Hybrid Shock Absorber Mounting for Heat Dissipation and Weight Reduction
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Solution Overview
Problem
Conventional shock absorbers face challenges with weight reduction while maintaining strength, durability, and heat dissipation due to limitations in materials like fiber-reinforced plastics, which are sensitive to environment, age poorly, have poor conductivity, and experience thermal issues.
Innovation Solution
A hybrid shock absorber combining a metal damper tube with a composite mounting attachment made of thermoplastic or fiber-reinforced thermoplastic, featuring windows for enhanced heat dissipation and reduced heat transmission, allowing for weight reduction and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If fiber-reinforced plastics are used to reduce weight, then weight is reduced, but heat dissipation capability deteriorates due to poor conductivity
Solution Approach 1:
The patent applies composite materials by combining fiber-reinforced plastic (for weight reduction) with metal components (for heat dissipation). The mounting attachment is made of fiber-reinforced plastic while metal components (damper rod, piston rod, valve assembly) provide thermal conductivity pathways, creating a hybrid structure that balances weight reduction with heat dissipation requirements.
Solution Approach 2:
The shock absorber is segmented into distinct material zones: fiber-reinforced plastic mounting attachment for weight reduction, metal damper rod and piston rod for structural strength and heat conduction, and metal valve components for heat dissipation. This segmentation allows each component to be optimized for its specific function while working together as a integrated system.
2Weight of moving object
If fiber-reinforced plastics are used for weight reduction, then weight is reduced, but durability and environmental resistance deteriorate due to ageing behaviour and environment sensitivity
Solution Approach 1:
The patent uses composite materials strategically - fiber-reinforced plastic provides weight reduction while metal components (stainless steel or aluminum alloys) provide durability and environmental resistance. The hybrid composite structure leverages the strengths of each material type to achieve overall system reliability that neither material could achieve alone.
Solution Approach 2:
Different regions of the shock absorber have different material qualities optimized for their specific requirements: fiber-reinforced plastic in non-critical mounting areas for weight reduction, while metal materials are used in high-stress and environmentally exposed areas (piston rod, valve assembly) for durability and corrosion resistance.
3Strength
If metal components are used to maintain strength and durability, then strength and durability are maintained, but weight increases compared to composite materials
Solution Approach 1:
The patent employs composite materials to create a hybrid structure where metal components provide necessary strength and durability only where required (piston rod, valve assembly, damper rod), while fiber-reinforced plastic is used in less critical areas (mounting attachment) to reduce overall weight, achieving an optimal strength-to-weight ratio.
Solution Approach 2:
The shock absorber features local quality differentiation where high-strength metal materials are concentrated in load-bearing and high-stress components, while lighter fiber-reinforced plastic is used in mounting and housing areas, creating a weight-optimized structure that maintains necessary strength characteristics.
4Weight of moving object
If composite materials are used for mounting attachment, then weight is reduced, but heat transmission from metal damper tube to composite material increases causing thermal issues
Solution Approach 1:
The patent introduces thermal management features as intermediaries between the metal damper tube and fiber-reinforced plastic mounting attachment. Thermal barriers or insulating layers are positioned at the interface to mediate heat transfer, preventing excessive heat transmission to the composite material while allowing the lightweight mounting attachment to function properly.
Solution Approach 2:
The mounting attachment exhibits local quality variations with thermal barriers or insulating features positioned specifically at heat-prone interfaces between metal and composite materials, while other areas maintain pure fiber-reinforced plastic construction for maximum weight reduction, creating a thermally managed lightweight structure.
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
The hybrid shock absorber achieves weight reduction while maintaining high strength and durability, with improved heat dissipation and extended service life by utilizing the composite material's properties and the metal damper tube's thermal conductivity.
Implementation Method 1
The metal damper tube is made of a metal material, such as steel or aluminum, that provides strength, durability, and heat dissipation
Implementation Method 2
the composite material's properties and the metal damper tube's thermal conductivity
Data Source
AI summary
A shock absorber having a metal damper tube and base assembly is provided. The base assembly, which includes a composite mounting attachment made of a composite material, such as a recyclable thermoplastic, is fixed to an external surface of the metal damper tube, which may be a finished product. A cavity in the composite mounting attachment houses at least a portion of the metal damper tube and thus defines an overlapping region where the composite mounting attachment and the metal damper tube are co-extensive with each other. One or more windows are provided in the overlapping region of the composite mounting attachment where the metal damper tube is left exposed. This helps to promote heat dissipation away from the metal damper tube while reducing weight and heat transmission from the metal damper tube to the composite mounting attachment to reduce overheating of the composite material.