Hybrid coil spring isolator

Abstract

An isolator (101) in a suspension system, the isolator (101) comprising: a. At least one microporous polyurethane (MCU); b. A composite region (103) encapsulating the at least one MCU, wherein the composite region (103) partially or completely encapsulates the at least one MCU.

Description

Technical Field

[0001] The present invention relates to an isolator, a method of forming an isolator, a suspension system, and a vehicle including the suspension system. Background Art

[0002] A vehicle's suspension system engages to limit vibration and absorb impact forces transmitted to the vehicle's frame members. Components of the suspension system include springs, spring isolators, and shock absorbers / struts. Coil springs are commonly used in suspension systems to absorb energy generated by impact forces. The capacity of the coil spring is configured according to the load-carrying capacity required for the vehicle.

[0003] Coil spring isolators are provided to absorb vibration, isolate rolling noise, and provide an even load on the spring. By absorbing vibration, the coil spring isolators reduce damage to the arms of the coil spring. Since the coil spring isolates the vehicle from vibration and bumps, the operation of the suspension system is also improved. Soft coil spring isolators cannot absorb excessive impact forces and bumps. However, as the stiffness of the coil spring isolator increases excessively, the coil spring isolator begins to transmit vibration and impact forces to the vehicle body. Therefore, the stiffness of the coil spring isolator must be maintained. Based on the materials used, the actual duration of use, and exposure to the environment, the structural integrity of the coil spring isolator deteriorates over time. Therefore, there is a need to improve the coil spring isolator in the suspension system.

[0004] Accordingly, it is an object of the present invention to provide an improved suspension system to absorb vibration, absorb bumps, manage variable axial loads without damage, reduce friction in components in a cost-effective manner with minimal modification to the suspension system and the vehicle. Summary of the Invention

[0005] Surprisingly, it has been found that the above object is met by providing an isolator for a suspension system, a method of forming the isolator, a suspension system, and a vehicle including the suspension system.

[0006] The isolator is disposed at an end of an arm of a spring in a suspension system for a vehicle. The isolator is articulated with the arm of the spring, a movable member, and the vehicle body. The isolator absorbs vibration, bumps, and excess energy transmitted by impact between the movable member and the spring. The isolator prevents vibration and impact forces from being transmitted to the vehicle body / frame and reduces failures of suspension system components. The isolator also provides a cost-effective solution to improve the suspension without implementing any other structural modifications to the vehicle.

[0007] Accordingly, in one aspect, the presently claimed invention relates to an isolator (101) in a suspension system (201), the isolator (101) comprising:

[0008] a. At least one microcellular polyurethane (MCU) (102);

[0009] b. A composite region (103) that encapsulates at least one MCU (102),

[0010] wherein the composite region (103) partially or completely encapsulates at least one MCU (102), and

[0011] c. Optionally, at least one support region (105) attached to at least one surface (104) of the composite region (103).

[0012] In another aspect, the presently claimed invention relates to a method of forming an isolator (101) according to claim 1, wherein the method comprises:

[0013] a. Providing at least one MCU (102) in a mold for the isolator (101);

[0014] b. Optionally, providing at least one support region (105) in a mold for the isolator (101);

[0015] c. Injecting a mixture for forming the composite region (103) into the mold and above the at least one MCU and the at least one support region (105);

[0016] d. Optionally curing the mixture to form the isolator (101);

[0017] e. Releasing the isolator (101) from the mold.

[0018] In another aspect, the presently claimed invention relates to a suspension system (200) for a vehicle (300) having a body (301) and a movable component (302) that is displaceable relative to the body (301), the suspension system (200) comprising:

[0019] a. A spring (400) comprising a first arm (401) articulated to a spring seat region (311) of the body (301) of the vehicle and a second arm (402) articulated to a spring seat region (312) of the movable component (302); and

[0020] b. At least one isolator (101) according to any one of claims 1 to 12,

[0021] wherein at least one isolator is disposed between:

[0022] The first arm (401) of the spring (400) and the spring seat region (311) of the body (301) of the vehicle, or

[0023] The second arm (402) and the spring seat area (312) of the movable part (302) of the vehicle, or both.

[0024] On the other hand, the presently claimed invention relates to a vehicle (300) comprising:

[0025] a. A vehicle body (301);

[0026] b. A movable part (302) that can be displaced relative to the vehicle body (301); and

[0027] c. A suspension system (200) having at least one isolator (101) according to claim 16. Description of the Drawings

[0028] Figure 1 shows the isolator (101). Figure 1a And Figure 1b Perspective views and cross-sectional views are respectively provided. Figure 1c A cross-sectional view of an isolator (101E) having two disk-shaped MCUs stacked coaxially is provided.

[0029] Figure 2 is respectively a cross-sectional view of isolators (101a), (101b) and (101c).

[0030] Figure 3 is a view of a suspension system (200) having a spring (400) and an isolator (101). Figure 3a A view of the suspension system (200) is provided, in which the spring (400), the arm (401) and the isolator (101) are not in a straight travel path. Figure 3b A view of the suspension system (200) is provided, in which the spring (400) and the isolator (101) are in a straight travel path.

[0031] Figure 4 Is a view of a suspension system (200) in the form of a MacPherson strut assembly.

[0032] Figure 5 Is a perspective view of a suspension system (200) of a vehicle (300) having an isolator (101). Detailed Description

[0033] It should be noted that embodiments of the present invention are described with reference to different subjects. In particular, some embodiments are described with reference to method-type claims, while other embodiments are described with reference to apparatus-type claims. However, those skilled in the art will learn from the description above and below that any combination between features related to different subjects is also considered to be disclosed in the present application, unless otherwise indicated, in addition to any combination of features belonging to one type of subject. However, all features can be combined together to provide a synergistic effect that exceeds the simple sum of the features.

[0034] Although the present invention has been illustrated and described in detail in the drawings and the foregoing description, such illustration and description should be considered illustrative or exemplary rather than restrictive. The present invention is not limited to the disclosed embodiments. By studying the drawings, the disclosure, and the dependent claims, those skilled in the art can understand and implement other variations of the disclosed embodiments when practicing the claimed invention. In the claims, the word "comprising" does not exclude other elements or steps, and the indefinite article "a" or "an" does not exclude a plurality. A single processor or other unit may perform the functions of several items recited in the claims. The fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used advantageously. Any reference signs in the claims should not be construed as limiting the scope.

[0035] Before describing the inventive compositions and formulations of the present invention, it should be understood that the present invention is not limited to the specific compositions and formulations described, as such compositions and formulations can of course vary. It should also be understood that the terminology used herein is not intended to be restrictive, as the scope of the present invention will be defined only by the appended claims.

