending downward through the upper fixing ring.

[0008] As a further technical solution of this utility model, the lower reinforcing rib assembly includes a first lower reinforcing rib, a second lower reinforcing rib, and a lower U-shaped opening. The two first lower reinforcing ribs divide the area between the lower fixing ring and the lower shell into a first lower cavity and a second lower cavity. A plurality of second lower reinforcing ribs are circumferentially distributed in the first lower cavity. The lower U-shaped opening is opened on the side of the second lower reinforcing rib away from the bottom of the lower shell.

[0009] As a further technical solution of this utility model, both the air guide port and the air inlet are connected to the second lower cavity, and the air inlet is used to assemble a pressure holding valve.

[0010] As a further technical solution of this utility model, one end of the mounting port extends into the lower shell and passes through one of the first lower reinforcing ribs to communicate with the second lower cavity, and a notch communicating with the first lower cavity is provided on the side wall of the mounting port.

[0011] As a further technical solution of this utility model, the bottom ends of the upper fixing ring, the upper shell cover and the upper reinforcing rib assembly are flush with each other to form an upper welding surface, and the top ends of the lower fixing ring, the lower shell cover and the lower reinforcing rib assembly are flush with each other to form a lower welding surface. The upper welding surface and the lower welding surface are sealed and welded together.

[0012] As a further technical solution of this utility model, the outer wall of the assembly port is provided with uniformly distributed external threads, and the assembly port is used to connect with the airbag of the air suspension.

[0013] As a further technical solution of this utility model, the upper reinforcing rib assembly includes a first upper reinforcing rib, a second upper reinforcing rib, and an upper U-shaped opening. The two first upper reinforcing ribs divide the area between the upper fixing ring and the upper shell into a first upper cavity and a second upper cavity. A plurality of second upper reinforcing ribs are circumferentially distributed in the first upper cavity. The upper U-shaped opening is opened on the side of the second upper reinforcing rib away from the top of the upper shell.

[0014] As a further technical solution of this utility model, the plastic shell is a long glass fiber reinforced nylon body.

[0015] As a further technical solution of this utility model, the bottom cross-section of the upper shell is the same as the top cross-section of the lower shell, the upper fixing ring and the lower fixing ring have the same cross-section, and the upper reinforcing rib assembly and the lower reinforcing rib assembly are correspondingly arranged.

[0016] Compared with the prior art, the beneficial effects of this utility model are: 1. This utility model employs an integrally injection-molded plastic shell structure, with mutually cooperating upper and lower shells. The upper shell integrates an upper fixing ring, an upper cover, and an upper reinforcing rib assembly, while the lower shell integrates a lower fixing ring, a lower cover, a lower reinforcing rib assembly, and functional interfaces such as an air inlet, assembly port, mounting port, and air guide port. This achieves lightweight and highly integrated air chamber structure. This design effectively reduces production costs and product weight, while the use of plastic material significantly improves corrosion resistance. The integrated design of each functional interface ensures the integrity and sealing reliability of the air chamber structure, solving the problems of large weight, high cost, poor corrosion resistance, and limited design flexibility inherent in traditional metal air chambers.

[0017] 2. In this utility model, by providing an assembly port and a connected air guide port at the bottom of the lower housing, and an installation port extending into the inner cavity on the side wall of the lower housing, the solenoid valve is directly integrated into the air chamber body. This structural design makes the air path connection control between the main and auxiliary chambers more direct and efficient. Simultaneously, the internal cavity is rationally partitioned by the lower reinforcing rib assembly, optimizing the airflow channel layout. This integrated design not only simplifies external pipeline connections and improves space utilization, but also ensures the stability and reliability of the air chamber under complex operating conditions through careful structural planning, solving the problems of complex structure, limited layout, and insufficient sealing performance of traditional air chambers. Attached Figure Description

[0018] Figure 1 This is a perspective view of an air suspension chamber according to the present invention; Figure 2 This is a cross-sectional view of an air suspension chamber according to the present invention; Figure 3 This is a perspective view of the upper shell of an air suspension chamber according to the present invention; Figure 4 This is a first-view perspective perspective view of the lower housing of the air suspension chamber according to the present invention; Figure 5 This is a perspective view of the lower housing of the air suspension chamber of this utility model from a second angle.

