Air Spring Component Overmolding Joining Areas
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Solution Overview
Problem
Air spring components in suspension systems face challenges in achieving a strong, airtight, and resilient connection, especially under high load conditions and limited installation space, with existing multi-part designs requiring complex sealing measures and being costly to manufacture.
Innovation Solution
An air spring component is created using a first and second material, with a joining material that overmolds the joining areas to form a cohesive, positive connection, allowing for the production of hollow bodies with high strength and tightness without additional welding processes, suitable for axially spaced components with varying cross-sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multi-part design is used for manufacturing reasons, then manufacturing ease is improved, but connection tightness and strength deteriorate due to complex sealing requirements
Solution Approach 1:
The patent merges the joining function with the molding process itself. The injection mold directly forms the joint between components during the molding cycle, eliminating the need for separate sealing operations. The mold cavity acts as the joining mechanism, integrating structural formation and sealing into a single process step.
Solution Approach 2:
The patent replaces complex mechanical sealing systems with a material-based bonding approach. Instead of using seals, gaskets, or mechanical fasteners that require precise alignment and assembly, the invention uses the molten material itself to create both the structural joint and the sealing interface simultaneously through the injection process.
2Adaptability or versatility
If multi-part design with special sealing measures is used, then manufacturing flexibility is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into the injection molding process itself. The same process that forms the component geometry also creates the joining interface and ensures sealing, eliminating the need for separate sealing components and assembly steps.
Solution Approach 2:
The injection mold system performs the sealing function automatically as part of the molding cycle. The molten material self-seals the joint as it fills the cavity and cools, without requiring additional sealing operations or components. The process is self-contained and self-ensuring for tightness.
3Ease of manufacture
If conventional joining methods are used, then manufacturing simplicity is maintained, but connection strength and airtightness under high load deteriorate
Solution Approach 1:
The patent changes the physical state of the joining material during the process. The material is injected in a molten state to ensure complete filling and bonding, then cooled and solidified to create a rigid, strong joint. This phase change enables both ease of manufacture and high connection strength.
Solution Approach 2:
The patent uses a material composition that combines the properties of the base component material with joining characteristics. The injection material is formulated to bond strongly with the component materials while maintaining the required mechanical properties, creating a composite joint structure with superior strength and sealing.
4Weight of moving object
If thin-walled components are used to reduce weight, then weight is reduced, but connection robustness and airtightness deteriorate
Solution Approach 1:
The patent applies different material properties to different locations. The thin-walled components maintain their lightweight structure in non-critical areas, while the injection-molded joint areas receive concentrated material and bonding energy to create locally reinforced, robust connection zones with superior airtightness.
Solution Approach 2:
The patent merges the joining process with the molding process, allowing the injection material to flow into and reinforce the joint areas of thin-walled components. This creates localized material concentration at the joint without requiring overall wall thickness increases, maintaining weight reduction while ensuring connection robustness.
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
This solution provides a cost-effective, high-strength, and airtight connection that can withstand numerous load cycles, ensuring the air spring's functionality and longevity while simplifying the manufacturing process.
Implementation Method 1
the first component and the second component are joined together by overmolding the joining areas with the joining material
Implementation Method 2
These are joined by a material bond under an inert atmosphere, so that the joint is sufficiently tight, strong, and resistant to temperature and aging
Data Source
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AI summary
The invention relates to an air spring component (10) for an air spring, an air strut, or an air spring damper, comprising a first component (11a) made of a first material, a second component (11b) made of a second material, and a joining material (20) made of a third material, wherein the first component (11a) and the second component (11b) have corresponding joining areas (12a, 12b), and wherein the first component (11a) and the second component (11b) are joined together by overmolding the joining areas (12a, 12b) with the joining material (20). The invention further relates to an air spring, an air strut, or an air spring damper with such an air spring component (10), and to a method for manufacturing such an air spring component (10).