Working Cylinder Piston With Continuous Low-Wear Guide Sleeve
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Solution Overview
Problem
Existing fluid-actuated working cylinders face challenges with high manufacturing costs and increased wear due to the need for chemical bonding agents and segmented piston guide surfaces.
Innovation Solution
A piston design featuring a ring element with a cylindrical outer radial support surface and annular axial support surfaces, where a rubber-elastic enveloping body completely covers the ring element, forming a sleeve-like guide section that provides a cylindrical piston guide surface, eliminating the need for chemical bonding and reducing wear through a positive fit between the ring element and piston base unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a chemical bonding agent is applied on the core body before injection moulding the enveloping body, then the enveloping body adheres reliably to the piston subassembly, but the manufacturing costs increase
Solution Approach 1:
The invention extracts and eliminates the chemical bonding agent from the manufacturing process. Instead of applying adhesive before injection moulding, the design relies on the mechanical interlocking between the ring element's support surfaces and the enveloping body, achieving reliable adhesion without additional chemical substances or processing steps.
Solution Approach 2:
The ring element's axial support surfaces and outer radial support surface automatically provide the necessary support and adhesion for the enveloping body during injection moulding. The structure serves its own function of securing the enveloping body without requiring external bonding agents or additional components.
2Ease of manufacture
If a segmented piston guide surface is used, then the piston can be manufactured with the ring element and piston base unit, but the wear resistance decreases
Solution Approach 1:
The invention merges the segmented piston guide surface sections into a single, continuous cylindrical piston guide surface formed by the sleeve-like guide section. This unified surface eliminates the gaps and segmentation that cause increased wear, while still allowing the piston to be manufactured as an integrated component with the ring element and piston base unit.
Solution Approach 2:
The cylindrical piston guide surface is formed by the rubber-elastic enveloping body that covers the ring element. This composite structure combines the rigid support of the plastic ring element with the wear-resistant, flexible sealing properties of the rubber-elastic material, creating a guide surface that is both manufacturable and highly wear-resistant.
3Ease of manufacture
If the ring element is supported positively by the piston base unit in both axial directions, then the adhesion without chemical bonding is achieved, but the structural complexity increases
Solution Approach 1:
The ring element serves multiple functions simultaneously: it provides axial support surfaces for the enveloping body, an outer radial support surface for the enveloping body, and forms part of the piston guide surface through the covered region. This multi-functionality achieves the goal of eliminating bonding agents without significantly increasing structural complexity, as the same component performs all support functions.
4Reliability
If the enveloping body completely covers the ring element at the support surfaces, then the adhesion and support are enhanced, but the manufacturing complexity increases
Solution Approach 1:
The axial support surfaces and outer radial support surface of the ring element are pre-formed during the injection moulding of the ring element itself, before the enveloping body is moulded. This preliminary creation of support surfaces ensures that when the enveloping body is subsequently injected, it automatically adheres to these pre-formed surfaces without requiring additional bonding steps or complex manufacturing procedures.
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 enables a cost-effective and low-wear piston operation by ensuring reliable adhesion and support without chemical bonding agents, enhancing manufacturing efficiency and reducing wear on the piston guide surface.
Implementation Method 1
ensuring reliable adhesion and support without chemical bonding agents
Implementation Method 2
an enveloping body intermediate section which connects the two enveloping body end sections to one another radially outside the piston subassembly
Data Source
AI summary
A piston for a fluid-actuated working cylinder, with a piston base unit which is coaxial to a piston longitudinal axis, consisting of a rigid core body which has radial outer peripheral surface and of an annular filling body which is seated in an annular receiving groove. The receiving groove is coaxial to the piston longitudinal axis and in the region of the radial outer peripheral surface is designed with a radially outwardly facing groove opening in the core body. The piston further includes a ring element which consists of plastic. The ring element radially outwardly coaxially encompasses the piston base unit at least in the region of the filling body, being radially supported with a radial inner peripheral surface on the piston base unit, projecting radially beyond the radial outer peripheral surface of the core body and comprising an axially orientated axial support surface radially outside the piston base unit on its two axial face sides. The piston further includes an annular enveloping body which has rubber elastic characteristics.