Air Suspension Coupler Vulcanization Without Parting Lines
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Solution Overview
Problem
The existing couplers for air suspension systems face issues with quality and durability due to parting lines formed during the vulcanization process, which can expose the cord of the topping cord sheet and affect the cardan motion properties, leading to a high defect rate.
Innovation Solution
A method and apparatus for manufacturing a coupler that involves connecting a rubber band to a topping cord sheet using a mold with an accommodation groove and a bladder to ensure close contact and uniform pressure, followed by vulcanization to form a hollow cylindrical shape without exposing the cord, thereby preventing parting lines and improving durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the composite sheet is vulcanized by separated first and second molds, then the manufacturing process can be completed, but a parting line is formed on the surface of the coupler
Solution Approach 1:
The patent combines the first and second molds into a single integrated mold structure. The single mold includes a first mold portion and a second mold portion that are formed as one piece, eliminating the parting line between molds. This merging approach maintains the vulcanization functionality while preventing the formation of surface defects caused by separate mold joining.
2Reliability
If the cord of the topping cord sheet is kept disposed without exposure, then cardan motion properties are ensured, but the cord may be pushed out or exposed by the parting line
Solution Approach 1:
By using a single integrated mold instead of separated molds, the patent eliminates the parting line that would otherwise push out or expose the cord. The continuous mold surface ensures the cord remains properly positioned within the topping cord sheet throughout the vulcanization process, maintaining cardan motion properties without cord exposure.
3Manufacturing precision
If a single mold is used for vulcanization, then parting lines are prevented, but the mold structure becomes more complex
Solution Approach 1:
The single mold is segmented into a first mold portion and a second mold portion that are integrally formed. This segmentation allows the mold to accommodate different regions (such as where the rubber band will be attached) while maintaining the integrity of a single-piece structure, thus preventing parting lines without excessive complexity.
Solution Approach 2:
The single mold structure serves multiple functions: it provides the vulcanization cavity, accommodates the rubber band attachment area, and eliminates the need for multiple separate molds. By integrating these functions into one mold, the patent reduces the number of components while maintaining manufacturing precision.
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 approach enhances the quality and durability of the coupler by preventing cord exposure and parting lines, reducing defects, and simplifying the manufacturing process while maintaining the cardan motion properties.
Implementation Method 1
vulcanizing an intermediately formed body made by the connecting of the topping cord sheet and the rubber band to each other
Implementation Method 2
pressing the topping cord sheet in a direction in which the outer circumferential surface of the topping cord sheet comes into close contact with an inner surface of the rubber band
Implementation Method 3
vulcanizing the composite sheet by apply heat and pressure to the composite sheet with the cylindrical shape
Data Source
AI summary
A method of manufacturing a coupler for an air suspension includes: preparing a topping cord sheet and a rubber band; connecting the topping cord sheet and the rubber band to each other by attaching the rubber band to an outer circumferential surface of the topping cord sheet; and vulcanizing an intermediately formed body made by the connecting of the topping cord sheet and the rubber band to each other.