Composite Flange for Vehicle Shock Absorber Weight Reduction
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Solution Overview
Problem
Existing shock absorbers face challenges in achieving a mechanically strong and lightweight connection between the module tube and the shock absorber tube, while also ensuring a pressure-tight fluid connection, particularly in applications where weight reduction is critical, such as in vehicle unsprung masses.
Innovation Solution
A flange with a plastics body containing fluid ducts and metallic connecting elements that extend between the shock absorber tube and the module tube, providing mechanical retention without optimizing the plastics body for mechanical forces, allowing for a lightweight and robust connection with improved load distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metallic flange is used to connect the module tube to the shock absorber tube, then the mechanical strength is improved, but the weight increases
Solution Approach 1:
The flange is constructed as a composite structure combining a plastics body with integrated metallic connecting elements. The plastics body provides the main structural form and fluid ducts, while the metallic elements (such as reinforcing ribs or embedded metal inserts) provide localized strength at critical connection points. This composite approach achieves the required mechanical strength without the weight penalty of a fully metallic flange.
2Length of moving object
If the distance between the module tube and shock absorber tube is increased, then structural requirements are met, but the mechanical load bearing capacity of the flange connection deteriorates
Solution Approach 1:
The flange design incorporates metallic connecting elements that extend in multiple dimensions between the tubes. Rather than a simple planar connection, the reinforcing elements create a three-dimensional structural framework that spans the increased distance, distributing mechanical loads across multiple pathways and maintaining connection capacity despite greater separation between the tube centers.
3Strength
If a welded connection is used to attach the flange to the tubes, then the mechanical strength is improved, but the sealing of fluid ducts becomes difficult
Solution Approach 1:
The flange design separates the mechanical connection function from the fluid sealing function. The metallic connecting elements are positioned and configured to handle mechanical loads and welding attachments, while the plastics body contains the fluid ducts and provides sealing surfaces. This segmentation allows each component to be optimized for its specific function without compromising the other.
Solution Approach 2:
The plastics body acts as an intermediary between the metallic connecting elements and the fluid ducts. It provides a transition zone where mechanical strength from the metal elements is transferred to the overall structure, while simultaneously maintaining the fluid-tight sealing environment for the ducts. The plastics material bridges the functional requirements of both metal and fluid containment.
Data Source
AI summary
A shock absorber having a shock absorber tube (10) is disclosed and has an external module tube (11) which is arranged retentively on the outside of the shock absorber tube (10) by a flange (12), wherein the flange (12) has one or more fluid ducts (13, 14) which fluidically couple the module tube (11) to the shock absorber tube (10). The flange (12) has a plastics body (15) in which the fluid ducts (13, 14) are formed, and the flange (12) furthermore has metallic connecting elements (16, 17) which extend between the shock absorber tube (10) and the module tube (11) and by which the mechanically retentive connection between the shock absorber tube (10) and the module tube (11) is formed.