A new protective housing cap for use in shock absorbers

Abstract

The invention relates to arrangements concerning the elimination of cracks encountered during the assembly of protective body covers (14) configured particularly to protect shock absorbers (10) located in vehicle suspension systems from external factors onto shock absorber (10) systems, and to the development of a new material that is more elastic and simultaneously has increased strength values compared to protective body covers (14) in the current art.

Description

[0001] A NEW PROTECTIVE HOUSING CAP FOR USE IN SHOCK ABSORBERS

[0002] TECHNICAL FIELD

[0003] The invention relates to arrangements concerning the elimination of cracks encountered during the assembly of protective body covers configured particularly to protect shock absorbers located in vehicle suspension systems from external factors onto shock absorber systems, and to the development of a new material that is more elastic and simultaneously has increased strength values compared to protective body covers in the current art.

[0004] PRIOR ART

[0005] A shock absorber is a mechanical component used to absorb and control vibrations, impacts, and sudden jolts that occur during the movement of a vehicle or machine. As a fundamental part of the suspension system, shock absorbers enhance driving comfort while ensuring the controllability and safety of the vehicle or machine.

[0006] Shock absorbers essentially comprise an outer body, piston, piston rod, hydraulic oil or gas, valves, dust protection bellows, protective body cover, and mounting elements.

[0007] The protective body cover, which is one of these components, is an element that provides additional protection against external factors in shock absorbers. It is generally manufactured from rubber and polymer materials, and by covering the outer body of the shock absorber, it protects the piston rod and sealing elements. These covers play a critical role especially in vehicles and machines exposed to harsh operating conditions.

[0008] Protective body covers must be manufactured from durable materials and possess various technical properties to ensure the long-lasting and efficient operation of shock absorbers. High impact resistance is important to prevent damage during contact with stones or hard objects kicked up from the road surface. Flexibility and UV resistance prevent deformation caused by prolonged sunlight exposure and temperature variations. Chemical resistance prevents wear of the protective body covers upon contact with oil, fuel, and other chemicals. Additionally, protective body covers must provide insulation against dust, water, and moisture to safeguard the internal mechanical components. Common problems encountered in the prior art include the loss of functionality of protective body covers due tocracking or deformation, ingress of dirt and water due to improper sealing, and premature wear caused by low material quality. These issues can directly affect the performance of the shock absorber, reducing both driving safety and comfort.

[0009] The occurrence of cracks during the assembly of protective body covers onto shock absorbers is generally caused by material properties and errors in the assembly process. Covers made from materials with low impact resistance or from hard and brittle materials may fail to withstand the forces applied during assembly and thus crack.

[0010] As a result, in order to provide the solutions needed by the current state of the art, it is necessary to research and develop new materials for the production of protective body covers from flexible and high-impact-resistant materials.

[0011] BRIEF DESCRIPTION OF THE INVENTION

[0012] The present invention relates to a protective body cover intended for use in shock absorbers, aimed at eliminating the above-mentioned disadvantages and bringing new advantages to the relevant technical field.

[0013] The main objective of the invention is to provide a new material for obtaining protective body covers in shock absorbers. In this way, material-related cracking or breakage, especially encountered during the assembly of the protective body covers onto shock absorbers, is prevented. In particular, it is expected that this new material possesses a high fracture elasticity property.

[0014] One objective of the invention is to provide a new material for protective body covers that exhibits elastic and flexible behavior against cracking encountered during the assembly onto shock absorbers.

[0015] One objective of the invention is to provide a new material for protective body covers that demonstrates resistance to impacts during the assembly and use of shock absorbers.

[0016] One objective of the invention is to provide a new material that exhibits better environmental resistance than existing protective body covers. In this way, a more durable material against temperature variations, humidity, and chemical substances can be used in the production of protective body covers.BRIEF DESCRIPTION OF THE DRAWING

[0017] Figure 1 presents a schematic view showing the position of the protective body cover, which is the subject of the invention, on the shock absorber.

[0018] BRIEF DESCRIPTION OF THE REFERENCES

[0019] 10 Shock Absorber

[0020] 11 Body Tube

[0021] 12 Piston Rod

[0022] 13 Seal

[0023] 14 Protective Body Cover

[0024] DETAILED DESCRIPTION OF THE INVENTION

[0025] In this detailed description, the invention relates to a protective body cover (14) intended for use in shock absorbers (10), and it is explained with examples that are solely for the purpose of better understanding the subject and do not have any limiting effect.

[0026] Figure 1 presents a schematic view of the shock absorber (10) of the invention. The shock absorber (10) is a component that absorbs shocks coming from the road surface in vehicles, thereby reducing vibrations and enhancing driving comfort. As a part of the suspension system, it ensures safe driving by maintaining the contact between the wheels and the road surface.The protective body cover (14) is a cover component used in vehicles to protect the shock absorber (10) system from external factors. With reference to Figure 1 , the protective body cover (14) is positioned in the upper vicinity of the piston rod (12) and the seal (13) in the shock absorber (10) system. The protective body cover (14) protects the seal (13) against environmental factors such as stones, dust, and impacts from the outside, thereby ensuring the oil and gas tightness of the shock absorber. In this position, the cover (14) regulates the interactions between the seal (13) and the piston rod (12), while also enhancing the overall durability and functionality of the system.