[0019] In the diagram: 10. Plastic outer shell; 100. Upper shell; 101. Upper fixing ring; 102. Upper shell cover; 1021. First upper cavity; 1022. Second upper cavity; 103. Upper reinforcing rib assembly; 1031. First upper reinforcing rib; 1032. Second upper reinforcing rib; 1033. Upper U-shaped opening; 104. Insert; 105. Upper welding surface; 200. Lower shell; 201. Lower fixing ring; 202. Lower shell cover; 2021. First lower cavity; 2022. Second lower cavity; 203. Lower reinforcing rib assembly; 2031. First lower reinforcing rib; 2032. Second lower reinforcing rib; 2033. Lower U-shaped opening; 204. Air inlet; 205. Assembly port; 2051. External thread; 206. Mounting port; 2061. Notch; 207. Air guide port; 208. Lower welding surface. Detailed Implementation

[0020] The specific embodiments of this utility model are described in detail below, but it should be understood that the protection scope of this utility model is not limited to the specific embodiments.

[0021] like Figures 1-5 As shown, an air suspension chamber includes a plastic housing 10, which is composed of an upper housing 100 and a lower housing 200. The upper housing 100 includes an integrally formed upper fixing ring 101, an upper housing cover 102, and an upper reinforcing rib assembly 103. The upper reinforcing rib assembly 103 is connected between the outer ring of the upper fixing ring 101 and the inner wall of the upper housing cover 102. The lower housing 200 includes an integrally formed lower fixing ring 201, a lower housing cover 202, a lower reinforcing rib assembly 203, an air inlet 204, an assembly port 205, and a mounting port 206. The lower reinforcing rib assembly 203 is connected between the lower fixing ring 201 and the lower housing 202, and the assembly port 205 is located at the bottom of the lower housing 202 and communicates with the lower fixing ring 201. The air guide port 207 is provided through the top side wall of the assembly port 205 and communicates with the inner cavity of the lower housing 202. The air inlet 204 is located at the bottom of the lower housing 202 and communicates with its inner cavity. One end of the mounting port 206 passes through the side wall of the lower housing 202 and extends into its inner cavity. The mounting port 206 is used to install a solenoid valve.

[0022] It should be noted that during use, external compressed air enters the main chamber formed by the lower housing 200 and the upper housing 100 through the air inlet 204. When the vehicle needs to reduce the suspension stiffness, the solenoid valve installed at the mounting port 206 opens, and the compressed air in the main chamber enters the auxiliary chamber connected to it through the mounting port 206, increasing the total system volume and achieving flexible support. When the stiffness needs to be increased, the solenoid valve closes, cutting off the air path to the auxiliary chamber, and only the main chamber works, reducing the system volume and stiffening the suspension. In addition, it maintains communication with the suspension airbag through the assembly port 205, and the gas can flow between the air chamber and the airbag through the air guide port 207. During this process, the upper reinforcing rib assembly 103 and the lower reinforcing rib assembly 203 jointly enhance the structural stability of the plastic shell 10, ensuring its reliability under repeated changes in air pressure.

[0023] like Figures 1-2 As shown, the upper housing 100 also includes an insert 104 mounted on the top of the upper housing cover 102. The top end of the insert 104 is flush with the top end of the upper housing cover 102, and the bottom end of the insert 104 extends downward through the upper fixing ring 101.

[0024] It should be noted that the insert 104 is embedded in the top of the upper shell 102 as a metal reinforcement structure. Its top end is flush with the upper shell 102 to ensure a flat installation interface, and its bottom end extends downward through the upper fixing ring 101, thereby directly transferring the installation load of the upper part to the entire upper shell 100. It works in conjunction with the upper reinforcing rib assembly 103 to jointly withstand gas pressure and mechanical vibration, ensuring the connection reliability and structural integrity of the plastic shell 10 under high pressure and long-term use.

