Monotube Shock Absorber Rod Guide Sealing With Sintered Metal
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Solution Overview
Problem
Existing shock absorbers face challenges in adequately sealing oil and gas within the cylinder while allowing the rod to move axially, and the rod guide assembly, typically made of solid aluminum, is costly and time-consuming to manufacture and install.
Innovation Solution
A method of manufacturing shock absorbers that includes using a sintered metal rod guide with a seat and seal, where the rod extends through the seal, and the tube wall is deformed to engage with the rod guide to inhibit axial movement, and a flange is formed over the rod guide to secure the seal, allowing for pressurization and gas reservoir formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a solid aluminum rod guide is used, then the structural strength is sufficient, but the manufacturing cost and time increase
Solution Approach 1:
The patent applies porous sintered metal material to manufacture the rod guide. This sintered metal rod guide provides sufficient structural strength while being more cost-effective and faster to manufacture compared to solid aluminum rod guides, directly resolving the contradiction between strength requirements and manufacturing efficiency
Solution Approach 2:
The patent uses composite construction by combining sintered metal material with sealing elements (O-rings, seals) within the rod guide assembly. This composite approach maintains the necessary mechanical strength while enabling more efficient manufacturing processes and reduced costs
2Duration of action of stationary object
If the rod guide is made of solid aluminum, then the durability is adequate, but the installation time increases
Solution Approach 1:
The sintered metal rod guide maintains adequate durability through its porous structure that provides both mechanical strength and compatibility with sealing elements, while its manufacturing process reduces installation time compared to traditional solid aluminum guides
3Reliability
If a seal is added to the rod guide, then the sealing performance improves, but the device complexity increases
Solution Approach 1:
The patent merges the seal into the rod guide assembly by positioning O-rings and seals within grooves of the sintered metal rod guide. This integration approach improves sealing performance while minimizing device complexity through unified design rather than separate components
Solution Approach 2:
The sintered metal rod guide serves as an intermediary structure that incorporates sealing elements within its porous matrix and grooves, enabling effective sealing without requiring complex separate sealing mechanisms
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 effectively seals the oil and gas, reduces manufacturing costs, and simplifies the installation process by using a sintered metal rod guide with varying densities for enhanced sealing and ductility, ensuring reliable axial movement and pressure retention.
Implementation Method 1
a sintered metal rod guide with a seat and seal, where the rod extends through the seal, and the tube wall is deformed to engage with the rod guide
Data Source
AI summary
A method of manufacturing a shock absorber includes inserting a floating piston into a tube, disposing oil into the tube, and inserting a piston-rod assembly into the tube. The piston-rod assembly has a piston coupled to a rod. The method includes inserting a rod guide assembly into the tube. The rod guide assembly includes a sintered metal rod guide having a seat and a seal disposed in the seat. The rod extends through the seal. The method also includes deforming a wall of the tube into engagement with the sintered metal rod guide to provide a piston-cylinder assembly and inhibit axial movement of the rod guide assembly relative to the tube. The method further includes pressurizing the piston-cylinder assembly and forming a flange portion of the tube over an upper surface of the sintered metal rod guide.