[0036] As used herein, the terms "comprising" and "consisting of" are synonymous with "including" or "containing", and are inclusive or open-ended and do not exclude additional, unrecited members, elements or method steps. It should be understood that the terms "comprising" and "consisting of" as used herein include the term "consisting of".

[0037] Additionally, the terms "first", "second", "third" or "(a)", "(b)", "(c)", "(d)", etc. in the specification and claims are used to distinguish between similar elements and are not necessarily used to describe an order of sequence or time. It should be understood that the terms so used are interchangeable under appropriate circumstances, and the embodiments of the present invention described herein are capable of operating in an order different from that described or illustrated herein. If the terms "first", "second", "third" or "(A)", "(B)", "(C)" or "(a)", "(b)", "(c)", "(d)", "i", "ii", etc. relate to steps of a method or use or measurement, there is no temporal or time interval coherence between these steps, that is, these steps can be carried out simultaneously, or there may be a time interval of seconds, minutes, hours, days, weeks, months or even years between such steps, unless otherwise indicated in the present application as set forth above or below herein.

[0038] In the following paragraphs, different aspects of the present invention are defined in more detail. Each aspect so defined can be combined with any other one or more aspects, unless the contrary is explicitly stated. In particular, any feature indicated as being preferred or advantageous can be combined with any other one or more features indicated as being preferred or advantageous.

[0039] Reference throughout this specification to "an embodiment" or "embodiments" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases "in an embodiment" or "in embodiments" in various places throughout this specification are not necessarily all referring to the same embodiment, but may refer to the same embodiment. Additionally, in one or more embodiments, the features, structures, or characteristics may be combined in any suitable manner, which will be apparent to those skilled in the art from this disclosure. Further, although some embodiments described herein include some features and do not include other features included in other embodiments, combinations of features of different embodiments are intended to be within the scope of the present invention and to form different embodiments, as will be understood by those skilled in the art. For example, any of the claimed embodiments may be used in any combination in the appended claims.

[0040] Furthermore, ranges defined throughout this specification also include the end values, that is, a range of 1 to 10 means that both 1 and 10 are included in the range. For the avoidance of doubt, the applicant shall enjoy any equivalent rights under applicable law.

[0041] Reference is made to the accompanying drawings, in which like reference numerals represent like or corresponding parts in several views.

[0042] Isolator

[0043] One aspect of the present invention relates to an embodiment of an isolator (101) in a suspension system (201), the isolator (101) comprising:

[0044] a. At least one microcellular polyurethane (MCU) (102);

[0045] b. A composite region (103) that encapsulates at least one MCU (102),

[0046] wherein the composite region (103) partially or completely encapsulates at least one MCU (102), and

[0047] c. Optionally, at least one support region (105) attached to at least one surface (104) of the composite region (103).

[0048] The isolator (101) includes at least one MCU (102) encapsulated by the composite region (103).

[0049] At least one isolator (101) is a helical spring isolator for positioning between:

[0050] a. A first arm (401) of a spring (400) and a spring seat region (311) of a vehicle body (301), or

[0051] b. A second arm (402) and a spring seat region (312) of a movable component (302) of the vehicle, or

[0052] c. Both.

[0053] The isolator (101) is shaped to fit in a complementary shape to the spring seat region (311) or (312). Additionally, the isolator (101) is shaped to fit in a complementary shape to the first arm (401) or the second arm (402) of the spring (400).

[0054] Microcellular polyurethane (MCU)

[0055] Compared to the composite region (103), at least one MCU (102) is softer / lower in stiffness. The MCU (102) that is softer than the composite region (103) is configured to absorb noise, vibration, and shock. The MCU (102) is subjected to compression to absorb impact forces.

[0056] In an embodiment, at least one MCU (102) of the isolator (101) is in a form selected from perforated disks, rings, half-rings, polygons, wires, wire meshes, files, inserts, spring coils, and sheets.

[0057] In another embodiment, at least one MCU (102) of the isolator (101) has a suitable configuration selected from a slit, a polyhedron, a parallelepiped, a prism, a prismatoid, a frustum of a pyramid, a cone, a cylinder, a parallelogram, a rhombus configuration, a rectangular configuration, an S-shaped configuration.

[0058] In an embodiment, the isolator (101) includes an MCU (102) in the shape of a disk having a central hole, as Figure 1a and Figure 1b shown, such that the composite region (103) of the MCU (102) and the isolator (101) is coaxial.

[0059] In another embodiment, the isolator (101a) includes a disk-shaped MCU (102) having a central hole and a disk-shaped support region (105) having a central hole, as Figure 2a shown, such that the MCU (102) and the support region (105) are coaxial with the composite region (103) of the isolator (101).

[0060] In another embodiment, the isolator (101) includes a disk-shaped MCU (102) having a central hole and a disk-shaped support region (105) having a central hole. In a preferred embodiment, the disk-shaped support region (105) defines a hollow space. In another preferred embodiment, the disk-shaped support region (105) is completely solid.

[0061] In another embodiment, the isolator (101b) includes three MCUs (102a, 102b, 102bb) shaped as inserts such that the MCUs (102a, 102b, 102bb) are distributed over the composite region (103), as Figure 2b shown.

[0062] In another embodiment, the isolator (101c) includes at least two MCUs (102c, 102cc) in the shape of disks having a central hole and stacked coaxially with each other, as Figure 2c shown, such that the two MCUs (102c and 102cc) are coaxial with the composite region (103) of the isolator (101).

[0063] In yet another embodiment, the isolator (101) includes at least one MCU (102) partially encapsulated by the composite region (103), as Figure 1a and Figure 1b shown.

[0064] In yet another embodiment, the isolator (101E) includes an MCU (102E) in the shape of a disk having a central hole, and the central hole is completely encapsulated by the composite region (103), as Figure 1cAs shown. The isolator (101E) with a fully encapsulated MCU (102E) has the ability to withstand more load because the composite region (103) provides support from the outer radial end and the inner radial end of the MCU (102E).

[0065] In yet another embodiment, at least one MCU (102) comprises a porous elastomer, a porous polyisocyanate addition product, or any combination thereof. In a preferred embodiment, the porous elastomer comprises a microporous polyurethane elastomer.

[0066] The microporous polyurethane has a microporous structure, i.e., the microporous polyurethane has pore walls that define pores or void spaces. The pore walls have an original shape, and the pores are typically filled with air. When the microporous polyurethane is subjected to a compressive force, the pore walls collapse and the air is expelled from the pores. When the compressive force is removed, the pore walls return to their original shape. It is beneficial to use microporous polyurethane in compression applications because the microporous polyurethane has a progressive load deflection curve, i.e., characteristics.

