Gas Spring End Member Segmentation for Reduced Spring Rate
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing gas spring assemblies for vehicle suspension systems face challenges in reducing spring rate while maintaining ease of manufacture, assembly, and installation, often requiring complex and costly manufacturing processes to create fluid-tight chambers.
Innovation Solution
The end member assembly features integrally formed securement features that allow for secure engagement without welded joints, forming a fluid-tight seal and inhibiting axial displacement, enabling the assembly of gas spring assemblies with reduced spring rate without increasing production time or tooling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional chambers or cavities filled with pressurized gas are placed into fluid communication with the primary spring chamber to reduce spring rate, then ride comfort is improved, but manufacturing complexity and assembly time increase due to permanent securing of multiple end member components
Solution Approach 1:
The end member is divided into multiple sections (first end member section, second end member section, third end member section) that can be assembled together using integrally formed securement features. Each section can be manufactured separately and then joined without welding, allowing the creation of multi-chamber configurations for reduced spring rate while maintaining manufacturing simplicity.
Solution Approach 2:
Multiple end member sections are merged together through integral securement features to form a unified end member assembly with multiple gas chambers. The securement features include engagement protrusions and recesses that permanently join sections while maintaining fluid-tight seals, combining the benefits of multiple chambers with simplified manufacturing.
2Reliability
If additional chambers or cavities filled with pressurized gas are placed into fluid communication with the primary spring chamber to reduce spring rate, then ride comfort is improved, but production time and tooling costs increase due to permanent securing operations
Solution Approach 1:
The end member is segmented into multiple manufacturable sections that can be produced using standard manufacturing processes and then quickly assembled using integrally formed securement features, avoiding time-consuming welding operations and enabling faster production cycles.
Solution Approach 2:
The securement features are integrally formed on the end member sections during manufacturing, so that no additional machining or modification is required during assembly. The sections are pre-configured with engagement protrusions and recesses that align and lock together automatically during the assembly process.
3Strength
If welded joints are used to form fluid-tight chambers within end members, then structural integrity is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The end member is segmented into multiple sections joined by integrally formed securement features that create mechanical interlocking without welding. The engagement protrusions and recesses provide structural integrity through friction and geometric constraint, eliminating the need for expensive welding operations.
Solution Approach 2:
The securement features act as intermediaries between end member sections, providing both mechanical connection and fluid-tight sealing. The engagement surfaces and sealing elements work together to transmit loads and prevent gas leakage without requiring welded joints.
4Reliability
If multiple end member components are permanently secured together to form fluid-tight chambers, then gas spring assembly performance is improved, but assembly ease and installation simplicity deteriorate
Solution Approach 1:
The end member is segmented into sections with integrally formed securement features that enable tool-free or minimal-tool assembly. The engagement protrusions and recesses guide alignment and provide self-locking action, making assembly straightforward while maintaining the performance benefits of multi-chamber configurations.
Data Source
AI summary
An end member assembly includes first and second end member sections. The first end member section includes a first securement feature integrally formed thereon. The second end member section includes a second securement feature integrally formed therein that is dimensioned to cooperatively engage the first securement feature. In an assembled condition, the first and second end member sections are operatively engaged to substantially inhibit axial displacement therebetween. A substantially fluid-tight joint can be formed between the first and second end member sections such that an end member chamber can be formed within the end member assembly. A third end member section can be included, and can be operatively connected to the second end member section. A gas spring assembly and a suspension system are also included.