Damper Dust Cover Flange Thickening for Bellows Strength Balance
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Solution Overview
Problem
The existing dust covers for vehicle dampers, made from thermoplastic resin, often have flange portions with insufficient strength due to thinner thickness compared to the bellows portions, which can compromise their structural integrity during expansion and contraction.
Innovation Solution
A dust cover design featuring bellows portions that expand and contract axially, with a flange portion extending radially outward and having a thickness larger than the radially outer end of the bellows portions, manufactured using a mold with a variable recess dimension to ensure the flange portion's thickness is increased while maintaining the bellows' expansion functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the flange portion is made with a larger outer diameter than the bellows portions, then the flange portion can extend radially outward to provide mounting functionality, but the thickness of the flange portion becomes smaller than the thickness of the bellows portions during blow molding, resulting in insufficient strength
Solution Approach 1:
The patent applies local quality by making the thickness of the flange portion larger than the thickness of the radially outer end of the bellows portions. This localized thickness increase specifically addresses the strength requirement of the flange portion without affecting the expansion and contraction functionality of the bellows portions. The differential thickness design allows each part to have the appropriate properties for its specific function.
2Strength
If the thickness of the flange portion is increased to ensure strength, then the structural integrity is improved, but the expansion and contraction functionality of the bellows portions may be compromised
Solution Approach 1:
The patent resolves this contradiction by applying local quality differently to different parts of the dust cover. The bellows portions maintain their original thickness to ensure expansion and contraction functionality, while the flange portion is specifically designed with a larger thickness to ensure strength. This localized differentiation allows both requirements to be satisfied simultaneously without compromise.
3Ease of manufacture
If a protrusion is formed on the flange portion, then the manufacturing complexity is reduced and attachment strength is improved, but the device complexity increases
Solution Approach 1:
The patent applies merging by integrating the protrusion feature directly into the flange portion during the blow molding process. This combines the mounting functionality and attachment strength requirements into a single integrated structure, reducing the need for separate components or post-manufacturing assembly steps. The protrusion is formed as part of the flange portion itself, simplifying the overall manufacturing process while providing enhanced attachment capability.
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 enhances the strength of the flange portion while allowing for effective expansion and contraction, reducing manufacturing complexity and costs by forming a protrusion on the flange portion, thereby improving the dust cover's structural integrity and attachment strength.
Implementation Method 1
air is fed into an inner side of the thermoplastic resin in a state where a molten tubular thermoplastic resin is disposed in a mold, and the thermoplastic resin is expanded in a radial direction
Implementation Method 2
the thermoplastic resin is expanded in a radial direction and is deformed into a shape along an inner wall surface of the mold
Data Source
AI summary
A dust cover is configured to cover an outer side of a damper extending in a predetermined direction. The dust cover includes bellows portions and a flange portion. The bellows portions are inclined alternately toward a radially outer side and a radially inner side in an axial direction. The flange portion extends radially outward from a cylindrical portion of the dust cover. The flange portion protrudes radially outward from the cylindrical portion of the dust cover by a dimension larger than a height dimension in a radial direction between a radially inner end and a radially outer end of each of the bellows portions. A thickness of the flange portion is larger than a thickness of the radially outer end of each of the bellows portions.