[0067] The microporous polyurethane is formed by a two-step process. In the first step of the process, an isocyanate prepolymer is formed by reacting a polyol (P1) and an isocyanate (ISO1). The polyol (P1) is a polyester (PEs1) and alternatively a polyether (PE1). The isocyanate (ISO1) is the monomeric methylene diphenyl diisocyanate and alternatively naphthalene diisocyanate. However, it should be understood that the isocyanate (ISO1) can be of any type without departing from the nature of the present invention. In the second step of the process, the isocyanate prepolymer reacts with water to produce carbon dioxide, and the carbon dioxide forms the pores of the microporous polyurethane.

[0068] The polyester polyol (PEs1) is produced by the reaction of a dicarboxylic acid and a diol having at least one primary hydroxyl group. For example, the dicarboxylic acids suitable for producing the polyester polyol are selected from the group consisting of, but not limited to: adipic acid, methyladipic acid, succinic acid, suberic acid, sebacic acid, oxalic acid, glutaric acid, pimelic acid, azelaic acid, phthalic acid, terephthalic acid, isophthalic acid, and combinations thereof. For example, the diols suitable for producing the polyester polyol are selected from the group consisting of, but not limited to: ethylene glycol, butanediol, hexanediol, bis(hydroxymethyl cyclohexane), 1,4-butanediol, diethylene glycol, 2,2-dimethylpropanediol, 1,3-propanediol, and combinations thereof. The hydroxyl number of the polyester polyol is from 30 to 130, the nominal functionality is from 1.9 to 2.3, and the nominal molecular weight is from 1000 to 3000.

[0069] The polyether polyol (PE1) is produced from the cyclic ether propylene oxide and optionally ethylene oxide or tetrahydrofuran. Propylene oxide is added to an initiator in the presence of a catalyst to produce the polyester polyol. The polyether polyol (PE1) is selected from the group consisting of but not limited to: polybutylene glycol, polyethylene glycol, polypropylene glycol, and combinations thereof. The polyether polyol (PE1) has a hydroxyl number of 30 to 130, a nominal functionality of 1.8 to 2.3, and a nominal molecular weight of 1000 to 5000.

[0070] The diisocyanate is selected from the group consisting of but not limited to: 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, ethylene diisocyanate, ethylidene diisocyanate, propylene diisocyanate, butylene diisocyanate, cyclopentylene-1,3-diisocyanate, cyclohexylene-1,4-diisocyanate, cyclohexylene-1,2-diisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, 2,2-diphenylpropane-4,4'-diisocyanate, p-phenylene diisocyanate, m-phenylene diisocyanate, xylylene diisocyanate, 1,4-naphthylene diisocyanate, 1,5-naphthylene diisocyanate, diphenyl-4,4'-diisocyanate, azobenzene-4,4'-diisocyanate, diphenyl sulfone-4,4'-diisocyanate, dichlorohexamethylene diisocyanate, tetramethylene diisocyanate, pentamethylene diisocyanate, hexamethylene diisocyanate, 1-chlorobenzene-2,4-diisocyanate, furfurylidene diisocyanate, and combinations thereof.

[0071] The monomeric methyl diphenyl diisocyanate is selected from the group consisting of: 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, and combinations thereof.

[0072] The terms isocyanate, polyol, polyester polyol, polyether, and prepolymer mentioned above for forming the MCU (102) also appear below for forming the composite region (103) and the support region (105). Although the terms mentioned have the same meaning and function, the formulation / composition of the composite region (103) and the support region (105) is different from the formulation / composition of the MCU (102).

[0073] Composite region

[0074] In an embodiment, the isolator (101) includes a composite region (103) having a stiffness greater than that of at least one MCU (102). The composite region (103) is configured to have a high load-bearing capacity. The composite region (103) with a higher stiffness than the MCU (102) distributes the load along the geometry of the isolator (101) onto the lower / stiffer material (i.e., the MCU (102)). The MCU (102) absorbs impact forces and undergoes compression. Thus, the interaction between the composite region (103) and the encapsulated MCU (102) provides the isolator (101) with a high load-bearing capacity. Despite the lower stiffness of the MCU (102), the interaction of the composite region (103) provides good damping for the suspension system (200). The total weight of the isolator (101) with the MCU (102) and the composite material (103) is less than that of a rubber isolator with a metal insert.

[0075] In an embodiment, the composite region (103) is made of a mixture of injection-molded materials selected from thermoplastic composites, polyamides, copolyamides, aramids, thermoplastic polyurethanes (TPU), or any combination thereof.

[0076] In an embodiment, the composite region (103) encapsulates at least one MCU (102) and provides a surface (104) for attaching an optional support region (105). In a preferred embodiment, the isolator (101) includes a composite region (103) that partially encapsulates at least one MCU (102). In another preferred embodiment, the isolator (101) includes a composite region (103) that fully encapsulates at least one MCU (102).

[0077] In yet another preferred embodiment, the isolator (101) includes a composite region (101) that partially encapsulates at least one MCU (102) and fully encapsulates at least one MCU (102).

[0078] In an embodiment, the composite region (103) defines a hollow space complementary in shape to the spring seat region (311) or (312).

[0079] Support region

[0080] In an embodiment, a support region (105) is optionally added to the isolator (101). The support region (105) is an elastic material configured to optionally be present on the surface (104) of the isolator (101). The support region (105) is configured to limit the deformation of the isolator (101) and provide structural stability. The support region (105) can be obtained in any shape and size complementary to the surface (104) of the isolator (101).

[0081] In yet another embodiment, at least one support region (105) comprises a material selected from: metals, steel, rigid plastics, fibers, nylon fibers with glass fillers, wood, an additional layer of the composite region (103), or a combination thereof.

[0082] In another embodiment, at least one support region (105) comprises a fiber selected from: metal fibers, metallized inorganic fibers, metallized synthetic fibers, glass fibers, polyester fibers, polyamide fibers, polyvinyl alcohol fibers, aramid fibers, graphite fibers, carbon fibers, ceramic fibers, mineral fibers, basalt fibers, inorganic fibers, aramid fibers, kenaf fibers, jute fibers, flax fibers, hemp fibers, cellulose fibers, sisal fibers, and coir fibers.

[0083] In another embodiment, at least one support region (105) is a metal selected from chemical elements, alloys, and molecular compounds.

[0084] In yet another embodiment, at least one support region (105) is made of a metal selected from: iron, aluminum, titanium, magnesium, copper, stainless steel, alloy steel, polymeric sulfur nitride, polythiazyl, bronze, and tin.

[0085] In a preferred embodiment, at least one support region (105) is a stainless steel ring. In a more preferred embodiment, at least one support region (105) is made of steel S430 or S304.

