Air Spring Sleeve Structure for Leak-Safe Vehicle Attachment
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Solution Overview
Problem
Air springs for vehicles face durability issues due to air leaks at attachment points, leading to reduced performance and increased manufacturing costs, especially in air suspension systems where the sleeve's design complexity hampers efficient production and assembly.
Innovation Solution
A sleeve design comprising a first and second sleeve with a closed structure and reinforcement features, made from thermoplastic materials, where the second sleeve's end is hermetically fixed to an end cap, and the first and second sleeves are bonded using laser welding, allowing for reduced parts and improved manufacturing efficiency through injection molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sleeve is attached to surrounding parts using conventional methods, then assembly is straightforward, but air leaks occur at attachment points reducing durability
Solution Approach 1:
The patent integrates the attachment function directly into the sleeve structure by forming attachment protrusions and grooves as integral parts of the sleeve during injection molding. This merging of the attachment mechanism with the sleeve body eliminates separate attachment components and prevents air leaks at attachment points, thereby improving reliability without significantly increasing device complexity.
2Ease of manufacture
If the sleeve design uses multiple separate parts for attachment, then assembly flexibility is improved, but manufacturing costs increase
Solution Approach 1:
The patent segments the sleeve into functional zones (attachment zones with protrusions/grooves and smooth zones) within a single integrated structure. This segmentation allows different regions of the sleeve to serve different functions while maintaining a unified manufacturing process through injection molding, reducing manufacturing costs while preserving design flexibility for various attachment configurations.
Solution Approach 2:
The sleeve design incorporates universal attachment features (protrusions and grooves) that can accommodate multiple attachment configurations and surrounding parts. These standardized features enable the same sleeve design to be used across different applications and positions, reducing the need for custom-designed parts and lowering overall manufacturing costs while maintaining adaptability.
3Reliability
If the sleeve is made as a single integrated piece, then manufacturing is simplified, but air leaks cannot be prevented at attachment points
Solution Approach 1:
The patent applies local quality by creating specific attachment protrusions and grooves only at the regions where attachment to surrounding parts is required, while the rest of the sleeve maintains a smooth, simple structure. This localized modification prevents air leaks at attachment points without unnecessarily complicating the overall sleeve design, achieving improved reliability with minimal increase in structural complexity.
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 design enhances durability by preventing air leaks, simplifies assembly, reduces manufacturing costs, and improves product performance by allowing for a more flexible design and efficient injection molding processes.
Implementation Method 1
the first and second sleeves are bonded using laser welding
Data Source
AI summary
A sleeve for an air spring for a vehicle includes at least a first sleeve and a second sleeve. The first sleeve has both open ends and includes a first circumferential portion and a second circumferential portion, the second sleeve has one open end and includes a third circumferential portion coupled to the second circumferential portion of the first sleeve, and an end opposite the one open end of the second sleeve is formed in a closed structure.