Gas Spring End Member Assembly With Flowed-Material Joints
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Solution Overview
Problem
Vehicle suspension systems with pressurized gas experience gas losses due to leakage pathways in complex piston designs, leading to reduced performance and increased operational costs, as well as manufacturing and assembly complexities.
Innovation Solution
A gas spring assembly with an end member assembly that uses flowed-material joints to form fluid-tight seals between components, reducing potential leakage pathways and maintaining seal integrity during deflection and deformation, comprising an outer shell, end plate, and attachment column made from thin-walled metal materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an increased number of components and sealing elements are used in piston design, then fluid isolation capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple sealing functions into a single integrated piston assembly. The piston includes an outer shell, end plate, and attachment column formed as unified components with integrated sealing surfaces, eliminating the need for separate sealing elements and reducing the total component count while maintaining fluid isolation capability.
Solution Approach 2:
The piston assembly utilizes thin-walled metal construction with flexible sealing surfaces that can deform to maintain fluid isolation. The outer shell and end plate are designed with appropriate wall thicknesses to provide both structural integrity and sealing flexibility, allowing the piston to maintain fluid isolation under varying pressure and vibration conditions.
2Reliability
If multiple sealing elements and components are assembled together, then fluid isolation is improved, but assembly time and manufacturing cost increase
Solution Approach 1:
The piston assembly combines multiple previously separate components (outer shell, end plate, attachment column) into an integrated assembly that requires fewer assembly steps. The unified design with built-in sealing surfaces eliminates the need to assemble separate sealing elements, thereby reducing assembly time and improving productivity.
3Reliability
If vibration and movement occur between component parts, then sealing elements degrade and leakage pathways develop, but using more sealing elements increases cost and complexity
Solution Approach 1:
The piston assembly employs flexible thin-walled metal construction with integrated sealing surfaces that can accommodate vibration and movement through elastic deformation. The unified structure with built-in sealing surfaces maintains seal integrity under dynamic conditions without requiring additional sealing elements, thereby avoiding increased complexity and cost.
Solution Approach 2:
The piston design incorporates compliance features and flexible sealing surfaces that anticipate and accommodate vibration and movement before they can cause seal degradation. The integrated construction allows the sealing surfaces to deform elastically in response to dynamic loads, preventing leakage pathway development without requiring extra sealing components.
Data Source
AI summary
A piston assembly includes an outer shell, an end plate and an attachment column. A first flowed-material joint is disposed between and fixedly attaches the end plate and the outer shell to one another such that a fluid-tight seal is formed therebetween. A second flowed-material joint is disposed between and fixedly attaches the attachment column and the end plate to one another such that a fluid-tight seal is formed therebetween. A gas spring assembly and method that include the piston assembly are also included.