[0086] In yet another embodiment, at least one support region (105) is in a form selected from: hooks, sockets, inserts, rods, half-rings, complementary coatings, protrusions, perforated disks, rings, half-rings, polygons, wires, wire meshes, and sheets.

[0087] In yet another embodiment, the support region (105) is a steel protrusion.

[0088] In yet another embodiment, the support region (105) is an additional layer of the composite region (103). In a preferred embodiment, the additional layer of the composite region (103) is made of the same material as the material of the composite region (103). In another preferred embodiment, the additional layer of the composite region (103) is made of a material different from the material of the composite region (103).

[0089] In yet another embodiment, the support region (105) is a combination of a steel protrusion and an additional layer of the composite region (103).

[0090] In yet another embodiment, the support region (105) is subjected to a surface treatment agent. The surface treatment agent is also referred to as sizing. The support region (105) further improves the mechanical properties of the injection molding material when subjected to the surface treatment agent. Generally, if it is the isolator (101), sizing provides adhesion between the support region (105) and the surface (104).

[0091] Method for forming an isolator

[0092] Another aspect of the present invention relates to an embodiment of a method of forming an isolator (101), the method comprising:

[0093] a. Providing at least one MCU (102) in a mold for the isolator (101);

[0094] b. Optionally, providing at least one support region (105) in a mold for the isolator (101);

[0095] c. Injecting a mixture for forming the composite region (103) into the mold and above at least one MCU (102) and optionally above at least one support region (105);

[0096] d. Optionally curing the mixture to form the isolator (101);

[0097] e. Releasing the isolator (101) from the mold.

[0098] In an alternative embodiment, the mixture is injected into the mold and above at least one MCU (102). Then, at least one support region (105) is snap-fitted onto the surface (104) of the isolator (101).

[0099] In an embodiment, the shape of the mold is complementary to the shape of the isolator (101). The isolator (101) is formed such that the isolator (101) fits precisely onto the spring seat region (311) or (312). Additionally, the isolator (101) is formed to be complementary to the shape of the arm (401) or (402) of the spring (400).

[0100] In an embodiment, at least one MCU (102) is disposed in the mold for the isolator (101).

[0101] In an embodiment, a mixture for forming the composite region (103) is injected into the mold and overmolded around at least one MCU (102) in the shape of the isolator (101). In an embodiment, after the mixture is injected above at least one MCU (102), the mixture is optionally cured. The cured or uncured isolator (101) is released from the mold. In a preferred embodiment, the mixture is cured.

[0102] Mixture for forming a composite region

[0103] In an embodiment, the mixture for forming the composite region (103) includes polyurethane, thermoplastic composite, polyamide, copolyamide and aromatic polyamide, thermoplastic polyurethane, or any combination thereof.

[0104] In a preferred embodiment, the mixture for forming the composite region (103) is TPU.

[0105] In another embodiment, the mixture for forming the composite region (103) is injection overmolded. Suitable overmolding techniques for the present invention are well known to those skilled in the art. For example, overmolding can be performed by arranging a screw for a heated injection barrel, the screw being disposed within the barrel and connected to a hopper containing TPU particles. The TPU is then fed into the injection barrel where the TPU is heated and, by the action of the screw shaft, the TPU is injected in a molten state through the nozzle. In additional embodiments, a plastic material can be blended with the TPU and the particles are injected through the nozzle in a molten state. In one embodiment, the temperature of the injection barrel is between 210 °C and 230 °C, while the nozzle temperature is between 220 °C and 240 °C.

[0106] The terms isocyanate, polyol, polyester polyol, polyether, and prepolymer mentioned above for forming the MCU (102) also appear below for the mixture for forming the composite region (103). Although the terms mentioned have the same meaning and function, the formulation / composition of the composite region (103) is different from the formulation / composition of the MCU (102).

[0107] Thermoplastic polyurethane (TPU)

[0108] In an embodiment, the Shore hardness of the TPU ranges from Shore D hardness 54D to 80D, or 60D to 80D, or 70D to 80D.

[0109] In another embodiment, the TPU is obtained by reacting:

[0110] a. a polyol (P2),

[0111] b. an isocyanate (ISO2), and

[0112] c. optionally, a chain extender (E2).

[0113] Polyol (P2)

[0114] The average functionality of the suitable polyol (P2) is between 1.9 and 8.0, or between 1.9 and 6.0, or between 1.9 and 4.0, and its hydroxyl number is between 10 mg KOH / g and 1800 mg KOH / g, or between 10 mg KOH / g and 1500 mg KOH / g, or even between 10 mg KOH / g and 1000 mg KOH / g. Based on the total weight of the TPU, the amount of the polyol present can be between 1% by weight and 99% by weight.

[0115] In one embodiment, the polyol (P2) is selected from polyether polyols (PE2), polyester polyols (PEs2), polyether-ester polyols (PE-Es2) or mixtures thereof.

[0116] According to the present invention, the average functionality of the polyether polyol (PE2) is between 1.9 and 8.0, or between 1.9 and 6.0, or between 1.9 and 4.0, or between 1.9 and 3.0, or even between 1.9 and 2.1, and its hydroxyl number is between 10 mg KOH / g and 1800 mg KOH / g, or between 10 mg KOH / g and 1500 mg KOH / g, or between 10 mg KOH / g and 1000 mg KOH / g, or even between 10 mg KOH / g and 500 mg KOH / g.

[0117] Suitable polyether polyols (PE2) can be obtained by known methods from one or more alkylene oxides having 2 to 4 carbon atoms in the alkylene moiety, for example, by anionic polymerization using an alkali metal hydroxide (such as sodium hydroxide or potassium hydroxide) or an alkali metal alkoxide (such as sodium methoxide, sodium ethoxide, potassium ethoxide or potassium isopropoxide) as a catalyst and by adding at least one amine-containing starting molecule, or by cationic polymerization using a Lewis acid (such as antimony pentachloride, boron trifluoride etherate, etc.) or bleaching earth as a catalyst.

[0118] The starting molecule is generally selected such that the average functionality of the starting molecule is between 2.0 and 8.0 or between 3.0 and 8.0. Optionally, a mixture of suitable starting molecules is used.

[0119] The starting molecules of the polyether polyol (PE2) include amine-containing and hydroxyl-containing starting molecules. Suitable amine-containing starting molecules include, for example, aliphatic and aromatic diamines such as ethylenediamine, propylenediamine, butylenediamine, hexamethylenediamine, phenylenediamine, toluenediamine, diaminodiphenylmethane and their isomers.

[0120] Other suitable starting molecules also include alkanolamines such as ethanolamine, N-methylethanolamine, and N-ethylethanolamine, dialkanolamines such as diethanolamine, N-methyldiethanolamine, and N-ethyldiethanolamine, and trialkanolamines such as triethanolamine and ammonia.