[0027] Accordingly, the shock absorber (10) comprises at least one body tube (11). In its preferred configuration, the body tube (11) has a cylindrical structure. The body tube (11) ensures the stability of the moving parts within the shock absorber (10). It also serves as the outer protective layer of the shock absorber (10).The present inventors have determined that, in order to prevent technical problems such as breakage and cracking encountered during the assembly of protective body covers (14) onto shock absorbers (10), these covers must possess specific tensile strength and impact resistance values. Furthermore, it is extremely important that the protective body covers (14) also have high fracture elasticity values to withstand the stresses that may occur during assembly and use.

[0028] On the other hand, due to their function, protective body covers (14) are expected not to undergo deformation under external forces and to retain their shape. This feature is critically important for the protective body covers (14) to provide effective protection over long-term use and for maintaining the functionality of the shock absorber (10) system.

[0029] Protective body covers (14) are expected to be resistant to environmental factors (such as temperature variations, humidity, or oil) both during and after assembly.

[0030] The present inventors have identified that the commonly used material in the production of protective body covers (14) in the prior art polyamide 66 reinforced with 30% by weight glass fiber (PA66GF30) does not meet the required technical specifications. Although PA66GF30 is structurally a strong material due to its high mechanical strength and rigidity, it faces technical issues such as breakage and cracking during assembly. Its low impact resistance increases the risk of cracking under sudden forces, and its limited elasticity causes breakage rather than deformation under high stress. Furthermore, although it exhibits a certain degree of resistance to environmental conditions (such as temperature fluctuations and humidity), a decline in mechanical properties can still occur under these conditions, which negatively affects the long-term durability and lifespan of the product.

[0031] The present inventors provide a new material to address the aforementioned technical problems.

[0032] The material of the invention comprises a polyamide component reinforced with 15% by weight glass fiber, which can be abbreviated as PAGF15. As the polyamide, at least one from the group of polyamide 6 or polyamide 66 may be preferred.

[0033] As mentioned, PAGF15 contains 15% by weight glass fiber. This level of glass fiber reinforcement increases the rigidity and mechanical strength of the material while providing impact resistance and chemical durability for the polyamide.The PA66GF30 material, which is commonly used in the prior art, offers a rigid and stiff structure due to its high glass fiber content, whereas the PAGF15 material, with its lower glass fiber ratio, has a more flexible structure. The present inventors have identified that one of the main causes of breakage and cracking problems encountered during the assembly of protective body covers (14) onto shock absorbers (10) is the insufficient flexibility of the material. A more flexible structure can prevent such technical issues by allowing the material to deform rather than fracture in response to sudden forces and impacts during assembly.

[0034] One indication of this is that PAGF15 has higher impact resistance values compared to PA66GF30. The notched impact strength (Charpy) of PAGF15 ranges from 8 to 10 kJ / m2, while that of PA66GF30 ranges from 5 to 7 kJ / m2. This difference demonstrates that PAGF15 is more resistant to sudden forces and impacts occurring during assembly, which significantly reduces the risk of breakage and cracking of the protective body covers (14).

[0035] On the other hand, the reduction in glass fiber content increases the elasticity of polyamide-based components. This reduces the risk of cracking and breakage in response to deformations that occur during assembly. The PAGF15 material stands out with an elongation at break of 30% and an elastic modulus of 3500 MPa, while the PA66GF30 material has an elongation at break of 14% and an elastic modulus of 5500 MPa. These differences indicate that PAGF15 has a more flexible structure and provides better performance against stresses that may arise during assembly.

[0036] The higher fatigue resistance of PAGF15 compared to PA66GF30 supports the long-term use of protective body covers (14). This property enables protective body covers (14) made from PAGF15 to deliver more durable and reliable performance in shock absorber (10) systems, which are continuously subjected to vibrations and repetitive stresses. As a result, maintenance and replacement costs throughout the product’s service life are reduced, providing a more sustainable solution in the long term.

[0037] The technical features described in this invention enable PAGF15 to offer superior technical solutions and advantages for protective body covers (14) compared to PA66GF30. Properties such as high impact resistance, increased elasticity, improved fatigue strength, and reduced risk of cracking during assembly make PAGF15 a more durable, long-lasting, and reliable option. As a result, the performance and service life of protective body covers (14) are significantly improved, especially in systems like shock absorbers (10) that are exposed to vibrations and impacts.Another innovative aspect of the invention is the inclusion of a second component ethylene propylene diene monomer rubber (EPDM) as a raw material in the production of the protective body cover (14). When used in combination with the PAGF15 component, EPDM enhances the flexibility and impact resistance of the protective body cover (14). This innovation further reduces the risk of cracking and breakage that may occur during assembly, ensuring that the product is long-lasting and durable. Moreover, thanks to EPDM’s high elasticity and environmental resistance, the protective body covers (14) become more resistant to external factors such as temperature fluctuations and humidity.

