Air Dryer Cartridge Base Plate With Metal Insert for Weight Reduction
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Solution Overview
Problem
Conventional air dryer cartridges with metal base plates are complex to manufacture, adding to weight and manufacturing costs, and are undesirable for reducing weight and fuel consumption in vehicles.
Innovation Solution
A base plate for an air dryer cartridge comprising a plastic plate with a tubular metal insert, allowing for a secure mechanical and pneumatic interface with the air dryer body, manufactured through overmolding or ultrasonic welding, reducing weight and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal base plate is used to provide mechanical and pneumatic interface, then the air dryer cartridge can be securely affixed to the air dryer body, but the weight and manufacturing complexity increase
Solution Approach 1:
The base plate is constructed as a composite structure combining a plastic plate with a metal insert. The plastic plate provides the base structure and pneumatic passages, while the metal insert (with internal threads) provides the mechanical fastening capability. This composite approach allows the air dryer cartridge to be securely affixed to the air dryer body through the metal insert while keeping the overall weight lower than a fully metal base plate.
2Reliability
If a metal base plate is used to provide mechanical and pneumatic interface, then the air dryer cartridge can be securely affixed to the air dryer body, but the manufacturing complexity and costs increase
Solution Approach 1:
The base plate uses a composite construction where a plastic plate is combined with a metal insert. The plastic plate can be manufactured using molding techniques to create the pneumatic passages and base structure, while the metal insert is separately manufactured and then integrated into the plastic plate. This division of manufacturing processes reduces the complexity compared to machining a fully metal base plate with both pneumatic passages and threading.
Solution Approach 2:
The base plate is segmented into two functional parts: the plastic plate component that provides pneumatic passages and base structure, and the metal insert component that provides threading for mechanical fastening. This segmentation allows each part to be optimized and manufactured separately using appropriate processes, then assembled together, reducing overall manufacturing complexity.
3Weight of moving object
If a plastic plate is used to reduce weight, then the weight and manufacturing complexity decrease, but the secure affixing capability is compromised
Solution Approach 1:
The plastic plate alone would lack sufficient mechanical strength for secure fastening, but by integrating a metal insert with internal threads into the plastic plate, the composite structure gains the mechanical fastening capability while maintaining the weight advantage of the plastic base structure. The metal insert provides the necessary strength for threading and fastening to the air dryer body.
Data Source
AI summary
An air dryer cartridge comprises a base plate. The base plate is configured for affixing the air dryer cartridge to an air dryer body. The base plate comprises a plastic plate comprising a central passage and a tubular metal insert received in the central passage.