Gearshift Selector Piston Clip Cap for Secure Seal Mounting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of pistons for gear-change selector modules is costly due to high requirements for reliability and quality, particularly in attaching sealing elements to ensure a defined seat and prevent loss during logistics or mounting.
Innovation Solution
A piston design featuring a cap attached to the piston body via a clip connection, which securely holds the sealing element, allowing for cost-effective assembly without stretching, ensuring a play-free connection and defined sealing performance under pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sealing elements are attached to the piston body using conventional methods, then reliability and quality requirements are met, but production cost increases
Solution Approach 1:
The cap integrates multiple functions: it closes the piston chamber, provides attachment points for sealing elements, and incorporates clip connections for secure mounting. By combining these functions into a single component, the design reduces the number of separate parts and assembly steps, thereby lowering production costs while maintaining reliable sealing element attachment
Solution Approach 2:
The cap serves as an intermediary component between the piston body and the sealing elements. It provides a structured interface that facilitates secure attachment of sealing elements through integrated clip connections, ensuring reliability while simplifying the overall assembly process and reducing manufacturing complexity
2Ease of manufacture
If sealing elements are stretched to reach their receiver during mounting, then attachment is achieved, but material properties deteriorate
Solution Approach 1:
The cap and piston body are designed with pre-configured clip connections and receiver geometries that align the sealing elements with their mounting positions before attachment. This preliminary alignment ensures that sealing elements can be installed without excessive stretching, preserving material properties while achieving secure attachment
Solution Approach 2:
The design modifies the geometric parameters of the cap and piston body to create adequate clearance and alignment between sealing element origins and receivers. By adjusting dimensions such as receiver depth, cap thickness, and clip connection positioning, the design enables sealing elements to reach their receivers without exceeding material elastic limits
3Ease of manufacture
If a clip connection is used to attach the cap to the piston body, then production cost is reduced, but connection reliability under high pressure must be ensured
Solution Approach 1:
The clip connection design incorporates dynamic features that enhance engagement under pressure. The latching elements are configured to deform slightly during assembly and then lock into position, creating a flexible yet secure connection that maintains reliability under high pressure while allowing for thermal expansion and pressure-induced dimensional changes
Solution Approach 2:
The cap and piston body are designed with complementary geometries that create a composite connection system. The clip connection combines elastic deformation of the cap material with rigid engagement features on the piston body, creating a hybrid connection that achieves both cost-effectiveness and high-pressure reliability through the synergistic interaction of different material properties
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 low-cost production and reliable attachment of sealing elements, maintaining material integrity and ensuring effective sealing performance under high pressures, thus reducing production costs and improving operational efficiency.
Implementation Method 1
The clip connection comprises corresponding latching elements which ensure an effective connection of the cap to the piston body
Implementation Method 2
the cap can be attached to the piston body in the axial direction by means of the clip connection. In this way, during operation of the piston, the cap is pressed by the pressure loading the piston end face into a closed position of the clip connection
Data Source
AI summary
A piston for a gear-change selector module of a gearshift has a piston body, at least one sealing element, and a cap which is attached to the piston body by means of a clip connection. Furthermore, the sealing element is here attached to the piston body by means of the cap. Also a gear-change selector module with a piston, and a method for mounting a piston, are provided.