Air Spring Composite Part for Strength and Gas Tightness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing air spring components for motor vehicles face challenges in achieving both sufficient strength for force transmission and tightness, particularly in air spring pots, which are critical for connecting to vehicle parts and maintaining gas integrity.
Innovation Solution
A composite component comprising a first element made of die-cast aluminum for strength and a second element made of glass fiber-reinforced thermoplastic for tightness, connected through material bonding and overmolding, ensuring both strength and tightness by forming a weld seam under an inert atmosphere.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single material is used for the air spring component, then the manufacturing process is simple, but it cannot achieve both sufficient strength for force transmission and sufficient tightness for gas retention
Solution Approach 1:
The patent applies composite materials by combining a thermoplastic base material with glass fiber reinforcement. The thermoplastic matrix provides gas tightness and sealing properties, while the glass fiber reinforcement enhances mechanical strength and stiffness. This composite structure enables the single-component air spring element to simultaneously achieve both sufficient strength for force transmission and sufficient tightness for gas retention, resolving the technical contradiction between these two requirements.
Solution Approach 2:
The patent utilizes parameter changes by controlling the crystallization behavior of the thermoplastic material during injection molding. By adjusting cooling rates and processing parameters, the material achieves optimal crystalline structure that enhances both mechanical properties and sealing characteristics. This parameter optimization allows the material to simultaneously deliver required strength and tightness without requiring multiple materials or components.
2Strength
If metal materials are used for the air spring component, then strength for force transmission is sufficient, but gas tightness and corrosion resistance are insufficient
Solution Approach 1:
The patent replaces traditional metal components with a thermoplastic-based composite that, while having different service life characteristics, provides superior corrosion resistance and gas tightness. The thermoplastic material does not rust or corrode like metal, eliminating a major harmful factor. Although thermoplastics may have different durability characteristics under certain conditions, they provide adequate service life for air spring applications while avoiding corrosion issues entirely.
3Object-affected harmful factors
If plastic materials are used for the air spring component, then corrosion resistance and gas tightness are sufficient, but strength for force transmission is insufficient
Solution Approach 1:
The patent employs composite materials by incorporating glass fiber reinforcement into the thermoplastic matrix. The glass fibers provide enhanced mechanical strength, stiffness, and dimensional stability, while the thermoplastic matrix maintains corrosion resistance and gas tightness. This composite construction allows the material to overcome the inherent weakness of pure plastics in force transmission applications while preserving their corrosion-resistant properties.
4Strength
If multi-component construction is used for the air spring component, then both strength and tightness can be achieved, but the manufacturing process becomes complex and post-processing is extensive
Solution Approach 1:
The patent merges multiple functions and material properties into a single injection-molded component. Instead of assembling separate metal and plastic parts to achieve both strength and tightness, the composite thermoplastic material with glass fiber reinforcement is formed as one integrated piece through injection molding. This single-component construction eliminates the need for complex assembly processes, reduces the number of parts, and minimizes post-processing requirements while maintaining both structural strength and gas tightness.
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 composite component achieves enhanced strength and tightness, allowing for effective force transmission and gas retention, while reducing weight and requiring minimal post-processing, thus improving the performance and durability of air spring components.
Implementation Method 1
heating and/or melting or plasticizing the joining areas (72) and subsequently pressing the joining areas (72) together to create a material bond, in particular a weld seam (70), under an inert atmosphere
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a composite part (10) for an air spring component of a motor vehicle, comprising a first element (14) made of a first material and a second element (16) made of a second material, wherein the second element (16) at least partially surrounds the first element (14). The invention also relates to an air spring component comprising such a composite part (10) and a second component which are bonded to each other.