Composite Air Spring Assembly With Injection-Molded Airtight Collar
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Solution Overview
Problem
Existing air springs face corrosion issues with metal components, particularly steel plates, which compromise the effectiveness of protective coatings due to attachment processes, and there is a desire to increase the use of composite parts for durability, weight, and cost reasons.
Innovation Solution
The air spring design incorporates a top plate, flexible sleeve, and clamp ring coupled by an injection molded collar, where at least one of the components is formed as a composite, with optional indentations or perforations to enhance the connection and structural integrity, and the process involves compressing these parts in a mold to form an air tight seal with injected plastic.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal plates (steel/iron) are used for top plate and clamp ring, then strength and structural integrity are improved, but corrosion resistance deteriorates due to exposure to environment and compromise of protective coatings during attachment
Solution Approach 1:
The patent applies composite materials by combining metal plates with corrosion-resistant coatings and sealing elements. The top plate and clamp ring are made from metal materials (steel or iron) that provide structural strength, while incorporating protective coatings and sealing mechanisms to prevent corrosion from environmental exposure and attachment process damage.
2Reliability
If protective coatings (e.g., zinc) are applied to metal plates, then corrosion resistance is improved, but the attachment process compromises the coating effectiveness, leading to reduced protection
Solution Approach 1:
The patent segments the attachment process into controlled stages that protect the coating. The collar is attached to the clamp ring first, then the assembly is attached to the top plate in a sequence that minimizes coating compromise. This segmented approach allows protective coatings to remain effective while still enabling necessary attachments.
3Reliability
If more composite parts are used in air spring, then durability and weight are improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges multiple functions into integrated components. The collar serves both as a structural connector and as a attachment mechanism for both the clamp ring and top plate. The sealing elements are integrated into the collar-clamp ring-top plate assembly, reducing the number of separate parts while maintaining durability and reducing manufacturing 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
This solution provides a robust, durable, and cost-effective air spring with reduced corrosion risk, as the composite parts and injection molded collar create a strong, air tight seal, improving structural integrity and resistance to environmental factors.
Implementation Method 1
The injection molded collar is formed to hold the top plate, flexible sleeve, and clamp ring in compression to form an air tight seal
Implementation Method 2
The elastomeric sleeve, top plate, and bottom plate form a pressurized chamber. The pressurized chamber contains a fluid, typically a gas such as air. The fluid contained in the pressurized chamber acts as a spring.
Data Source
Figure 1
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AI summary
An air spring having at least one composite part is provided. The air spring will have a top plate, a flexible sleeve, and a clamp ring coupled together by an injection molded collar. The injection molded collar will be formed to hold the top plate, flexible sleeve, and clamp ring in compression to form an air tight seal. In certain aspects, the top plate and/or the clamp ring may be formed from composites or metals.