Composite Air Spring Assembly for Corrosion-Resistant Sealing
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Solution Overview
Problem
Existing air springs face challenges with corrosion and durability due to the use of metal components, which can lead to reduced effectiveness of coatings and increased wear.
Innovation Solution
The air spring design incorporates composite parts, such as an injection molded collar, top plate, and clamp ring, to form a robust and corrosion-resistant structure, enhancing durability and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal plates (iron or steel) are used for top plate and bottom plate, then structural strength is achieved, 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 protective coatings (such as zinc) and elastomeric sealing elements. The top plate and bottom plate are made of metal for strength, while the coating provides corrosion resistance. The elastomeric sleeve attached to the plates creates an air-tight seal that further protects the metal surfaces from environmental exposure, resolving the contradiction between needing structural strength and maintaining corrosion resistance.
2Reliability
If protective coating (such as zinc) is applied to metal plates, then corrosion resistance is improved, but the coating effectiveness deteriorates during the attachment process to the sleeve
Solution Approach 1:
The protective coating is applied to the metal plates before the attachment process. By performing the coating operation in advance, the patent ensures that the protective layer is already in place on the metal surfaces before they are subjected to the mechanical stresses of attachment to the elastomeric sleeve. This preliminary action protects the coating integrity during the attachment process, resolving the contradiction between maintaining corrosion resistance and preserving coating integrity.
3Reliability
If more composite parts are used in air spring, then durability and weight reduction are improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the air spring into distinct functional components: metal plates for structural support, elastomeric sleeves for sealing and cushioning, and composite elements for enhanced durability. Each segment is optimized for its specific function and can be manufactured separately using appropriate processes, then assembled into the final product. This segmentation allows for increased use of durable composite materials without excessively complicating the overall manufacturing process, as each component can be produced independently.
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 use of composite parts in the air spring design significantly reduces corrosion, increases durability, and provides a cost-effective solution for heavy-duty applications.
Implementation Method 1
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
Implementation Method 2
An air spring may comprise a flexible member, such as an elastomeric sleeve that extends between a pair of plates... The elastomeric sleeve is attached to each of the top plate and the bottom plate to form an air tight seal. 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
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.