Angled Flange Dust Boot Blow Molding
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Solution Overview
Problem
Existing dust boots manufactured through blow molding lack sufficient strength in the flange portion due to its thin thickness, which is inadequate for securely holding between the suspension spring and spring seat, leading to potential assembly difficulties and reduced durability.
Innovation Solution
The dust boot is designed with a flange portion angled between 0° and 90° relative to the boot body's axis, allowing for increased thickness and strength through blow molding, facilitating both assembly and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If blow molding is used to manufacture the dust boot, then manufacturing cost is reduced, but the flange portion thickness becomes thin and strength is insufficient
Solution Approach 1:
The flange portion is designed with a specific angled structure (0°<α<90°) that creates local structural reinforcement. This angular configuration increases the effective thickness and load-bearing capacity of the flange portion at the critical holding location, while the rest of the boot body maintains the thin-walled structure enabled by blow molding. This local structural optimization allows blow molding to be used while achieving sufficient flange strength.
2Ease of operation
If the flange portion is made perpendicular to the boot body axis, then assembly is simplified, but the flange portion thickness becomes thin when using blow molding
Solution Approach 1:
The angle parameter α of the flange portion is optimized to a range of 0°<α<90° instead of being fixed at 90° (perpendicular). This parameter change allows the flange portion to achieve both adequate thickness for strength and reasonable assembly characteristics. The optimal angle balances structural integrity with assembly ease, resolving the contradiction between simplified assembly and sufficient thickness.
3Strength
If injection molding is used to manufacture the dust boot, then the flange portion strength is sufficient, but manufacturing cost increases and mold fabrication time increases
Solution Approach 1:
Instead of using injection molding for the entire boot, the design uses blow molding with a locally optimized flange portion structure. The angular configuration (0°<α<90°) provides local reinforcement where strength is needed, eliminating the need for expensive injection molding tools while maintaining sufficient flange strength for holding between the suspension spring and spring seat.
Solution Approach 2:
The patent adopts blow molding, a cheaper and simpler manufacturing process compared to injection molding. Although blow molding typically produces thinner walls, the angular flange design compensates for this by providing sufficient strength through geometric optimization rather than material thickness alone, making the process economically viable.
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 design enhances the strength of the flange portion while maintaining the cost-effectiveness of blow molding, ensuring secure attachment and protection from pollutants without excessive manufacturing complexity.
Implementation Method 1
In the blow molding, air is blown into a hollow of a tubular material to press the material into the mold.
Implementation Method 2
An angle between the flange portion and a line perpendicular to an axis of the boot body in an outer side of the flange portion is set to be larger than 0° and smaller than 90°.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A dust boot (1) includes a tubular boot body (2) and an annular flange portion (3) linked to an upper end of the boot body (2). In an outer side of the flange portion (3), an angle between the flange portion (3) and a line perpendicular to an axis of the boot body (2) is set to be larger than 0° and smaller than 90°.