Polyketone Air Spring Piston Material for Lower GWP Suspension Loads

Solution Overview

Problem

Conventional air spring pistons made from high global warming potential (GWP) materials like polyamide generate significant greenhouse gases during production, posing an environmental concern and requiring more eco-friendly alternatives.

Innovation Solution

Replace conventional pistons with polyketone material, particularly fiber-reinforced polyketone, which has lower emissions and comparable mechanical properties, using injection molding techniques.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If polyamide material is used for the piston, then the piston has good mechanical properties and durability, but it generates significant greenhouse gases during production

Engineering Contradiction:

Improvegreenhouse gas emissionsVSAvoidpiston mechanical properties

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent changes the material parameter from polyamide to polyketone, which has different chemical composition and production characteristics. Polyketone is synthesized from carbon monoxide and olefins through polymerization, resulting in significantly lower greenhouse gas emissions compared to polyamide production, while maintaining or improving mechanical properties

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs fiber-reinforced polyketone composite material, combining polyketone matrix with reinforcing fibers (such as glass or carbon fibers). This composite structure enhances the mechanical strength, stiffness, and impact resistance of the piston while retaining the environmental benefits of polyketone, effectively resolving the contradiction between eco-friendliness and mechanical performance

Inventive Principle:

Principle #40Composite materials

2Object-affected harmful factors

If polyamide material is used for the piston, then the piston provides adequate load-bearing capacity, but it has high global warming potential

Engineering Contradiction:

Improveglobal warming potentialVSAvoidload-bearing capacity

Core Design Contradiction:

Object-affected harmful factorsVSForce

Solution Approach 1:

The patent changes the material parameter from polyamide to polyketone, which has different chemical composition and production characteristics. Polyketone is synthesized from carbon monoxide and olefins through polymerization, resulting in significantly lower greenhouse gas emissions compared to polyamide production, while maintaining or improving mechanical properties

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs fiber-reinforced polyketone composite material, combining polyketone matrix with reinforcing fibers (such as glass or carbon fibers). This composite structure enhances the mechanical strength, stiffness, and impact resistance of the piston while retaining the environmental benefits of polyketone, effectively resolving the contradiction between eco-friendliness and mechanical performance

Inventive Principle:

Principle #40Composite materials

Data Source

PatentEP4644477A1Polyketone material for air spring piston

Publication Date: 2025.11.05 CONTITECH DEUTSCHLAND GMBH

Figure 1

AI summary

An air spring includes a piston and a bellows operably attached to the piston, the piston having a main piston body, wherein at least a majority of an overall polymer content of the main piston body is formed from polyketone material.