Gas Spring End Member Assembly for Rotation Without Lateral Shift
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Solution Overview
Problem
Existing gas spring and damper assemblies in vehicle suspension systems face issues with relative rotation between components, leading to performance degradation and manufacturing challenges, such as increased costs and assembly time, due to lateral movement of end members relative to the damper housing.
Innovation Solution
The design incorporates an end member assembly with a specific configuration of projections and a band that forms a groove, allowing for securement to the damper housing and flexible spring member, reducing lateral movement and enhancing manufacturability by forming a substantially fluid-tight connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the lower end member is rotatably supported on the damper housing using a friction-reducing bearing, then relative rotation is permitted, but lateral movement of the end member relative to the damper housing occurs
Solution Approach 1:
A wear ring is introduced as an intermediary component between the end member and damper housing. The wear ring rotates with the end member while being constrained by the damper housing, mediating the rotational motion and preventing direct contact and lateral movement between the end member and housing.
Solution Approach 2:
The rotational support function is segmented into two independent features: a wear ring that handles rotation and a retaining feature that prevents lateral movement. This segmentation allows each feature to optimize its specific function without compromising the other.
2Reliability
If attempts are made to minimize lateral movements of the end member, then lateral movement is reduced, but manufacturability decreases and assembly time increases
Solution Approach 1:
The wear ring and retaining feature are merged into a single integrated component. This combination eliminates the need for separate parts and complex assembly steps, maintaining ease of manufacture while achieving both lateral movement reduction and rotation permission.
Solution Approach 2:
The integrated component serves multiple functions simultaneously: it acts as a wear ring for rotational support and as a retaining feature for preventing lateral movement. This multi-functionality reduces the number of parts and simplifies the assembly process.
3Ease of operation
If relative rotation occurs between end members and damper housing, then rotation is accommodated, but twisting of the gas spring flexible wall occurs leading to performance degradation
Solution Approach 1:
The rotational capability is extracted from the gas spring assembly itself and placed in the end member bearing arrangement. This allows the gas spring flexible wall to remain stationary and free from twisting, while rotation is accommodated by the dedicated bearing mechanism.
Data Source
AI summary
End members are supportable along a damper housing and dimensioned for securement to flexible spring member. End members include a wall with a side wall portion including an inner side surface portion. First projections extend toward a first inner edge with a first shoulder surface portion faces a second end. Second projections extend inward beyond the inner side surface portion toward a second inner edge with a second shoulder surface portion facing a first end. Second projections are spaced axially from first projections such that a groove is formed inward of the inner side surface portion between first and second shoulder surface portions. End member assemblies including such an end member as well as gas spring and damper assemblies and suspension systems are also included.