[0121] In one embodiment, the amine-containing starting molecule is selected from ethylenediamine, phenylenediamine, toluenediamine, and their isomers. In other embodiments, the amine-containing starting molecule includes ethylenediamine.

[0122] The hydroxyl-containing initiator molecules are selected from the following: sugars, sugar alcohols such as glucose, mannitol, sucrose, pentaerythritol, sorbitol; polyphenols, novolac resins (e.g., oligomeric condensation products formed from phenol and formaldehyde), trimethylolpropane, glycerol, diols (such as ethylene glycol, propylene glycol, and their condensation products (such as polyethylene glycol and polypropylene glycol, e.g., diethylene glycol, triethylene glycol, dipropylene glycol)), and water or combinations thereof.

[0123] In one embodiment, the hydroxyl-containing starting molecule comprises sugars and sugar alcohols such as sucrose, sorbitol, glycerol, pentaerythritol, trimethylolpropane, and mixtures thereof. In other embodiments, the hydroxyl-containing starting molecule comprises sucrose, glycerol, pentaerythritol, and trimethylolpropane.

[0124] Suitable alkylene oxides having 2 to 4 carbon atoms are, for example, ethylene oxide, propylene oxide, tetrahydrofuran, 1,2-butylene oxide, 2,3-butylene oxide, and styrene oxide. The alkylene oxides can be used alone, used alternately continuously, or used as a mixture. In one embodiment, the alkylene oxide is propylene oxide and / or propylene oxide. In other embodiments, the alkylene oxide is a mixture of ethylene oxide and propylene oxide containing more than 50% by weight of propylene oxide.

[0125] In one embodiment, the suitable polyether polyol (PE2) is derived from tetrahydrofuran. Tetrahydrofuran is a cyclic ether and is converted to a linear polymer called poly(tetramethylene ether) glycol (PTMEG) before obtaining the TPU. Poly(tetrahydrofuran) commercially available from BASF under the trade name can also be used.

[0126] Based on the total weight of the TPU, the suitable amount of the polyether polyol (PE2) is between 1% and 99% by weight.

[0127] The average functionality of the suitable polyester polyol (PEs2) is between 1.9 and 6.0, or between 1.9 and 5.0, or between 1.9 and 4.0, and its hydroxyl number is between 10 mg KOH / g and 500 mg KOH / g.

[0128] According to the present invention, the polyester polyol (PEs2) is based on the reaction product of a carboxylic acid or acid anhydride with a compound containing a hydroxyl group. Suitable carboxylic acids or acid anhydrides have from 2 to 20 carbon atoms or from 4 to 18 carbon atoms, such as succinic acid, glutaric acid, adipic acid, suberic acid, azelaic acid, sebacic acid, dodecanedioic acid, maleic acid, fumaric acid, phthalic acid, isophthalic acid, terephthalic acid, oleic acid, phthalic anhydride. Particularly included are phthalic acid, isophthalic acid, terephthalic acid, oleic acid and phthalic anhydride or combinations thereof.

[0129] Suitable hydroxyl-containing compounds are selected from ethanol, ethylene glycol, propan-1,2-diol, propan-1,3-diol, butan-1,4-diol, butan-2,3-diol, hexan-1,6-diol, octan-1,8-diol, neopentyl glycol, cyclohexanedimethanol (1,4-bis-hydroxymethylcyclohexane), 2-methyl-propan-1,3-diol, glycerol, trimethylolpropane, hexan-1,2,6-triol, butan-1,2,4-triol, trimethylolethane, pentaerythritol, p-cyclohexanediol, mannitol, sorbitol, methyl glycoside, diethylene glycol, triethylene glycol, tetraethylene glycol, polyethylene glycol, dipropylene glycol, polypropylene glycol, polyethylene-propylene glycol, dibutylene glycol and polybutylene glycol. In one embodiment, the hydroxyl-containing compound is selected from ethylene glycol, propan-1,2-diol, propan-1,3-diol, butan-1,4-diol, butan-2,3-diol, hexan-1,6-diol, octan-1,8-diol, neopentyl glycol, cyclohexanedimethanol (1,4-bis-hydroxy-methylcyclohexane), 2-methyl-propan-1,3-diol, glycerol, trimethylolpropane, hexan-1,2,6-triol, butan-1,2,4-triol, trimethylolethane, pentaerythritol, p-cyclohexanediol, mannitol, sorbitol, methyl glycoside and diethylene glycol. In some embodiments, the hydroxyl-containing compound is selected from ethylene glycol, propan-1,2-diol, propan-1,3-diol, butan-1,4-diol, butan-2,3-diol, hexan-1,6-diol, octan-1,8-diol, neopentyl glycol and diethylene glycol. In other embodiments, the hydroxyl-containing compound is selected from hexan-1,6-diol, neopentyl glycol, diethylene glycol.

[0130] The hydroxyl number of the suitable polyether-ester polyol (PE-Es2) is between 10 mg KOH / g and 500 mg KOH / g, and the average functionality is between 1.9 and 5.0.

[0131] Such polyether-ester polyols (PE-Es2) can be obtained as the reaction product of: i) at least one hydroxyl-containing starting molecule; ii) one or more fatty acids, fatty acid monoesters or mixtures thereof; iii) one or more alkylene oxides having 2 to 4 carbon atoms.

[0132] The starting molecules of component i) are typically selected such that the average functionality of component i) is between 1.9 and 5.0. Optionally, a mixture of suitable starting molecules can be used.

[0133] In one embodiment, the hydroxyl-containing starting molecules of component i) are selected from sugars, sugar alcohols (glucose, mannitol, sucrose, pentaerythritol, sorbitol), polyphenols, novolac resins such as the oligomeric condensation products formed from phenol and formaldehyde, trimethylolpropane, glycerol, diols such as ethylene glycol, propylene glycol and their condensation products such as polyethylene glycol and polypropylene glycol, e.g., diethylene glycol, triethylene glycol, dipropylene glycol, water and mixtures thereof.

[0134] In other embodiments, the hydroxyl-containing starting molecules of component i) are selected from sugars and sugar alcohols such as sucrose and sorbitol, glycerol, and mixtures of said sugars and / or sugar alcohols with glycerol, water and / or diols such as diethylene glycol and / or dipropylene glycol.

