Polymeric Gas Spring End Member with Composite Reinforcement
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Solution Overview
Problem
Gas spring assemblies face a challenge in achieving increased load capacity and reduced weight while maintaining structural integrity, as polymeric end members used for weight reduction compromise strength and rigidity.
Innovation Solution
The design includes an end member with an outer crimp wall and an inner crimp wall, interconnected by connector walls, forming a composite beam-like structure that enhances strength and rigidity without the need for metal backing rings, and is formed from polymeric materials like fiber-reinforced thermoplastics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If polymeric materials are used for end members to reduce weight, then weight is reduced, but strength and rigidity deteriorate
Solution Approach 1:
The end member is constructed as a composite structure combining polymeric material with a metal reinforcement element (such as a metal ring or mesh). This composite construction allows the end member to achieve both weight reduction from the polymeric material and sufficient strength and rigidity from the metal reinforcement, resolving the contradiction between weight reduction and structural integrity.
2Strength
If metal end members with crimped metal ring connections are used to increase strength, then strength and rigidity are improved, but weight increases
Solution Approach 1:
Instead of using solid metal end members, the invention employs a composite construction where a polymeric end member is reinforced with a metal ring or mesh. This approach maintains the necessary strength and rigidity while significantly reducing the overall weight compared to traditional metal constructions.
Solution Approach 2:
The metal reinforcement is strategically placed in specific locations within the end member structure where strength is most needed, rather than using metal throughout the entire end member. This localized reinforcement approach optimizes the strength-to-weight ratio by providing structural support only where required.
3Force
If gas pressure is increased to improve load capacity, then load capacity is improved, but structural integrity requirements increase
Solution Approach 1:
The composite construction with metal reinforcement provides the enhanced structural integrity necessary to withstand increased gas pressures while maintaining load capacity improvements. The metal reinforcement elements distribute and bear the stresses generated by high pressure, allowing the polymeric portions to maintain their weight advantages.
Data Source
AI summary
End members are dimensioned for securement to a flexible wall of a gas spring assembly. The end members can include an end wall, and inner and outer crimp walls that extend from the end wall and are disposed in spaced relation to one another such that gap is formed therebetween. A plurality of connector walls extend between and operatively interconnect the inner and outer crimp walls. Gas spring assemblies including such an end member and suspension systems including one or more of such gas spring assemblies are also included.