Polymeric End Member Assemblies for Gas Spring Weight Reduction
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Solution Overview
Problem
Conventional end member constructions for gas spring assemblies are heavy, limiting weight reduction in vehicle suspension systems, which can compromise performance and increase manufacturing costs.
Innovation Solution
An end member assembly with a single flowed-material joint, comprising a polymeric base and cap section that form a fluid-tight reservoir chamber, reducing the need for additional joints and materials while maintaining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metal end members are used to provide strength and rigidity, then performance characteristics are maintained, but weight increases
Solution Approach 1:
The end member transitions from conventional metal construction to polymeric material construction, fundamentally changing the material parameter. This allows weight reduction while maintaining structural integrity through the single flowed-material joint design that provides adequate strength and rigidity for the application
Solution Approach 2:
Multiple separate components (base section, cap section, and multiple joints) are merged into a unified structure with a single flowed-material joint. The base section and cap section are joined through one continuous material flow process, eliminating the need for multiple separate joints and reducing overall complexity and weight
2Reliability
If multiple joints are used in end member construction, then structural integrity is ensured, but manufacturing complexity and cost increase
Solution Approach 1:
Multiple separate joints are merged into a single flowed-material joint that connects the base section and cap section. This single joint design simplifies the manufacturing process, reduces assembly steps, and lowers production costs while maintaining the structural integrity needed for the end member assembly
Solution Approach 2:
The flowed-material joint process creates a self-sealing, self-reinforcing connection where the material flows and solidifies to form an integrated structure. The single joint design inherently provides the necessary structural integrity without requiring additional reinforcing features or multiple connection points
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 solution enables weight reduction in vehicle suspension systems while maintaining performance and reducing manufacturing costs by using a single flowed-material joint in the end member assembly, enhancing ease of installation and overall efficiency.
Implementation Method 1
The base section and the cap section can be secured together by way of a single flowed-material joint... a substantially fluid-tight joint is formed between the at least one connector fitting and at least one of the base section and the cap section
Data Source
AI summary
End member assemblies are dimensioned for securement to an end of a flexible spring member for forming gas spring assemblies. An end member assembly can include an end member body and at least one connector fitting. The end member body includes a base section and a cap section that are secured together at a single flowed-material joint. The base section and the cap section together at least partially define a reservoir chamber within the end member body. The at least one connector fitting is at least partially embedded within the end member body. Gas spring assemblies including at least one end member assembly and suspension systems including at least one gas spring assembly are also included.