Air Spring Valve Channel Element for Leak-Resistant Seal Fixation
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Solution Overview
Problem
Existing valve designs for air springs face challenges in cost-effectiveness, robustness, and sealant fixation, with complex production processes and a risk of leakage due to the reliance on weld seams for both sealing and clamping forces.
Innovation Solution
A valve design featuring a channel element that holds the sealant in a form-fitting or non-positive manner, eliminating the need for material connections and allowing for easier production of complex geometries, including undercuts, which reduces the risk of leakage and simplifies the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sealant is clamped between the first and second elements by assembly clamping forces during welding, then the sealant is held in position, but the weld seam must cool sufficiently to maintain the clamping force and the welding process is complex
Solution Approach 1:
The invention divides the housing body into separate elements (first element, second element, and channel element) that can be manufactured independently and assembled. The channel element is specifically segmented as a separate component that can be fixed by simple form-fit or force-fit connections, eliminating the need for complex welding processes while maintaining reliable sealant fixation.
Solution Approach 2:
The invention extracts the clamping function from the welding process. Instead of relying on weld seam cooling to maintain clamping force, the channel element is designed with integrated clamping features (such as clamping lugs or elastic deformation capabilities) that provide the necessary holding force independently of thermal processes.
2Manufacturing precision
If a complex slide tool is used to produce flow openings with undercuts, then flow-optimized geometries are achieved, but the manufacturing cost and complexity increase
Solution Approach 1:
The invention changes the manufacturing parameters and methods for producing the channel element. Instead of using complex slide tools with drawing operations, the channel element is manufactured using simple injection molding or similar processes that can easily produce undercuts and complex geometries without additional tooling complexity. The material selection and molding parameters are optimized to achieve the required flow characteristics.
Data Source
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AI summary
A valve for an air spring is proposed, comprising a housing body (4) which is penetrated by a central longitudinal axis (Z) and includes a channel (10), wherein the housing body (4) comprises a first element (7) and a second element (9) which are connected by means of a material bond in a first region (92) and are abutting each other or arranged immediately adjacent to each other in a second region (94), wherein a sealing means (28) is arranged in the channel (10) which can close the channel (10) or reduce the effective opening cross-section of the channel (10), wherein the valve (2) comprises a channel element (72) which guides or forms the channel (10) at least section by section.wherein the channel element (72) is positively and/or force-fit fixed in the housing body (4) and the channel element (72) holds the sealing medium (28) in a third area (96) between itself and the second element (9), or the channel element (72) is positively and/or force-fit fixed in or on the first element (7) and the channel element (72) holds the sealing medium (28) in a third area (96) between itself and the first element (7).