Gas Spring End Member Assembly With Torsional Isolator
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Solution Overview
Problem
Existing gas spring and damper assemblies in vehicle suspension systems face issues with relative rotation-induced twisting of flexible walls, leading to performance degradation, and known solutions often compromise manufacturability, assembly time, and cost.
Innovation Solution
The use of a torsional isolator supported on a damper assembly with a compliant body between rigid bodies, forming a substantially-fixed rotational position to isolate rotational displacement from the flexible spring member, combined with end member assemblies that secure the gas spring and damper components in a manner that minimizes lateral movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the lower end member is rotatably supported on the damper housing using a friction-reducing bearing, then rotation-induced twisting of the gas spring is reduced, but lateral movement of the end member relative to the damper housing occurs undesirably
Solution Approach 1:
A torsional isolator is introduced as an intermediary component between the end member and damper housing. This isolator comprises a compliant body that permits rotational movement while restraining lateral movement, thereby mediating between the need for rotation and the need for lateral stability
Solution Approach 2:
The compliant body's material properties are designed to exhibit different resistance characteristics for different types of movement: high compliance for rotation and high stiffness for lateral movement. This parameter differentiation allows the same component to address both requirements
2Stability of the object's composition
If attempts are made to minimize lateral movement of the end member, then lateral movement stability improves, but manufacturability decreases and assembly time increases
Solution Approach 1:
The torsional isolator employs a compliant body constructed from flexible material that can be molded as a single piece. This flexible structure achieves lateral movement restraint through its material properties rather than complex mechanical constraints, simplifying manufacturing
Solution Approach 2:
The compliant body is made from composite material exhibiting both compliance and stiffness characteristics. This material approach allows a single-component design that is easier to manufacture than multi-component mechanical solutions while achieving both rotational freedom and lateral stability
3Object-affected harmful factors
If known designs are used to address rotation, then rotational issues are partially mitigated, but assembly complexity and cost increase
Solution Approach 1:
The torsional isolator merges multiple functions into a single component: it provides rotational freedom, restrains lateral movement, and maintains axial positioning. This consolidation eliminates the need for separate bearing elements and sealing arrangements, reducing assembly complexity
Solution Approach 2:
The compliant body serves multiple functions simultaneously: it acts as a rotational joint, a lateral movement constraint, and a sealing surface. This multi-functionality reduces the total number of components and simplifies the overall 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 effectively reduces the adverse effects of relative rotation on the gas spring, enhancing the performance and manufacturability of gas spring and damper assemblies while maintaining assembly efficiency and reducing costs.
Implementation Method 1
a torsional isolator (700) supported on the damper assembly with a compliant body (702) between rigid bodies (704, 706), forming a substantially-fixed rotational position to isolate rotational displacement from the flexible spring member
Data Source
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AI summary
End members (604) are supportable along a damper housing (200) and dimensioned for securement to a flexible spring member (300). The end members (604) include a wall (616) with a first wall portion (618) having an outer surface portion (622) dimensioned to receivingly engage the flexible spring member (300). A second wall portion (650) includes an inner surface portion (650A) dimensioned to receivingly engage a torsional isolator (700) supported on the damper housing (200). A third wall portion (652) extends radially outward beyond the second wall portion (650) and includes a passage surface (662) at least partially defining a passage (602) extending axially through the third wall portion (652). The passage (602) is dimensioned to receive a projection (732) of the torsional isolator (700). End member assemblies (600) including such an end member (604) as well as gas spring and damper assemblies (AS1) and suspension systems (100) are also included.