Air Suspension Strut Cover With Reinforcing Core for Gas-Tight Strength
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current air suspension struts face challenges in achieving optimal strength and gas-tightness due to the need for pressure-tight connections between metallic and thermoplastic components, which are heavy and require additional sealing measures, leading to increased complexity and weight.
Innovation Solution
Incorporating a reinforcing core made of a material with higher modulus of elasticity, such as metal or ceramic, within the plastic air spring cover's damper bearing receptacle to enhance structural integrity and distribute forces effectively, eliminating the need for separate sealing measures and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a composite cover made of metallic and thermoplastic components is used, then the strength requirements are satisfied, but the weight increases and additional sealing measures are required
Solution Approach 1:
The patent applies local quality by using a thermoplastic cover with a localized reinforcing core made of metal or ceramic material positioned specifically in the damper bearing receptacle area. This allows the cover to have high strength only where needed (at the bearing receptacle) while maintaining low weight overall, rather than making the entire cover heavy metal. The reinforcing core provides localized structural support to handle the high forces at the damper bearing mounting point.
Solution Approach 2:
The patent employs composite materials by combining thermoplastic material for the cover body with a reinforcing core made of metal or ceramic material. This composite structure integrates the advantages of both materials: the thermoplastic provides lightweight construction and corrosion resistance, while the metal or ceramic core provides high strength and stiffness where required. The composite design eliminates the need for separate metallic components and sealing measures.
2Strength
If separate metallic components are used for the bearing receptacle, then the strength properties are improved, but the device complexity increases due to additional sealing requirements
Solution Approach 1:
The patent merges the cover body and bearing receptacle into a single integrated thermoplastic component with an embedded reinforcing core. Instead of having separate metallic bearing receptacle components that require sealing connections, the bearing receptacle is formed as an integral part of the thermoplastic cover, reinforced locally by the core. This merging eliminates the need for separate sealing measures and reduces assembly complexity while maintaining the required strength properties.
3Weight of moving object
If a thermoplastic material is used for the entire cover, then the weight is reduced, but the strength at the damper bearing receptacle is insufficient
Solution Approach 1:
The patent applies local quality by using a thermoplastic cover with a localized reinforcing core made of metal or ceramic material positioned specifically in the damper bearing receptacle area. This allows the cover to have high strength only where needed (at the bearing receptacle) while maintaining low weight overall, rather than making the entire cover heavy metal. The reinforcing core provides localized structural support to handle the high forces at the damper bearing mounting point.
Solution Approach 2:
The patent employs composite materials by combining thermoplastic material for the cover body with a reinforcing core made of metal or ceramic material. This composite structure integrates the advantages of both materials: the thermoplastic provides lightweight construction and corrosion resistance, while the metal or ceramic core provides high strength and stiffness where required. The composite design eliminates the need for separate metallic components and sealing measures.
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 improved strength and gas-tightness without additional sealing requirements, reducing weight and complexity by effectively channeling dynamic and static forces through the air spring cover, enhancing the overall performance of the air suspension strut.
Implementation Method 1
the air spring cover comprises a reinforcing core in order to increase the strength of the damper bearing receptacle, said reinforcing core being arranged in the base of the damper bearing receptacle and being at least partially surrounded by the plastic material of the air spring cover
Data Source
AI summary
Air suspension strut for a motor vehicle comprising an air spring with a shock damper, wherein the air spring comprises an air spring cover and a rolling piston, wherein a rolling bellows of elastomer material is clamped in an airtight manner between the air spring cover and the rolling piston, the air spring cover comprises a damper bearing receptacle having a base and receiving a damper bearing of the shock damper, and the air spring cover comprises a clamping base to which a first end of the rolling bellows is attached, wherein the air spring cover is manufactured from a plastic material and comprises a reinforcing core in order to increase the strength of the damper bearing receptacle, the reinforcing core being arranged in the base of the damper bearing receptacle and being at least partially surrounded by the plastic material of the air spring cover.