Gas Spring End Member Bracket Wall Securement
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Solution Overview
Problem
Existing gas spring assembly designs face challenges in securement on suspension components, particularly due to reduced size and weight requirements in vehicle development, leading to less effective mounting and securement of gas spring assemblies, which can result in inadequate energy efficiency and performance.
Innovation Solution
A gas spring end member and assembly design featuring a bracket wall and base wall configuration that allows securement on structural members with a planar and side surface, using a fastener to carry axial forces and generate shear forces, accommodating variations in structural member dimensions and tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If vehicle suspension components are reduced in size and weight to reduce energy consumption, then energy efficiency is improved, but the securement capability for gas spring assemblies deteriorates
Solution Approach 1:
The end member is segmented into distinct functional zones: a bearing surface for load distribution, a bracket wall with passage for fastener securement, and a base wall for structural support. This segmentation allows each zone to optimize its function independently, enabling reliable securement on reduced-size components.
Solution Approach 2:
The bracket wall extends perpendicular to the bearing surface, creating a three-dimensional securement structure. The passage through the bracket wall allows fasteners to engage the structural member from a different spatial dimension, enhancing securement capability without increasing the footprint on the reduced-size component.
2Ease of manufacture
If material usage is reduced to lower costs and weight, then manufacturing cost is improved, but mounting effectiveness deteriorates
Solution Approach 1:
Different regions of the end member have different structural properties optimized for their specific functions. The bearing surface has high local stiffness for load bearing, while the bracket wall provides localized securement points. This local quality optimization allows effective mounting with reduced overall material usage.
Solution Approach 2:
The end member can be constructed from composite materials or material combinations that provide high strength-to-weight ratio. This allows maintaining mounting effectiveness while reducing overall material usage and manufacturing cost.
3Productivity
If alternate designs are used for mass-reduced components, then productivity is improved, but tolerance range and finish quality worsen
Solution Approach 1:
The end member design with its standardized bearing surface and bracket wall configuration can accommodate various structural member shapes and sizes. The passage in the bracket wall can receive different fastener types, making the design universal and tolerant of variations in structural member dimensions and tolerances.
Solution Approach 2:
The design allows for parameter variations in the structural member (such as thickness, width, and position of mounting features) while maintaining securement effectiveness. The bracket wall and passage dimensions can be adjusted to accommodate different tolerance ranges in mass-produced components.
Data Source
AI summary
A gas spring end member is dimensioned for securement along an associated suspension member having an associated planar surface and at least an associated first side surface. The gas spring end member can include a base wall disposed transverse to a longitudinal axis and a bracket wall that extends longitudinally-outwardly from the base wall. The bracket wall can be adapted for operative connection to the associated suspension member such that the gas spring end member can be supported thereon with the base wall disposed in longitudinally spaced-apart relation to the associated planar surface of the associated suspension member. A gas spring assembly including such an end member can be included. A suspension system and a method of installation including such a gas spring assembly can also be included.