[0135] The fatty acid or fatty acid monoester ii) is selected from polyhydroxy fatty acids, ricinoleic acid, hydroxy-modified oils, hydroxy-modified fatty acids and myristic-based fatty acid esters, palmitoleic acid, oleic acid, stearic acid, palmitic acid, vaccenic acid, petroselinic acid, gadoleic acid, erucic acid, nervonic acid, linoleic acid, α- and γ-linolenic acid, stearidonic acid, arachidonic acid, eicosapentaenoic acid, docosapentaenoic acid, docosahexaenoic acid and mixtures thereof. The fatty acid can be used as the pure fatty acid. In this regard, fatty acid methyl esters such as, for example, biodiesel or methyl oleate are preferably used.

[0136] Biodiesel is to be understood as meaning fatty acid methyl esters within the meaning of the EN 14214 standard of 2010. The main components of biodiesel are typically produced from rapeseed oil, soybean oil or palm oil and are methyl esters of saturated C16 to C18 fatty acids and methyl esters of mono- or polyunsaturated C18 fatty acids (such as oleic acid, linoleic acid and linolenic acid).

[0137] Suitable alkylene oxides iii) having 2 to 4 carbon atoms are, for example, ethylene oxide, propylene oxide, tetrahydrofuran, 1,2-epoxybutane, 2,3-epoxybutane and / or styrene oxide. The alkylene oxides can be used individually, used alternately in succession or used as a mixture.

[0138] In one embodiment, the alkylene oxide comprises propylene oxide and / or ethylene oxide. In other embodiments, the alkylene oxide is a mixture of ethylene oxide and propylene oxide, which mixture comprises more than 50% by weight of propylene oxide. In another embodiment, the alkylene oxide comprises only propylene oxide.

[0139] Chain extender (CE2)

[0140] In an embodiment, the molecular weight of the chain extender (CE2) is between 49 g / mol and 499 g / mol. In another embodiment, suitable chain extenders (CE2) are selected from alkanolamines, diols, and / or triols having a molecular weight between 49 g / mol and 499 g / mol. Suitable amounts of these chain extenders (CE2) are known to those skilled in the art. For example, based on the total weight of the TPU, the chain extender (CE2) may be present in an amount of up to 99 wt% or up to 20 wt%.

[0141] In one embodiment, suitable chain extenders (CE2) may be selected from ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,4-butanediol, 1,5-pentanediol, methylpentanediol, 1,6-hexanediol, neopentyl glycol, trimethylolpropane, glycerol, pentaerythritol, diglycerol, glucose, 1,4:3,6-dianhydrohexitol, hydroquinone bis(2-hydroxyethyl) ether, and bis-2-(hydroxyethyl) terephthalate. In another embodiment, it may be selected from triethylene glycol, propylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 1,4-butanediol, 1,5-pentanediol, methylpentanediol, and 1,6-hexanediol. In yet another embodiment, it may be selected from triethylene glycol, propylene glycol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, and 1,4-butanediol. In still another embodiment, the chain extender comprises 1,4-butanediol.

[0142] Isocyanate (ISO2)

[0143] Suitable isocyanates (ISO2) for use in the present invention include aliphatic isocyanates or aromatic isocyanates. It should be understood that the isocyanates (ISO2) include aliphatic isocyanates and aromatic isocyanates in monomeric and polymeric forms. The term "polymeric" refers to the polymeric grades of aliphatic isocyanates and / or aromatic isocyanates, including different oligomers and homologues that are independent of each other.

[0144] In an embodiment, the aliphatic isocyanate is selected from 1,4-tetramethylene diisocyanate, 1,5-pentamethylene diisocyanate, 1,6-hexamethylene diisocyanate, decamethylene diisocyanate, 1,12-dodecane diisocyanate, 2,2,4-trimethyl-hexamethylene diisocyanate, 2,4,4-trimethyl-hexamethylene diisocyanate, 2-methyl-1,5-pentamethylene diisocyanate, cyclobutane-1,3-diisocyanate, 1,2-cyclohexane diisocyanate, 1,3-cyclohexane diisocyanate and 1,4-cyclohexane diisocyanate, 2,4-methylcyclohexane diisocyanate and 2,6-methylcyclohexane diisocyanate, 4,4'-dicyclohexyl diisocyanate and 2,4'-dicyclohexyl diisocyanate, 1,3,5-cyclohexane triisocyanate, isocyanatomethyl cyclohexane isocyanate, isocyanatoethyl cyclohexane isocyanate, bis(isocyanatomethyl)-cyclohexane diisocyanate, 4,4'-diisocyanatodicyclohexylmethane, 1,5-pentamethylene diisocyanate, isophorone diisocyanate and mixtures thereof.

[0145] In one embodiment, an aromatic isocyanate is used to obtain the TPU of Embodiment 1. Suitable aromatic isocyanates are selected from: toluene diisocyanate; polymeric toluene diisocyanate, diphenylmethane diisocyanate and / or polymeric diphenylmethane diisocyanate; m-phenylene diisocyanate; 1,5-naphthalene diisocyanate; 4-chloro-1,3-phenylene diisocyanate; 2,4,6-toluene triisocyanate, 1,3-diisopropylphenylene-2,4-diisocyanate; 1-methyl-3,5-diethylphenylene-2,4-diisocyanate; 1,3,5-triethylphenylene-2,4-diisocyanate; 1,3,5-triisopropyl-phenylene-2,4-diisocyanate; 3,3'-diethyl-diphenyl-4,4'-diisocyanate; 3,5,3',5'-tetraethyl-diphenylmethane-4,4'-diisocyanate; 3,5,3',5'-tetraisopropyl diphenylmethane-4,4'diisocyanate; 1-ethyl-4-ethoxyphenyl-2,5-diisocyanate; 1,3,5-triethylbenzene-2,4,6-triisocyanate; 1-ethyl-3,5-diisopropylbenzene-2,4,6-triisocyanate, tolidine diisocyanate and 1,3,5-triisopropylbenzene-2,4,6-triisocyanate.

[0146] In other embodiments, the aromatic isocyanate is selected from: toluene diisocyanate; polymeric toluene diisocyanate, diphenylmethane diisocyanate and / or polymeric diphenylmethane diisocyanate; m-phenylene diisocyanate; 1,5-naphthalene diisocyanate; 4-chloro-1,3-phenylene diisocyanate; 2,4,6-toluene triisocyanate, 1,3-diisopropylphenylene-2,4-diisocyanate; 1-methyl-3,5-diethylphenylene-2,4-diisocyanate. In another embodiment, the aromatic isocyanate comprises: toluene diisocyanate; polymeric toluene diisocyanate, diphenylmethane diisocyanate and / or polymeric diphenylmethane diisocyanate; m-phenylene diisocyanate; 1,5-naphthalene diisocyanate; 4-chloro-1;3-phenylene diisocyanate. In another embodiment, the aromatic isocyanate is selected from: toluene diisocyanate; polymeric toluene diisocyanate, diphenylmethane diisocyanate and / or polymeric diphenylmethane diisocyanate; m-phenylene diisocyanate. In a further embodiment, the isocyanate comprises methylene diphenyl diisocyanate and / or polymeric methylene diphenyl diisocyanate.

