Composite Divider Assembly for Lightweight Spring Brake Actuators
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Solution Overview
Problem
Existing spring brake actuators in pneumatic braking systems face challenges in achieving a cost-efficient and robust separation between different chambers, often relying on metal flanges that are heavy and costly to manufacture.
Innovation Solution
A divider arrangement using a plastic divider with a metal support member is introduced, which separates the parking brake and service brake pressure chambers, enhancing mechanical robustness and stiffness while allowing for efficient manufacturing and mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal flange is used to separate chambers, then structural strength and sealing capability are improved, but weight and manufacturing cost increase
Solution Approach 1:
The patent employs a composite structure consisting of a plastic divider combined with a metal support member. The plastic divider provides the separation function and basic structural integrity, while the metal support member reinforces specific areas to maintain chamber separation under pressure without requiring a fully metal construction. This composite approach achieves the necessary strength while significantly reducing weight compared to traditional metal flange solutions.
2Strength
If a metal flange is used to separate chambers, then structural strength and sealing capability are improved, but manufacturing cost increases
Solution Approach 1:
The plastic divider can be manufactured using injection molding or similar plastic forming processes, which are generally more cost-effective and easier to manufacture than metal flanges requiring machining, welding, or other metal fabrication processes. The metal support member can be produced separately and assembled with the plastic divider, allowing for optimized manufacturing of each component and reducing overall production complexity and cost.
Solution Approach 2:
The separation structure is divided into two functional components: the plastic divider that provides the basic separation and sealing surface, and the metal support member that provides structural reinforcement. This segmentation allows each component to be optimized for its specific function and manufactured using the most appropriate and cost-effective process for that material and function.
3Weight of moving object
If a plastic divider is used to separate chambers, then weight and manufacturing cost are reduced, but mechanical robustness and stiffness decrease
Solution Approach 1:
The plastic divider is combined with a metal support member that is integrated into its structure. The metal support member provides the necessary mechanical robustness and stiffness to maintain chamber separation under pneumatic pressure, while the plastic divider maintains the weight and cost advantages. The combination creates a structure that achieves the mechanical properties of metal with the weight and manufacturing advantages of plastic.
Data Source
AI summary
A divider arrangement (100) for a vehicle spring brake actuator (250) having a parking brake pressure chamber (251), a service brake non-pressure chamber (252), a service brake pressure chamber (256), and a diaphragm (253) to separate the service brake non-pressure chamber (252) from the service brake pressure chamber (256) includes an annular shaped divider (110) and a support member (120). The divider (110) is adapted to receive the diaphragm (253) and to divide the parking brake pressure chamber (251) and the service brake pressure chamber (256) from each other. The divider (110) is made of plastic and is lightweight, and the support member (120) mechanically and/or structurally supports the divider (110). The support member is metal and provides increased stiffness relative to the plastic divider. The divider is configured to be fixed to a cylinder of the spring brake actuator.