[0025] like Figure 2 and Figure 4 As shown, the lower reinforcing rib assembly 203 includes a first lower reinforcing rib 2031, a second lower reinforcing rib 2032, and a lower U-shaped opening 2033. The two first lower reinforcing ribs 2031 divide the area between the lower fixing ring 201 and the lower shell 202 into a first lower cavity 2021 and a second lower cavity 2022. Several second lower reinforcing ribs 2032 are distributed circumferentially within the first lower cavity 2021. The lower U-shaped opening 2033 is opened on the side of the second lower reinforcing rib 2032 away from the bottom of the lower shell 202.

[0026] It should be noted that the two first lower reinforcing ribs 2031 divide the area between the lower fixing ring 201 and the lower shell 202 into the first lower cavity 2021 and the second lower cavity 2022, realizing the structural partitioning of the gas chamber. The several second lower reinforcing ribs 2032 distributed circumferentially in the first lower cavity 2021 mainly undertake the function of structural reinforcement, while the lower U-shaped openings 2033 on them, while ensuring structural strength, provide a smooth flow channel for gas in the entire main chamber formed by the inner cavity of the lower shell 202, especially when flowing through the area of ​​the first lower cavity 2021, ensuring that the gas can respond quickly and be evenly distributed, thereby maintaining pressure balance and system stability.

[0027] like Figures 4-5 As shown, both the air inlet 207 and the air outlet 204 are connected to the second lower cavity 2022, and the air outlet 204 is used to assemble a pressure holding valve.

[0028] It should be noted that the pressure holding valve installed at the air inlet 204 controls the one-way entry of external gas, through which compressed air enters the second lower cavity 2022; at the same time, the air guide port 207 is also connected to the second lower cavity 2022, forming a key flow channel for gas to reach the assembly port 205 and the airbag connected thereto; this layout makes the second lower cavity 2022 the core area for gas distribution and temporary storage, the pressure holding valve ensures that the system pressure is maintained, and the gas can be efficiently transported and regulated through the air guide port 207.

[0029] like Figure 4 As shown, the mounting port 206 extends into the lower housing 202, with one end passing through one of the first lower reinforcing ribs 2031 and communicating with the second lower cavity 2022. The side wall of the mounting port 206 is provided with a notch 2061 that communicates with the first lower cavity 2021.

[0030] It should be noted that when the solenoid valve in the mounting port 206 is closed, the compressed gas entering the second lower cavity 2022 from the air inlet 204 can flow into the lower housing 202 through the mounting port 206 and be supplemented into the first lower cavity 2021 through the notch 2061 on the side wall of the mounting port 206. This achieves gas flow and pressure balance between the first lower cavity 2021 and the second lower cavity 2022, ensuring a stable pressure distribution inside the gas chamber.

[0031] like Figures 3-4 As shown, the bottom ends of the upper fixing ring 101, the upper shell cover 102, and the upper reinforcing rib assembly 103 are flush with each other to form an upper welding surface 105, and the top ends of the lower fixing ring 201, the lower shell cover 202, and the lower reinforcing rib assembly 203 are flush with each other to form a lower welding surface 208. The upper welding surface 105 and the lower welding surface 208 are sealed and welded together.

[0032] It should be noted that by flushing the bottom ends of the upper fixing ring 101, the upper shell cover 102, and the upper reinforcing rib assembly 103 to form the upper welding surface 105, and by flushing the top ends of the lower fixing ring 201, the lower shell cover 202, and the lower reinforcing rib assembly 203 to form the lower welding surface 208, in this embodiment, ultrasonic welding or hot plate welding is used to seal the upper welding surface 105 and the lower welding surface 208, thereby achieving a high-strength airtight connection between the upper shell 100 and the lower shell 200. This integrated welding structure ensures the overall sealing performance and structural integrity of the plastic shell 10 and effectively withstands the internal gas pressure.

[0033] like Figures 4-5 As shown, the outer wall of the assembly port 205 is provided with uniformly distributed external threads 2051, and the assembly port 205 is used to connect with the airbag of the air suspension.