[0147] Methylene diphenyl diisocyanate can be obtained in three different isomeric forms, namely, 2,2'-methylene diphenyl diisocyanate (2,2'-MDI), 2,4'-methylene diphenyl diisocyanate (2,4'-MDI) and 4,4'-methylene diphenyl diisocyanate (4,4'-MDI). Methylene diphenyl diisocyanate can be classified as monomeric methylene diphenyl diisocyanate and polymeric methylene diphenyl diisocyanate known as industrial methylene diphenyl diisocyanate. The polymeric methylene diphenyl diisocyanate includes oligomeric species and methylene diphenyl diisocyanate isomers. Thus, the polymeric methylene diphenyl diisocyanate can contain a single methylene diphenyl diisocyanate isomer or an isomeric mixture of two or three methylene diphenyl diisocyanate isomers, the balance being oligomeric species. The polymeric methylene diphenyl diisocyanate tends to have an isocyanate functionality greater than 2.0. In these products, the isomer ratio as well as the amount of oligomers can vary over a wide range. For example, the polymeric methylene diphenyl diisocyanate typically can contain 30 wt.% to 80 wt.% of methylene diphenyl diisocyanate isomers, the balance being the oligomeric species. The methylene diphenyl diisocyanate isomers are typically a mixture of 4,4'-methylene diphenyl diisocyanate, 2,4'-methylene diphenyl diisocyanate and very low levels of 2,2'-methylene diphenyl diisocyanate.

[0148] In another embodiment, reaction products of an isocyanate (ISO2) with a polyol (P2) and mixtures of these reaction products with other diisocyanates and polyisocyanates can also be used.

[0149] In yet another embodiment, the isocyanate (ISO2) comprises a polymeric methylene diphenyl diisocyanate as described above.

[0150] A suitable amount of the isocyanate (ISO2) results in an isocyanate index between 70 and 350, or between 80 and 300. In one embodiment, the isocyanate index is between 80 and 200, or 80 and 150, or 90 and 140. In another embodiment, the isocyanate index is between 90 and 130, or 90 and 120, or 90 and 110. The isocyanate index describes the molar ratio of NCO groups to isocyanate-reactive groups (polyol (P2) and chain extender (CE2)). An index of 100 refers to a 1:1 ratio.

[0151] Other reinforcing agents

[0152] In one embodiment, the TPU further comprises other reinforcing agents. For the purposes of the present invention, the reinforcing agents are selected from metal fibers, metallized inorganic fibers, metallized synthetic fibers, glass fibers, polyester fibers, polyamide fibers, polyvinyl alcohol fibers, aramid fibers, graphite fibers, carbon fibers, ceramic fibers, mineral fibers, basalt fibers, inorganic fibers, aramid fibers, kenaf fibers, jute fibers, flax fibers, hemp fibers, cellulose fibers, sisal fibers, and coir fibers.

[0153] In one embodiment, the reinforcing agents can be obtained in any shape and size. In another embodiment, the reinforcing agents are subjected to a surface treatment agent. The surface treatment agent is also referred to as sizing. The reinforcing agents further improve the mechanical properties of the TPU when subjected to the surface treatment agent. Generally, the sizing provides adhesion between the reinforcing agents and the TPU.

[0154] In one embodiment, the surface treatment agent is a coupling agent and is selected from silane coupling agents, titanium coupling agents, and aluminate coupling agents.

[0155] In one embodiment, the coupling agent comprises a silane coupling agent. Suitable silane coupling agents are selected from amino silanes, epoxy silanes, methyltrimethoxysilane, methyltriethoxysilane, γ-glycidoxypropyltrimethoxysilane, vinyltriacetoxysilane, and vinyltrimethoxysilane.

[0156] A suitable amount of the reinforcing agents in the TPU is well known to those skilled in the art. In one embodiment, as described herein, the amount of the reinforcing agents results in a weight ratio between the reinforcing agents and the TPU between 0.01:1.0 and 1.0:1.0.

[0157] Method for preparing TPU

[0158] In yet another embodiment, the TPU can be obtained in the presence of a catalyst and / or an additive. Suitable catalysts are well known to those skilled in the art. The catalysts are selected from tertiary amines and phosphine compounds, metal catalysts such as chelates of various metals, acidic metal salts of strong acids; strong bases, alcoholates and phenolates of various metals, salts of organic acids with various metals, tetravalent tin, trivalent As and pentavalent As, organometallic derivatives of Sb and Bi, and metal carbonyl compounds of iron and cobalt and mixtures thereof can be used as catalysts.

[0159] In one embodiment, the catalyst is a tertiary amine. Tertiary amines include triethylamine, tributylamine, N-methylmorpholine, N-ethylmorpholine, N,N,N',N'-tetramethylethylenediamine, pentamethyldiethylenetriamine and higher homologues (as described, for example, in DE-A 2,624,527 and 2,624,528), 1,4-diazabicyclo(2.2.2)octane, N-methyl-N'-dimethylaminoethylpiperazine, bis-(dimethylaminoalkyl)piperazine, tris-(dimethylaminopropyl)hexahydro-1,3,5-triazine, N,N-dimethylbenzylamine, N,N-dimethylcyclohexylamine, N,N-diethylbenzylamine, bis-(N,N-diethylaminoethyl)adipate, N,N,N',N'-tetramethyl-1,3-butanediamine, N,N-dimethyl-phenethylamine, 1,2-dimethylimidazole, 2-methylimidazole, monocyclic and bicyclic amines, together with bis-(dialkylamino)alkyl ethers such as 2,2-bis-(dimethylaminoethyl) ether. Triazine compounds such as, but not limited to, tris-(dimethylaminopropyl)hexahydro-1,3,5-triazine can also be used.

[0160] In other embodiments, the metal catalysts include, but are not limited to, metal salts and organometallic compounds, which include tin, titanium, zirconium, hafnium, bismuth, zinc, aluminum and iron compounds such as organotin compounds, preferably alkyltin such as dimethyltin or diethyltin, or organotin compounds based on aliphatic carboxylic acids, preferably tin diacetate, tin dilaurate, dibutyltin diacetate, dibutyltin dilaurate, bismuth compounds such as alkylbismuth or related compounds, or iron compounds, preferably iron-(II) acetylacetonate or metal salts of carboxylic acids such as tin-II isooctanoate, tin dioctanoate, titanates or bismuth-(III) neodecanoate or combinations thereof.

[0161] As described above, the amount of catalyst present can be up to 20 wt% based on the total weight of the TPU.

