Damper Tube Loop Forming With Reinforcing Insert Integration
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Solution Overview
Problem
Conventional methods of manufacturing damper tubes are complex, time-intensive, labor-intensive, and expensive, with materials contributing to weight and cost, and design changes require significant adjustments in manufacturing processes.
Innovation Solution
A method involving a tube with a reinforcing insert, where the first end is flattened and bent into a loop, with the loop edge connected to the tube, simplifying the manufacturing process and reducing complexity and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional manufacturing methods with multiple components and joints are used, then structural integrity can be maintained, but manufacturing complexity and production costs increase
Solution Approach 1:
The patent merges multiple components (tube, reinforcing insert, loop structure) into a single integrated damper tube structure. The reinforcing insert is positioned within the tube and the loop is formed by bending the tube itself, eliminating the need for separate joints and connections. This integration reduces manufacturing complexity while maintaining structural integrity through the unified design.
Solution Approach 2:
The damper tube is segmented into functional zones: a main tube body, a reinforcing insert positioned at a specific location, and a loop structure formed from the tube material itself. This segmentation allows each part to serve its specific function while being manufactured as an integrated structure, reducing the number of separate components and assembly steps.
2Weight of moving object
If traditional materials and processes are used, then production rate can be maintained, but weight and costs increase
Solution Approach 1:
The patent changes the structural parameters of the damper tube by introducing a loop configuration and a reinforcing insert. These parameter changes optimize the strength-to-weight ratio, reducing the overall material required while maintaining or enhancing structural performance. The loop structure provides mechanical advantage that allows for reduced material usage.
Solution Approach 2:
The damper tube employs a composite structure combining the tube material with a reinforcing insert. This composite approach allows optimization of weight and strength properties by selecting materials with appropriate characteristics for each component, reducing overall weight while maintaining structural requirements.
3Adaptability or versatility
If design changes are made to the damper tube, then functionality can be improved, but manufacturing process adjustments increase complexity and costs
Solution Approach 1:
The patent creates a dynamic loop structure that can adapt to different functional requirements. The loop configuration allows for varying degrees of flexibility and mechanical advantage depending on the application. This dynamic structure can be manufactured using standard forming processes, maintaining ease of manufacture while providing design adaptability.
4Ease of manufacture
If multiple components and joints are used in the damper tube, then structural requirements can be met, but production costs and investment costs increase
Solution Approach 1:
The patent extracts the reinforcing function from separate components and integrates it directly into the tube structure through the reinforcing insert and loop configuration. This extraction eliminates the need for additional joints and connection materials, reducing the total quantity of substance required while maintaining structural requirements.
Data Source
AI summary
A method of manufacturing a damper tube is provided. The method includes providing a tube having a first end and a second end opposite to the first end. The method includes providing a reinforcing insert, at least partly, within the first end of the tube. The method includes flattening a portion of the first end of the tube. The method also includes bending at least one of the reinforcing insert and the flattened portion of the first end of the tube into a loop. The method further includes connecting an edge of the loop to the tube.