Air Spring Bellows Chlorinated Polymer Blend
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Solution Overview
Problem
Air springs used in vehicle suspension face challenges with flex fatigue and crack growth resistance, leading to material integrity issues and the need for frequent replacements.
Innovation Solution
The development of air spring bellows using a vulcanizable composition that includes a combination of saturated and unsaturated chlorinated polymers, with a sulfur-based cure system, to enhance flexibility and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If unsaturated chlorinated rubber (neoprene) is used for air spring bellows, then good resilience and abrasion resistance are achieved, but flex fatigue and crack growth resistance are insufficient
Solution Approach 1:
The patent uses a composite material system combining unsaturated chlorinated rubber (neoprene) with saturated chlorinated polyethylene (CPE) and peroxide curing agents. This composite approach leverages the resilience and abrasion resistance of neoprene while adding crack growth resistance through CPE and peroxide crosslinking, resolving the contradiction between initial strength and long-term reliability.
2Reliability
If saturated chlorinated polyethylene (CPE) is used to improve heat, weather, and oil resistance, then durability is enhanced, but conventional sulfur vulcanization systems cannot be used and additive selection becomes complex
Solution Approach 1:
The patent changes the curing mechanism from sulfur-based to peroxide-based vulcanization. This parameter change in the curing chemistry enables the use of saturated CPE while avoiding the compatibility issues and complex additive selection requirements of sulfur systems, thus improving reliability without sacrificing ease of manufacture.
3Duration of action of moving object
If air spring bellows undergo countless compression and extension cycles, then suspension function is maintained, but material properties change over time leading to crack formation and reduced integrity
Solution Approach 1:
The patent applies peroxide curing during manufacturing to pre-establish a robust crosslinked network structure in the rubber composition. This preliminary action creates a more stable material that resists property changes during subsequent compression-extension cycles, delaying crack formation and maintaining integrity over the service life of the air spring.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides air springs with improved flex fatigue resistance and crack growth resistance, maintaining material integrity and extending the lifespan of air spring components.
Implementation Method 1
the vulcanization product of a composition that includes an unsaturated chlorinated polymer; and a saturated chlorinated polymer
Data Source
AI summary
An air spring having an airsleeve, wherein at least one layer of said airsleeve includes the vulcanization product of a composition that includes an unsaturated chlorinated polymer; and a saturated chlorinated polymer.