Hybrid Air Spring Bellows Decoupling Comfort and Torsional Rigidity
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Solution Overview
Problem
Existing air spring arrangements for motor vehicles face a trade-off between meeting comfort requirements and reducing torsional rigidity, as designs that absorb torsional movements often lead to premature failure under larger loads, and vice versa.
Innovation Solution
The air spring arrangement features a hybrid bellows with a first partial bellows in a cross-layer design for comfort and a second partial bellows with thread reinforcements parallel to the axis for torsion and cardanic absorption, using different elastomer mixtures and layer configurations to achieve both comfort and reduced torsional rigidity simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If air spring bellows uses thread reinforcements running parallel to the central longitudinal axis to reduce torsional rigidity, then comfort requirements are met, but the bellows structure becomes insufficient for absorbing torsional movements and leads to premature failure under larger loads
Solution Approach 1:
The air spring bellows is divided into multiple layers of fabric reinforcements with different thread reinforcement orientations. The first fabric reinforcement has threads running parallel to the central longitudinal axis for comfort, while the second fabric reinforcement has threads running at an angle for torsional absorption, allowing both functions to coexist in a single integrated structure.
Solution Approach 2:
The bellows uses a composite construction with multiple fabric reinforcements having different thread orientations embedded in the elastomeric material. This composite structure combines the benefits of parallel threads (comfort) and angled threads (torsional absorption) within a single unified bellows design.
2Strength
If air spring bellows uses cross-layer construction with additional fabric and elastomer layers to absorb torsional movements, then torsional rigidity is increased, but the bellows becomes too rigid to meet comfort requirements
Solution Approach 1:
Different regions of the bellows have different structural characteristics. The first fabric reinforcement provides local compliance for comfort in areas requiring flexibility, while the second fabric reinforcement provides local strength for torsional absorption in areas requiring rigidity, creating a non-uniform but optimized structure.
Solution Approach 2:
The bellows structure dynamically adapts to different operational conditions through its multi-layer fabric reinforcement design. Under normal conditions, the parallel thread reinforcement provides comfort compliance, while under torsional loads, the angled thread reinforcement activates to provide necessary strength and absorption capability.
3Ease of operation
If air spring bellows uses a single layer of fabric reinforcement to reduce torsional rigidity, then comfort requirements are met, but the bellows lacks the structural integrity for durable operation
Solution Approach 1:
The single layer is segmented into multiple fabric reinforcement layers with different thread orientations. The first layer provides comfort through parallel threads, while the second layer provides structural integrity through angled threads, achieving both goals within a unified multi-layer construction.
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 design effectively decouples rolling and elasticity areas, allowing for simultaneous fulfillment of comfort requirements and reduced torsional rigidity, enhancing the air spring's adaptability and durability by stabilizing against transverse forces and extending its service life.
Implementation Method 1
an air spring bellows which has a small number of layers of fabric reinforcements and is designed as a variant guided on the outside
Implementation Method 2
the respective thread reinforcements are arranged crossed at a defined angle, for example 70°, to the central longitudinal axis of the spring strut
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
The invention relates to an air spring assembly for a motor vehicle, comprising an air spring (210), an air spring bellows (104), an air spring cover, and a rolling piston (212), wherein the air spring bellows (104) is a tubular rolling bellows, wherein the air spring bellows (104) is arranged concentrically about a central longitudinal axis (214) of the air spring (210) between the air spring cover and the rolling piston (212), wherein the air spring bellows (104) has a first partial air spring bellows (100) and a second partial air spring bellows (102), wherein the first partial air spring bellows (100) partially encloses an air volume (116) at the end of the air spring (210) on the cover side, wherein the second partial air spring bellows (102) encloses the air volume (116) at the end of the air spring (210) on the rolling piston side, wherein the first partial air spring bellows (100) has a first embedded textile reinforcing material, wherein the second partial air spring bellows (102) has a second embedded textile reinforcing material, wherein the first textile reinforcing material has first thread reinforcements, the preferred axis of which extends parallel or nearly parallel to the axis of the central longitudinal axis (214) of the air spring (210), wherein the second textile reinforcing material has second thread reinforcements, the first preferred axis of which extends at an angle to the longitudinal axis (214) of the air spring (210) and the second preferred axis of which extends at an angle to the longitudinal axis (214) of the air spring (210), wherein the first preferred axis and the second preferred axis are at an angle to each other.