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A High Flow Piezoelectric Ceramic Choke for an Adaptive Vehicle Gas Spring Damper Manufactured by Ceramic Injection and Ceramic Insert Molding
Keywords: ceramic insert molding, piezo ceramic choke, gas spring damper
The current research presents recent work respective to the development of a high flow ceramic choke unit to control the air flow of an adaptive gas spring damper in a vehicle. Accordingly, the choke comprises a hybrid structure of a piezoelectric ceramic and a polymer. A small contraction of the integrated piezoelectric ceramic ring actuator is transformed by a particular polymer spoke design. At the same time, the resulting angular displacement of the chokes outer ring is increased. Multiple micro structured holes are placed in the actuator ring to adjust the air flow through the choke and, thereby, the damping characteristic of the gas spring damper system. The actuator disc is manufactured by ceramic injection molding (CIM). CIM is a low cost process for large-scale production which is distinguished by high size accuracy. In order to conjoin the polymer spokes with the ceramic actuator a new technology is developed: The ceramic insert molding. Hence, a lot of research is carried out with regard to material behaviour and most importantly the occurrence of material shrinking. In the process, shrinking is caused by debinding and sintering of the ceramic feedstock. These technical expertises are used for the final design of two required injection molding tools and forming processes. Another challenge focuses on deriving the piezoelectric properties of the final product. Due to the fact of using a mixed compound piezoelectric ceramic powder and a thermoplastic binder composite as injection molding aid, the properties of the finally polarized PZT are equivalent to other processing technologies like dry pressing, thick film, etc. Respectively, only the ceramic injection molding process and, especially, the ceramic insert molding principles allow for the implementation of such a piezoelectric ceramic choke unit. It is distinguished by the required adjusting range for controlling an accurate airflow in a commercial gas spring damper.
Matthias Hartmann, Dipl.-Ing.
University of Magdeburg
Magdeburg, Sachsen-Anhalt 39016,

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