Hydraulic Shock Absorber Assembly Without Welding
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Solution Overview
Problem
Conventional hydraulic shock absorbers require a gas-supplying hole for assembling, which can lead to issues like deterioration of rubber diaphragms and malfunction of sliding surfaces due to welding heat and sputter, and potential damage to the diaphragm from the plug.
Innovation Solution
A method of assembling a hydraulic shock absorber that involves introducing a first gas into a cylindrical outer shell to define a gas chamber, followed by the introduction of hydraulic fluid and a second gas of different pressure, without the need for a gas-supplying hole, using a dividing member such as a flexible membrane or free piston.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gas-supplying hole is formed and a plug is welded to seal the gas chamber, then the gas chamber can be sealingly closed, but heat and sputter from welding cause deterioration of the rubber diaphragm or malfunction of the sliding surface
Solution Approach 1:
The harmful welding process is completely removed from the assembly method. Instead of forming a gas-supplying hole and welding a plug to seal it, the invention uses a cap member that is press-fit or interference-fit onto the outer shell, eliminating the need for welding entirely and thus preventing heat and sputter damage to the diaphragm and sliding surfaces.
Solution Approach 2:
The cap member serves as a simple, inexpensive sealing component that can be easily installed and removed. Rather than using a permanent welded plug, the cap member provides sufficient sealing through press-fit or interference-fit connection, sacrificing the permanence of welding for the benefit of avoiding thermal damage.
2Reliability
If a plug is welded in the gas-supplying hole, then the gas chamber is sealingly closed, but the tip of the plug might damage the diaphragm
Solution Approach 1:
The plug component that could potentially damage the diaphragm is completely removed from the design. The cap member directly seals the gas chamber without requiring an intermediate plug, eliminating the mechanical damage risk associated with plug insertion and welding.
3Reliability
If welding is used to close the gas-supplying hole, then the gas chamber is sealingly closed, but sputter from welding may cause malfunction of the sliding surface
Solution Approach 1:
The welding process is completely extracted from the assembly method. The cap member provides sealing through press-fit or interference-fit connection, eliminating the sputter that would otherwise contaminate and malfunction the sliding surface of the free piston.
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
This method allows for the assembly of hydraulic shock absorbers without the need for a gas-supplying hole, preventing damage and malfunction associated with welding, and ensuring the gases are sealed effectively, maintaining the integrity of the diaphragm and other components.
Implementation Method 1
introducing a first gas having a first pressure from the opening into the outer shell; inserting a dividing member into the outer shell under the pressure of the first gas
Data Source
AI summary
Before inner components of a hydraulic shock absorber, such as a cylinder, a piston and a piston rod, are placed, an outer shell is joined with a joint portion of an assembling apparatus so that a gas pressure chamber and the outer shell are in communication with each other. A low-pressure gas is supplied in the gas pressure chamber and the outer shell. Under a pressure of the low-pressure chamber, an oil tank subassembly is inserted in the outer shell and is fitted therein to form an oil tank. The oil tank is divided into an oil chamber and a gas chamber by a diaphragm. By this assembling method, it is possible to supply the low-pressure gas into the gas chamber without a need for a gas-supplying hole for supplying the gas into the gas chamber.