Fiber Composite Vibration Damper Conical Connection
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Solution Overview
Problem
Conventional vibration damper production techniques face challenges such as gas leaks, early failure of adhesive connections, complex production processes, and increased costs due to thermal expansion issues and the need for precise surfaces, which hinder lightweight construction.
Innovation Solution
The vibration damper features conical or wedge-shaped end areas with a corresponding external shape, a clamping sleeve with a conical or wedge-shaped inner shape, and a combined pressing process with friction welding, using materials like thermoplastic fiber-reinforced plastics to create a robust, leak-resistant connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive bonding is used to connect the support tube with guide element and fastening element, then a material connection is achieved, but gas leaks may form and early total failure occurs with additional pre-processing and post-processing required
Solution Approach 1:
The patent replaces adhesive bonding (chemical connection) with a mechanical connection system consisting of a conical connection element inserted into a correspondingly shaped recess in the support tube. The connection is secured through friction and geometric interlocking, eliminating the need for adhesives and their associated reliability issues such as gas leaks and premature failure.
Solution Approach 2:
The patent utilizes thermal expansion parameter changes during the curing process of fiber composite materials. The connection element is inserted before curing, and as the material cures and expands, it creates a tight friction fit that secures the connection without requiring adhesives or additional processing.
2Strength
If form-fitting connection with T-spigot is used, then connection is achieved, but additional component costs and complex production process integration are required
Solution Approach 1:
The patent merges the connection element with the guide element or fastening element by integrating the conical connection feature directly into these components during the fiber composite curing process. This eliminates the need for separate T-spigot components and simplifies the production process by combining multiple functions into single integrated parts.
Solution Approach 2:
The connection element is inserted into the support tube recess before the fiber composite material is cured. This preliminary action allows the connection to be established in advance, and the subsequent curing process secures it through thermal expansion and friction, eliminating the need for complex post-assembly operations.
3Strength
If conventional connection techniques are used, then connection is achieved, but lightweight construction is restricted due to complex production and processing
Solution Approach 1:
The patent utilizes fiber composite materials for the support tube, guide element, and fastening element, taking advantage of their high strength-to-weight ratio. The integrated conical connection design allows these lightweight composite components to be connected without requiring heavy reinforcement or complex joining hardware, thereby maintaining the lightweight construction of the vibration damper.
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 design achieves a high-quality, robust, and leak-resistant connection between the damper cylinder and its components, enhancing the vibration damper's performance and reducing production complexity and costs while ensuring reliable sealing.
Implementation Method 1
a combined pressing process with friction welding
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to an arrangement for a vibration damper (1) of a vehicle comprising: at least one damping cylinder (3) made from a fibre composite material; a guiding element (4) for guiding a piston rod (5) of a piston (6) that can be movably arranged in the damping cylinder (3), said guiding element (4) being arrangeable in a guiding end region (3a) arranged at one end of the damping cylinder (3); and a fastening element (7), arrangeable in a fastening end region (3b) of the damping cylinder (3) arranged at the other end of the damping cylinder (3), for fastening the damper cylinder (3) on another part of the vehicle. At least one of the two end regions of the damping cylinder (3) is conical or wedge-shaped and the element (4, 7) arranged in this end region has a corresponding external form that is conical or wedge-shaped. A conical or wedge-shaped guiding end region (3a) tapers down toward the end of the damping cylinder (3) which the guiding end region (3a) adjoins, and a conical or wedge-shaped fastening end region (3b) widens toward the end of the damping cylinder (3) which the fastening end region (3b) adjoins.