Creep-Resistant Plastic Support Ring for Air Spring Radial Loads
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Solution Overview
Problem
Conventional air spring assemblies require a costly metal support ring to withstand compressive radial forces, as plastic top caps lack sufficient strength under the force applied by clamping rings.
Innovation Solution
A plastic support ring with high creep resistance is used, made through injection molding, which can be overmolded or press-fit into the top cap, providing structural reinforcement and reducing manufacturing costs by utilizing similar equipment and materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal support ring is used to withstand compressive radial forces, then the structural strength is sufficient, but the manufacturing cost is high and the manufacturing process is complex
Solution Approach 1:
The patent changes the material parameters by selecting a specific plastic material (polyoxymethylene or polyacetal) with high creep resistance and mechanical properties that can withstand compressive radial forces. The material parameters include tensile strength of at least 40 MPa, elongation at break of at least 20%, and Izod impact strength of at least 100 J/m, replacing metal materials while maintaining sufficient strength.
Solution Approach 2:
The patent uses composite material approach by combining plastic material with specific additives and fillers to enhance the mechanical properties and creep resistance of the support ring, achieving metal-like strength while maintaining plastic manufacturing advantages.
2Ease of manufacture
If a plastic support ring is used to reduce manufacturing cost, then the manufacturing complexity is reduced, but the creep resistance is insufficient under sustained compressive loads
Solution Approach 1:
The patent changes the material parameters by selecting polyoxymethylene or polyacetal plastics with specific mechanical properties including tensile strength of at least 40 MPa, elongation at break of at least 20%, and Izod impact strength of at least 100 J/m. These parameter changes ensure the plastic material has sufficient creep resistance for sustained compressive loads while maintaining ease of manufacturing through injection molding.
3Strength
If the plastic material is oriented during injection molding to provide strength, then the structural integrity is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies preliminary action by designing the injection molding process to automatically orient the plastic material during the molding process itself, rather than requiring post-manufacturing operations. The material orientation is achieved through the molding process parameters and tooling design, ensuring sufficient strength while avoiding complex additional manufacturing steps.
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 high creep resistance plastic support ring effectively withstands radial forces, reducing material costs and manufacturing complexity while maintaining structural integrity, suitable for various air spring applications.
Implementation Method 1
The support ring having the high creep resistance plastic material is made using an injection molding process having one or more gates through which the molten plastic material is injected into a mold
Data Source
AI summary
A support ring used as part of an air spring assembly, where the support ring provides support for a top cap against radial forces applied by a clamping ring. The support ring is made of a plastic material which is less costly than a metal support ring. The plastic material is a high creep resistance plastic material, which provides increased strength and improved creep resistance, to withstand the compressive radial forces of the clamping ring. Once the support ring is formed, the top cap, which is also made of plastic, is overmolded such that a portion of the top cap is overmolded around the support ring. The high creep resistance plastic material is oriented during the injection molding process around the entire circumference of the support ring, to provide sufficient strength to withstand the radial forces from the clamping ring.