Composite Gas Cup Decoupler for Low-Leakage Damper Tuning
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Solution Overview
Problem
Conventional gas cups in damper assemblies suffer from durability issues due to long-term gas leakage through large elastomeric areas and gas permeability characteristics of elastomeric materials.
Innovation Solution
A gas cup design featuring a decoupler with improved durability, made from materials with different elasticity, and a bridging member that allows for variable tuning of the damper assembly, reducing gas pressure loss and enhancing ride comfort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a decoupler made entirely from elastomeric material is used to seal the gas compartment, then the sealing function is achieved, but gas leakage occurs over time due to gas permeability characteristics of the elastomeric material
Solution Approach 1:
The decoupler is constructed as a composite structure combining an elastomeric material outer layer with an inner core made of a different material (such as foam or rigid material). This composite construction reduces gas permeability while maintaining the necessary sealing and cushioning functions, thereby reducing long-term gas pressure loss.
Solution Approach 2:
Different regions of the decoupler are made from materials with different properties - the outer elastomeric layer provides sealing and flexibility, while the inner core material provides structural support and reduced gas permeability. This local differentiation of material properties optimizes both sealing durability and gas retention.
2Reliability
If a large elastomeric area is used in the decoupler to ensure flexibility and sealing, then the sealing effectiveness is improved, but gas leakage increases due to the large surface area for permeation
Solution Approach 1:
By combining elastomeric material with a low-permeability inner core material, the design maintains the flexibility and sealing effectiveness of the elastomeric outer layer while the inner core reduces gas permeation through the overall structure, addressing the contradiction between large elastomeric area and gas leakage.
3Loss of substance
If a rigid decoupler is used to reduce gas permeability, then gas pressure loss is reduced, but the ability to accommodate volumetric changes and provide variable tuning is limited
Solution Approach 1:
The composite structure of elastomeric material combined with foam or rigid inner core creates a material system that exhibits both rigidity (reducing gas permeability) and flexibility (allowing volumetric changes and variable tuning). The elastomeric outer layer maintains adaptability while the inner core reduces gas loss.
Solution Approach 2:
The decoupler's material composition parameters are optimized to achieve a balance between rigidity and flexibility, allowing the structure to accommodate volumetric changes in the gas compartment while maintaining reduced gas permeability over time.
4Ease of manufacture
If a single-component piston part with elastic sealing part is used (as in DE4335327A1), then manufacturing is simplified, but gas leakage still occurs due to the elastic sealing part's permeability
Solution Approach 1:
The single-component decoupler is constructed using composite materials (elastomeric material combined with foam or rigid material) that are molded together as one piece. This maintains the manufacturing simplicity of single-component construction while the composite material composition reduces gas permeability and leakage compared to pure elastomeric materials.
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 significantly reduces gas pressure loss over time, improves damping characteristics, and increases the operational life of the damper assembly, providing enhanced ride comfort, especially at high frequency inputs and small amplitudes.
Implementation Method 1
The decoupler and the bridging member are made from materials having different elasticity to allow the decoupler to move in the aperture in response to a volumetric change in the damper assembly
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A gas cup (50) for a damper assembly (20) comprises a body (52) including an upper surface (56), a lower surface (58), an exterior surface (60) and an interior surface (62). The body (52) defines an aperture (54) extending through the upper surface (56) and the lower surface (58). A decoupler (70) is located in the aperture (54) and secured to the body (52). A bridging member (106) is located between the decoupler (70) and the body (52) and coupled to the decoupler (70) and the body (52). The decoupler (70) and the bridging member (106) is made from materials having different elasticity to allow the decoupler (70) to move in the aperture (54) in response to a volumetric change in the damper assembly (20) and to provide variable tuning of the damper assembly (20). A damper assembly (20) including the gas cup (50) is also disclosed herein.