Diaphragm Structured Membrane Air Spring Vulcanization
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Solution Overview
Problem
Conventional air spring membranes face issues with surface bubbles during vulcanization, leading to bumps and reduced service life, and existing solutions either make the surface brittle or accelerate aging due to air escape or deep structuring.
Innovation Solution
A membrane design with strategically placed elevations of up to 0.5 mm, differing from the surface, allowing for problem-free demolding and enhanced resilience, and featuring rounded edges to prevent breaking points, using an elastic material like rubber for adaptability and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If the membrane surface is coated with solutions to make it brittle before vulcanization, then air can escape easily during vulcanization, but the surface becomes brittle and accelerates aging
Solution Approach 1:
The invention applies local structuring only in specific areas where air pockets are most likely to form during vulcanization, rather than treating the entire membrane surface. This localized approach allows air to escape from critical zones while preserving the integrity and elasticity of the overall membrane surface, thus preventing brittleness and aging acceleration.
Solution Approach 2:
The invention changes the surface geometry parameter by creating elevations with specific height ranges (0.1-0.5mm) and aspect ratios. These dimensional parameters are optimized to provide sufficient air escape pathways during vulcanization while maintaining membrane flexibility and preventing the brittleness associated with chemical coatings.
2Object-generated harmful factors
If rubber powder is sprinkled on the membrane before vulcanization, then air can escape easily, but the powder gets into the surface and causes breaking points
Solution Approach 1:
Instead of applying a uniform coating like rubber powder across the entire membrane surface, the invention creates localized elevation structures in specific areas. These structured zones provide air escape pathways without introducing foreign particles that could compromise membrane strength or create breaking points during deformation.
Solution Approach 2:
The invention uses elevation structures that are formed as integral parts of the membrane itself, rather than applying external materials like rubber powder. These elevations are essentially 'copies' of the membrane material in elevated form, ensuring complete material compatibility and eliminating the risk of foreign particle contamination that leads to breaking points.
3Object-generated harmful factors
If a mold with surface pattern channels is used, then air can escape during vulcanization, but the membrane surface becomes strongly structured and accelerates fracture formation
Solution Approach 1:
The invention applies surface structuring only in localized areas where air pocket formation is most problematic during vulcanization, rather than across the entire membrane surface. This selective approach allows air to escape from critical zones while leaving the majority of the membrane surface smooth and free from fracture-promoting structures.
Solution Approach 2:
The invention uses mild, limited surface structuring with controlled elevation heights (0.1-0.5mm) rather than deep, extensive channel patterns. This partial action provides sufficient air escape capability while avoiding the excessive structuring that would create stress concentration points and accelerate fracture formation during membrane deformation.
4Object-generated harmful factors
If elevations with height greater than 0.5 mm are created, then air can escape easily during vulcanization, but the membrane forms breaking points under heavy loads
Solution Approach 1:
The invention optimizes the elevation height parameter within a specific range of 0.1-0.5mm. This parameter is carefully selected to be sufficient for air escape during vulcanization but limited enough to avoid creating stress concentration points that would lead to breaking points under heavy loads or frequent deformation.
Solution Approach 2:
The invention uses moderate elevation heights rather than excessive height. This partial action provides adequate air escape pathways during vulcanization while avoiding the creation of deep structures that would form breaking points during membrane deformation under heavy loads.
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 membrane achieves a significantly longer service life and problem-free operation by preventing air pocket formation and maintaining surface quality under heavy loads, suitable for use in air springs and axle systems of motor vehicles.
Implementation Method 1
The base body (1) is made of an elastic material, namely rubber
Data Source
Figure 1~3
Figure 4~5
AI summary
The membrane comprises a base body (1) with structured areas (3) with protrusions (4) projecting a maximum of 0.1 mm away from the surface (2) of the body. The edges of the protrusions can be rounded. The base body is made from an elastic material such as rubber. The structured area can be provided between shoulders (5) of the cylindrical shaped body. Independent claim describes pneumatic spring with structured membrane.