Gas Spring Piston with Integral Surrounding Chamber
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Solution Overview
Problem
Existing gas spring assemblies in vehicle suspension systems face limitations in reducing spring rate due to constraints in adding additional volume, such as limited space for mounting and potential leak points when using external reservoirs or connecting piston chambers, which affects ride comfort.
Innovation Solution
The design incorporates an integral piston chamber with a mounting arrangement that allows the piston chamber to surround structural members on multiple sides, utilizing adjacent space for increased volume, and a flexible sleeve to form a main chamber with an end member, enhancing the internal volume and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external reservoirs are used to increase gas volume, then the spring rate is reduced and ride comfort is improved, but additional leak points and manufacturing complexity are introduced
Solution Approach 1:
The patent merges the reservoir function into the piston assembly itself by creating a piston chamber that surrounds the mounting surface on multiple sides. This integration eliminates the need for separate external reservoirs and their connecting hoses, thereby reducing leak points while maintaining the increased gas volume needed for reduced spring rate and improved ride comfort.
Solution Approach 2:
The piston chamber is designed to nest around the mounting surface, utilizing the space between the piston and the structural member to which it is mounted. This nesting approach allows the piston chamber to occupy otherwise wasted space, increasing gas volume without adding external components or increasing the overall footprint of the gas spring assembly.
2Reliability
If piston chamber volume is increased by traditional mounting, then ride comfort is improved, but mounting space constraints limit the additional volume
Solution Approach 1:
The patent transitions from a traditional planar mounting approach to a three-dimensional configuration where the piston chamber surrounds the mounting surface on multiple sides. This dimensional change allows the piston chamber to utilize space in directions other than just above the mounting surface, thereby increasing gas volume without being constrained by traditional mounting geometry.
Solution Approach 2:
The piston chamber is designed to nest around the mounting surface, utilizing the space between the piston and the structural member to which it is mounted. This nesting approach allows the piston chamber to occupy otherwise wasted space, increasing gas volume without adding external components or increasing the overall footprint of the gas spring assembly.
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
This configuration increases the volume of the piston chamber, improving ride comfort by reducing the spring rate without introducing additional leak points or manufacturing complexities, providing a more efficient and effective gas spring assembly for vehicle suspension systems.
Implementation Method 1
a flexible sleeve extending between and sealingly connected to the end member and the gas spring piston assembly. The flexible sleeve can at least partially form a main chamber between the end member and the gas spring piston assembly for containing a pressurized gas
Data Source
AI summary
A piston assembly (204) including an integral piston chamber (218) with an increased volume that is maximized by providing a mounting arrangement whereby the piston can be mounted to a structural member (stz) such that the piston chamber (218) surrounds at least two sides of the structural member (stz). The piston chamber (218) can therefore utilize space adjacent the structural member (stz) to which it is mounted thereby resulting in a piston chamber of a greater volume than prior art designs. A gas spring assembly (200) utilizing such a piston is also included.