Integrally Formed Plastic Actuating Lever for Air Suspension Valves
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Solution Overview
Problem
Existing air suspension valve systems for vehicles require a separate actuating arm and driver, leading to complex and cumbersome assembly processes, mechanical weak points, and potential for corrosion, while lacking a robust and cost-effective solution for transmitting actuation forces efficiently.
Innovation Solution
An integrally formed one-piece actuating lever with a double-curved longitudinal sectional profile and a cylindrical driver section, made from plastic material with a reinforcing section, which serves both as an actuating arm and driver, mechanically coupled to the valve body to transmit forces directly to the shut-off element, eliminating the need for separate components and enhancing mechanical rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate actuating arm and driver components are used, then the valve system can be assembled with standardized parts, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines the actuating arm and driver into a single integrated actuating lever made of plastic material. This merging eliminates the need for separate standardized parts and their complex assembly, while maintaining the functional requirements of both components through a unified structure with appropriate geometric features for force transmission and mounting.
2Adaptability or versatility
If separate actuating arm and driver components are used, then each component can be optimized independently, but mechanical weak points arise at the connection interfaces
Solution Approach 1:
By integrating the actuating arm and driver into one piece, the patent eliminates the connection interface that would create mechanical weak points. The unified plastic structure ensures continuous material flow and stress distribution throughout the component, removing the risk of failure at joints while still allowing independent optimization of different sections through varied geometry within the single component.
3Ease of repair
If separate actuating arm and driver components are used, then replacement of individual parts is easier, but corrosion and wear affect the connection points
Solution Approach 1:
The integrated plastic actuating lever eliminates metal-to-metal connection points that are susceptible to corrosion and wear. The single-piece construction removes fasteners and joints from the force transmission path, thereby eliminating the harmful effects of corrosion and wear at connection interfaces while maintaining ease of repair through replacement of the entire lever as a single component.
4Device complexity
If an integrally formed actuating lever is used, then the assembly process is simplified, but the mechanical rigidity must be ensured within a single component
Solution Approach 1:
The patent applies local quality by varying the cross-sectional geometry and thickness of the plastic actuating lever in different regions. The actuating section has optimized dimensions for force application, the driver section has appropriate geometry for valve engagement, and transition regions are designed with sufficient material to maintain rigidity. This localized optimization ensures the required mechanical strength throughout the single integrated component.
Solution Approach 2:
The patent utilizes plastic material with potential reinforcement elements or composite structure to achieve the required mechanical rigidity in the integrally formed actuating lever. The plastic material provides corrosion resistance and ease of manufacturing, while structural design features or reinforcement ensure sufficient strength and stiffness for the application.
Data Source
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Figure 3~5
AI summary
The valve (400) has a valve body (405) provided with fluid channels and a shut-off element. An integrally formed actuating lever (300) is provided with an actuating portion (320) and a driver portion (310). The driver portion transmits exercisable actuating force to the actuating section, and is coupled to the shut-off element that is mechanically connected to the valve body. The actuating lever is made of a plastic material. The actuating lever comprises a shaped reinforcing portion for amplifying mechanical rigidity of the actuating lever in the actuating portion. An independent claim is also included for a method for assembling a valve.