Vibration Damper Extension with Bend Pleat
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vibration dampers face challenges in tight axial installation spaces within vehicle chassis, particularly in larger vehicles, where the connection between the tubular extension shaft and the base is not clearly defined, leading to potential structural instability and increased material requirements.
Innovation Solution
A vibration damper extension featuring a circumferential bend pleat connecting the tube portion to the base, providing axial distance, structural strengthening, and eliminating the need for welding, with a method involving deep-drawing and folding to create a dimensionally stable and rigid connection, allowing for separate optimization of component loads and minimal material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a weld construction is used between the tubular body and the base, then the connection strength is improved, but the manufacturing complexity and inspection requirements increase
Solution Approach 1:
The base is merged with the tubular body through a bend pleat connection, combining two separate components into a unified structure that eliminates the need for additional welding while maintaining connection strength
Solution Approach 2:
The bend pleat introduces a curved, folded geometry between the base and tubular body, creating a dimensionally stable connection that provides structural strength without requiring weld construction
2Strength
If the tube portion has greater wall thickness, then the structural strength is improved, but the weight increases
Solution Approach 1:
The tube portion has locally increased wall thickness specifically in the region of the bend pleat where structural strength is most needed, while other portions can maintain thinner walls to reduce overall weight
Solution Approach 2:
The bend pleat creates a double-layered structure in the longitudinal portion, providing dimensional stability and strength through geometric configuration rather than uniformly increasing wall thickness throughout
3Stability of the object's composition
If the outer diameter is increased in the bend pleat region, then the structural stability is improved, but the material usage increases
Solution Approach 1:
The bend pleat utilizes curved folding geometry to create a dimensionally stable connection, achieving structural stability through form rather than through increased material quantity
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 solution achieves a strong, lightweight, and dimensionally stable connection between the base and tubular body, reducing material costs and weight while ensuring tightness against pressurized media, with the ability to maintain structural integrity without additional machining, thus optimizing the vibration damper's performance.
Implementation Method 1
the tube portion (23) has a circumferential bend pleat (27) with respect to the base (21). The bend pleat (27) provides an axial distance of the base (21) with respect to an end-side end face (33)
Implementation Method 2
deep-drawing a tubular body with an end-side base; and folding back the base into the tubular body
Data Source
AI summary
Extension for a cylinder of a vibration damper comprising a base and a tube portion adjoining the latter. The base and the tube portion are formed in one piece. The tube portion has a circumferential bend pleat with respect to the base.