Cast Shock Absorber Spring Seat With Mold-Release Rib
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a demand to suppress the increase in cost of shock absorbers, particularly due to issues with mold release and yield during the casting process, where thin spring seats can cause galling and require additional mold release pins, leading to increased maintenance and running costs.
Innovation Solution
A shock absorber design featuring a bottomed cylindrical cylinder with a spring seat formed integrally and a mold release rib that connects the spring seat to the cylinder, allowing smooth removal from the mold without galling and reducing the need for multiple mold release pins, combined with a separate resin spring receiving member for enhanced strength and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a thin spring seat is formed integrally with the cylinder by casting, then cost is reduced and manufacturing is simplified, but galling occurs during mold release and yield decreases
Solution Approach 1:
The invention divides the spring seat into two functional parts: a thin-walled integral casting portion (first spring seat) that reduces cost and weight, and a separate thick-walled resin spring seat that prevents galling during mold release. This segmentation allows each part to fulfill its specific function optimally - the thin metal portion achieves cost reduction while the separate resin portion ensures reliable mold release and prevents defects.
Solution Approach 2:
The invention introduces a resin spring seat as an intermediary component between the metal cylinder and the suspension spring. This resin mediator prevents direct contact between the mold and the thin metal spring seat during casting, eliminating galling issues. The resin spring seat acts as a protective interface that allows smooth mold release while maintaining the structural integrity of the thin-walled design.
2Reliability
If additional mold release pins are added to prevent galling, then yield is improved, but device complexity and maintenance cost increase
Solution Approach 1:
The invention extracts the mold release function from the metal spring seat by using a separate resin spring seat. Instead of modifying the metal spring seat with additional mold release pins or features, the solution removes the mold release requirement from the metal casting process entirely by having the resin spring seat serve as the mold release interface. This eliminates the need for complex mold structures and additional pins.
3Weight of moving object
If the spring seat is made thinner to reduce weight, then weight is reduced, but strength decreases and galling occurs
Solution Approach 1:
The invention segments the spring seat into a thin-walled metal portion for weight reduction and a separate thick-walled resin portion for strength and mold release. The thin metal first spring seat achieves weight reduction goals, while the separate resin spring seat provides the necessary structural strength and prevents galling during mold release, allowing the metal portion to remain thin without compromising overall performance.
Data Source
AI summary
This shock absorber is disposed between a vehicle body and an axle. The shock absorber includes a bottomed cylindrical cylinder, a spring seat, and a mold release rib. The spring seat is formed integrally with the cylinder. The spring seat protrudes in a radial direction of the cylinder from the cylinder to support a suspension spring. The mold release rib is formed integrally with the cylinder and the spring seat. The mold release rib connects an outer circumferential portion of the spring seat and the cylinder. The mold release rib has a face part provided at an outer end portion of the cylinder in the radial direction.