[0034] It should be noted that the assembly port 205 is screwed and fixed to the interface of the air suspension airbag through the external thread 2051 provided on its outer side wall, forming a reliable mechanical connection and airtight seal; at the same time, the air guide port 207 located on the top side wall of the assembly port 205 connects the inner cavity of the lower cover 202 with the inside of the airbag, thereby forming a complete gas passage, ensuring that the gas can flow smoothly between the air chamber and the airbag, and realizing the normal inflation and deflation function of the suspension system.

[0035] like Figures 2-3 As shown, the upper reinforcing rib assembly 103 includes a first upper reinforcing rib 1031, a second upper reinforcing rib 1032, and an upper U-shaped opening 1033. The two first upper reinforcing ribs 1031 divide the area between the upper fixing ring 101 and the upper shell cover 102 into a first upper cavity 1021 and a second upper cavity 1022. Several second upper reinforcing ribs 1032 are distributed circumferentially within the first upper cavity 1021. The upper U-shaped opening 1033 is opened on the side of the second upper reinforcing rib 1032 away from the top of the upper shell cover 102.

[0036] It should be noted that the two first upper reinforcing ribs 1031 divide the annular area between the upper fixing ring 101 and the upper shell 102 into independent first upper cavities 1021 and second upper cavities 1022. The second upper reinforcing ribs 1032, which are circumferentially distributed in the first upper cavity 1021, provide the main structural support. The upper U-shaped opening 1033 on the second upper reinforcing rib 1032, while ensuring structural rigidity, provides a channel for gas to circulate in the upper space formed by the first upper cavity 1021, the second upper cavity 1022 and the upper shell 102, thus promoting rapid equalization and stabilization of gas pressure.

[0037] like Figure 1 As shown, the plastic shell 10 is a long glass fiber reinforced nylon body.

[0038] It should be noted that the plastic outer shell 10 is made of long glass fiber reinforced nylon material. This material gives the upper shell 100 and the lower shell 200 high strength, high toughness and lightweight characteristics. This makes the overall structure composed of the upper fixing ring 101, upper shell cover 102, upper reinforcing rib assembly 103, lower fixing ring 201, lower shell cover 202 and lower reinforcing rib assembly 203 have excellent compressive strength and fatigue resistance when subjected to internal gas pressure and external load. At the same time, it achieves a weight reduction of 30%-50% compared with traditional metal air chambers, effectively reducing vehicle energy consumption.

[0039] like Figures 2-4 As shown, the bottom cross-section of the upper shell 102 is the same as the top cross-section of the lower shell 202, the upper fixing ring 101 and the lower fixing ring 201 have the same cross-section, and the upper reinforcing rib assembly 103 and the lower reinforcing rib assembly 203 are correspondingly arranged.

[0040] It should be noted that by setting the bottom cross-section of the upper shell 102 to be the same as the top cross-section of the lower shell 202, setting the cross-sections of the upper fixing ring 101 and the lower fixing ring 201 to be the same, and setting the upper reinforcing rib assembly 103 and the lower reinforcing rib assembly 203 accordingly, the upper shell 100 and the lower shell 200 are ensured to have a perfectly matched contour and structure when docked. This symmetrical design enables the upper welding surface 105 and the lower welding surface 208 to achieve perfect planar fit, providing optimal process conditions for ultrasonic welding or hot plate welding, thereby ensuring the airtightness and reliability of the welding interface, and allowing the pressure of gas in the inner cavity to be evenly distributed and effectively supported through the symmetrical reinforcing rib structure, thus improving the stability and durability of the overall structure.

[0041] The above-disclosed embodiments are only a few specific examples of the present utility model. However, the embodiments of the present utility model are not limited thereto. Any changes that can be conceived by those skilled in the art should fall within the protection scope of the present utility model.

