Composite Gas Spring End Member Weight Reduction
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Solution Overview
Problem
Conventional gas spring assemblies for vehicles face challenges in reducing weight while maintaining performance, as altering components to reduce weight often leads to decreased performance and known travel-restraint devices increase system weight, and there is a need for improved constructions that offer enhanced performance and cost-effectiveness.
Innovation Solution
The development of gas spring assemblies with flexible spring members, end member assemblies, and over-extension devices that include a restraint assembly and a pressurized gas reservoir with an elongated gas damping passage to manage vibrations and prevent over-extension, while maintaining a fluid-tight seal and reducing weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional end members are designed and constructed from metal materials to provide desired performance characteristics, then strength and rigidity are improved, but weight increases
Solution Approach 1:
The end member is constructed as a composite structure combining a polymer material body with an embedded metal reinforcement cage. The polymer matrix provides corrosion resistance and weight reduction, while the metal cage embedded within provides structural strength and rigidity. This composite approach allows the end member to meet strength requirements while significantly reducing overall weight compared to conventional solid metal constructions.
2Reliability
If travel-restraint devices are added to prevent over-extension conditions, then reliability is improved, but weight increases
Solution Approach 1:
The travel restraint function is merged with the end member assembly itself rather than being a separate device. The restraint mechanism is integrated into the existing structural components, combining the functions of support, restraint, and connection in a single unified assembly. This integration eliminates the need for additional separate restraint devices, maintaining reliability while avoiding weight increase from redundant components.
Solution Approach 2:
The end member assembly is designed to perform multiple functions simultaneously: it provides structural support, acts as a travel restraint mechanism, and serves as a connection point. By making the assembly multi-functional, the patent eliminates the need for separate dedicated restraint devices, thereby maintaining reliability without adding weight.
3Weight of moving object
If the size of components is reduced to contribute to reduced weight, then weight is improved, but performance decreases
Solution Approach 1:
The use of composite materials allows for reduced component size while maintaining performance. The polymer-metals cage structure provides high strength-to-weight ratio, enabling smaller dimensional footprint compared to solid metal components of equivalent strength. This allows weight reduction through both material selection and size reduction without sacrificing performance.
Solution Approach 2:
The metal reinforcement cage is strategically positioned and dimensioned to provide strength only where needed, rather than uniformly thick walls throughout. This localized reinforcement approach minimizes material usage and component size while maintaining necessary performance characteristics at critical stress points.
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 proposed solution enhances the performance of gas spring assemblies by reducing weight, improving damping capabilities, and preventing over-extension, thereby maintaining or improving vehicle suspension system performance while minimizing costs.
Implementation Method 1
a pressurized gas reservoir with an elongated gas damping passage to manage vibrations
Implementation Method 2
a flexible spring member having a longitudinal axis
Data Source
AI summary
An end member assembly (EMI) includes an end member body (400) and a support column (500). The end member body (400) includes an outer side wall and an inner side wall that together at least partially define an end member reservoir. The inner side wall at least partially defines a passage through the end member body. The support column (500) extends into the passage and is accessible from along opposing ends of the passage. A sealing element can be disposed in fluid communication between the end member body and the support column. An elongated gas damping passage can extend through the end member assembly in fluid communication with the end member reservoir. A gas spring assembly can include a flexible spring member (200) that at least partially defines a spring chamber with an end member (900) and the end member assembly (EMI) on opposing ends thereof. A restraining assembly (1000) can be secured within the spring chamber.