[0038] EPDM is a synthetic elastomer obtained through the polymerization of three primary monomers. Its chemical structure comprises ethylene in the range of 45% to 75% by weight, propylene in the range of 25% to 55% by weight, and diene in the range of 2% to 10% by weight.

[0039] The Mooney viscosity value (ML 1+4 @100 °C) of EPDM ranges from 20 to 90, which is considered a low viscosity range. This low viscosity enables EPDM to provide easy processability, homogeneous distribution, and high flexibility in protective body covers (14). Additionally, the low viscosity enhances the material’s impact resistance and deformation resistance, thereby reducing the risk of cracking and breakage that may occur during assembly.

[0040] The elongation at break of EPDM ranges from 300% to 600%, and this high value is a significant indicator of the material’s flexibility. This property allows the material to undergo deformation under high stress without breaking or cracking. For protective body covers (14), such flexibility enhances resistance to sudden forces during assembly and to longterm vibrations, thereby optimizing the product’s performance and service life.

[0041] With these technical properties, EPDM imparts flexibility and high tensile strength to the PAGF15 component used in the protective body cover (14). Thanks to these contributions provided by EPDM, the protective body cover (14) becomes more resistant to sudden forces that may occur during assembly and to external factors. As a result, the risk of cracking and breakage is reduced, while the overall performance and long-term durability of the product are enhanced.

[0042] EPDM (Ethylene Propylene Diene Monomer Rubber) is a synthetic elastomer capable of operating over a wide temperature range by providing high elasticity between -40 °C and150 °C. It exhibits excellent resistance to ozone, UV radiation, moisture, and various chemical substances, thereby offering superior durability against wear and degradation caused by environmental conditions. Its low density makes it an ideal solution for lightweight structures, while maintaining its shape and functionality under continuous repetitive vibrations and impacts, ensuring long-lasting performance.

[0043] For this reason, the present inventors recommend the use of a material comprising 70% to 90% by weight of PAGF15 and 10% to 30% by weight of EPDM components for the production of the protective body cover (14), as a suitable solution for the relevant technical field.

[0044] In this way, it becomes possible to utilize the aforementioned raw material that provides superior technical properties for the protective body cover (14).

[0045] The protective body covers (14) produced with the material disclosed in the invention also exhibit improved fatigue resistance; in tests conducted up to 100,000 cycles, the product was found not to break. In contrast, protective body covers (14) manufactured from the commonly used PA66GF30 material in the prior art were observed to fail at around 700-800 cycles during testing.

[0046] The use of the material disclosed in the invention as a protective body cover (14) in shock absorbers enhances durability and addresses the issues of breakage and cracking encountered during assembly. Due to the brittle nature of the PA66GF30 material used in the current art, protective body covers (14) exposed to high forces during the assembly process tend to crack. In contrast, the new material offers a more flexible structure, thereby eliminating these problems. As a result, the product’s service life is extended, and a more reliable solution is provided for users.

[0047] The flexibility of EPDM enhances the elasticity of the PAGF15 material, allowing the protective body covers (14) to be used in assembly processes with a reduced risk of deformation and cracking. High elasticity enables better distribution and absorption of impact energy within the material, thereby minimizing damage to the protective body covers (14) during assembly.

[0048] The material disclosed in the invention has provided a significant improvement in the fatigue resistance of protective body covers (14). In conducted tests, the protective body covers (14) of the invention demonstrated durability up to 100,000 cycles. This representsa major advancement compared to the current material used in the prior art, PA66GF30, which was observed to fail after only 700-800 cycles.

[0049] Thanks to the addition of EPDM, the environmental resistance properties of the protective body cover (14) have been significantly enhanced. This structure provides excellent protection against external factors such as ozone, UV radiation, and humidity, allowing the protective body covers (14) to maintain their durability even under prolonged outdoor conditions.

[0050] The scope of protection of the invention is defined in the appended claims and shall by no means be limited to the examples described in this detailed description. It is evident that a person skilled in the art may develop similar configurations in light of the above explanations without departing from the main concept of the invention.

Claims

CLAIMS1. A protective body cover (14) configured to prevent the formation of cracks and breakages encountered during assembly onto shock absorbers (10), and having elastic and mechanical strength properties for this purpose, characterized in that it comprises, as components, polyamide reinforced with 15% by weight glass fiber (PAGF15) and ethylene propylene diene monomer rubber (EPDM).

2. A protective body cover (14) according to claim 1, characterized in that the mentioned polyamide comprises at least one from the group of polyamide 6 or polyamide 66.

3. A protective body cover (14) according to any one of the preceding claims, characterized in that it comprises, by weight, polyamide reinforced with 15% glass fiber in an amount ranging from 70% to 90%.

4. A protective body cover (14) according to any one of the preceding claims, characterized in that it comprises ethylene propylene diene monomer rubber in an amount ranging from 10% to 30% by weight.

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