Claims

1. An air suspension chamber, characterized in that, The device includes a plastic housing (10), which is composed of an upper housing (100) and a lower housing (200). The upper housing (100) includes an integrally formed upper fixing ring (101), an upper housing cover (102), and an upper reinforcing rib assembly (103). The upper reinforcing rib assembly (103) is connected between the outer ring of the upper fixing ring (101) and the inner wall of the upper housing cover (102). The lower housing (200) includes an integrally formed lower fixing ring (201), a lower housing cover (202), a lower reinforcing rib assembly (203), an air inlet (204), an assembly port (205), an installation port (206), and an air guide. The lower reinforcing rib assembly (203) is connected between the lower fixing ring (201) and the lower housing (202). The assembly port (205) is located at the bottom of the lower housing (202) and communicates with the lower fixing ring (201). The air guide port (207) is disposed through the top side wall of the assembly port (205) and communicates with the inner cavity of the lower housing (202). The air inlet (204) is located at the bottom of the lower housing (202) and communicates with its inner cavity. One end of the mounting port (206) penetrates the side wall of the lower housing (202) and extends into its inner cavity. The mounting port (206) is used to install a solenoid valve.

2. The air suspension chamber according to claim 1, characterized in that, The upper housing (100) also includes an insert (104) mounted on the top of the upper housing cover (102), the top end of the insert (104) being flush with the top end of the upper housing cover (102), and the bottom end of the insert (104) extending downward through the upper fixing ring (101).

3. An air suspension chamber according to claim 1, characterized in that, The lower reinforcing rib assembly (203) includes a first lower reinforcing rib (2031), a second lower reinforcing rib (2032), and a lower U-shaped opening (2033). The two first lower reinforcing ribs (2031) divide the area between the lower fixing ring (201) and the lower shell (202) into a first lower cavity (2021) and a second lower cavity (2022). A plurality of second lower reinforcing ribs (2032) are circumferentially distributed in the first lower cavity (2021). The lower U-shaped opening (2033) is opened on the side of the second lower reinforcing rib (2032) away from the bottom of the lower shell (202).

4. An air suspension chamber according to claim 3, characterized in that, Both the air inlet (207) and the air outlet (204) are connected to the second lower cavity (2022), and the air outlet (204) is used to assemble a pressure holding valve.

5. An air suspension chamber according to claim 3, characterized in that, The mounting port (206) extends into the lower housing (202) through one of the first lower reinforcing ribs (2031) and communicates with the second lower cavity (2022). The mounting port (206) has a notch (2061) on its side wall that communicates with the first lower cavity (2021).

6. An air suspension chamber according to claim 1, characterized in that, The bottom ends of the upper fixing ring (101), the upper shell cover (102), and the upper reinforcing rib assembly (103) are flush with each other to form an upper welding surface (105), and the top ends of the lower fixing ring (201), the lower shell cover (202), and the lower reinforcing rib assembly (203) are flush with each other to form a lower welding surface (208). The upper welding surface (105) and the lower welding surface (208) are sealed and welded together.

7. An air suspension chamber according to claim 1, characterized in that, The outer wall of the assembly port (205) is provided with uniformly distributed external threads (2051), and the assembly port (205) is used to connect with the airbag of the air suspension.

8. An air suspension chamber according to claim 1, characterized in that, The upper reinforcing rib assembly (103) includes a first upper reinforcing rib (1031), a second upper reinforcing rib (1032), and an upper U-shaped opening (1033). The two first upper reinforcing ribs (1031) divide the area between the upper fixing ring (101) and the upper shell (102) into a first upper cavity (1021) and a second upper cavity (1022). A plurality of second upper reinforcing ribs (1032) are circumferentially distributed in the first upper cavity (1021). The upper U-shaped opening (1033) is opened on the side of the second upper reinforcing rib (1032) away from the top of the upper shell (102).

9. An air suspension chamber according to claim 1, characterized in that, The plastic shell (10) is a long glass fiber reinforced nylon body.

10. An air suspension chamber according to claim 1, characterized in that, The bottom section of the upper shell (102) is the same as the top section of the lower shell (202), the upper fixing ring (101) and the lower fixing ring (201) have the same cross section, and the upper reinforcing rib assembly (103) and the lower reinforcing rib assembly (203) are correspondingly arranged.

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