[0162] In another embodiment, the additives are selected from alkylene carbonates, ureas, pyrrolidones, fillers, flame retardants, dyes, pigments, IR absorbing materials, UV stabilizers, plasticizers, antistatic agents, fungistatic agents, hydrolysis control agents, antioxidants, cell regulators, and mixtures thereof. Additional details regarding the additives can be found, for example, in Szycher's Handbook of Polyurethanes, 2nd Edition, 2013. Suitable amounts of these additives are well known to those skilled in the art. However, for example, based on the total weight of the TPU, the amount of additive present can be up to 20 wt%.

[0163] Suspension system

[0164] Another aspect of the present invention relates to an embodiment of a suspension system (200) for a vehicle (300), the vehicle having a body (301) and a movable component (302) that is displaceable relative to the body (301), the suspension system (200) comprising:

[0165] a. a spring (400) comprising a first arm (401) hinged to a spring seat area (311) of the body (301) of the vehicle and a second arm (402) hinged to a spring seat area (312) of the movable component (302) of the vehicle; and

[0166] b. at least one isolator (101) according to any one of claims 1 to 12,

[0167] wherein at least one isolator is disposed between:

[0168] the first arm (401) of the spring (400) and the spring seat area (311) of the body (301) of the vehicle, or

[0169] the second arm (402) and the spring seat area (312) of the movable component (302) of the vehicle, or both.

[0170] The suspension system (200) includes a spring (400), at least one isolator (101), and optionally a shock absorber / strut.

[0171] Figure 3 provides a view of the suspension system (200). Figure 3a and Figure 3b provides a variation of the spring (400) in the suspension system (200). Figure 3a provides a view of the suspension system (200) in which the spring (400), arm (401), and isolator (101) are not in a straight travel path. Figure 3b provides a view of the suspension system (200) in which the spring (400) and isolator (101) are in a straight travel path.

[0172] Figure 4 A view of a suspension system (200) in the form of a MacPherson strut assembly is provided. Figure 4 A view of a suspension system having a spring seat (401), an isolator (401), a spring (400), a strut piston rod (211), an isolator (101), an isolator (402), and a strut (212) is provided, as seen in a MacPherson strut type system.

[0173] Figure 5 A view of a suspension system (200) in a vehicle (300) is provided.

[0174] Spring

[0175] The movement of the spring (400) in response to an impact force provides a suspension action in the suspension system (200). The spring 400 includes a coil spring, which is a curved wire in a helical shape. The coil spring includes a constant stiffness coil spring, a progressive stiffness coil spring, and a dual stiffness coil spring.

[0176] In an embodiment, the spring (400) includes

[0177] a. A first arm (401) that is hinged to a spring seat area (311) of the vehicle body (301), and

[0178] b. A second arm (402) that is hinged to a spring seat area (312) of a movable part (302) of the vehicle.

[0179] Vehicle

[0180] Another aspect of the present invention relates to an embodiment of a vehicle (300) that includes:

[0181] a. A vehicle body (301);

[0182] b. A movable part (302) that is displaceable relative to the vehicle body (301); and

[0183] c. A suspension system (200) having at least one isolator (101).

[0184] The vehicle body (301) includes a passenger seat unit.

[0185] The movable part (302) includes a wheel.

[0186] The vehicle (300) is shown in Figure 5 in.

[0187] Articulation of an isolator in a suspension system

[0188] In an embodiment, the isolator (101) is hinged between:

[0189] a. the first arm (401) of the spring (400) and the body (301) of the vehicle (300), or

[0190] b. the second arm (402) of the spring (400) and the movable part (302) of the vehicle, or

[0191] c. both.

[0192] The first end of at least one isolator (101) is disposed on the arm (401 or 402, or both) of the spring (400). At least one isolator (101) is configured to interlock with the arm (401, 402) of the spring (400) to avoid slippage. The isolator (101) is customized to fit the corresponding shape of the arm (401, 402) of the spring (400). In a preferred embodiment, the spring (400) is a helical spring, and at least one isolator (101) is customized to fit the pigtail end and barrel shape of the spring (400).

[0193] The second end of at least one isolator (101) is disposed on the spring seat area (311) of the body (301) or the spring seat area (312) of the movable part (302) of the vehicle or both. The spring seat areas (311, 312) are cast into the body (301) or the movable part (302) or both. The spring seat areas (311, 312) are alternatively welded into the body (301) or the movable part (302) or both.

[0194] At least one isolator (101) is configured to assume a preselected position and shape based on the shape of the spring seat area (311 or 312) of the body (301) or the movable part (302) of the vehicle or both.

[0195] Articulation of a vehicle and a suspension system

[0196] A moving vehicle (300) generates vibrations and rolling noise. When a wheel associated with the movable part (302) of the vehicle 300 hits an obstacle (such as a curb) during movement, an impact force is generated. If the impact force is greater than the impact force that the spring (400) can absorb, the excess impact force is absorbed by the isolator (101).

[0197] Alternatively, when the suspension system (200) includes a MacPherson strut assembly as Figure 4 shown, the impact force is absorbed by the strut (212) and the spring (400). The impact force greater than the capacity of the strut (212) and the spring (400) is then absorbed by the isolator (101).

[0198] As described above, when the wheel rolls on the road and on uneven surfaces, the vehicle also undergoes noise, vibration, and shock. The arms (401) and (402) of the spring (400) transmit the vibration and shock to the isolator (101).

[0199] The composite region (103) of the isolator (101) that is stiffer than at least one MCU (102) distributes the load along the geometry of the isolator (101) to at least one MCU (102). At least one MCU (102) absorbs the vibration and shock. At least one MCU also absorbs the transmitted excessive impact force.

[0200] The impact force compresses the isolator (101). The greater the impact force, the greater the compression of at least one MCU (102). The support region (105) limits the excessive compression of the isolator and prevents structural deformation of the isolator (101).

[0201] It should be understood that the isolator (101) provides additional load management capabilities to absorb excess energy. The stiffness of the composite region (103) provides additional load-bearing capacity for the isolator (101). The composite region (103) overmolded on at least one MCU (102) directs the vibration, shock, and excessive impact force (if any) to at least one MCU (102). In addition, the composite region (103) and optionally at least one support region (105) provide much-needed structural stability for the isolator (101) and prevent deformation and degradation. At least one MCU (102) helps absorb the vibration, shock, and received excessive impact force. When the isolator (101) absorbs the vibration, shock, and excess energy due to the impact force, at least one MCU (102) undergoes compression.

[0202] As described herein, at least one isolator (101) that interacts with the arms (401) and (402) of the spring absorbs vibration, shock, and excessive impact force. The isolator (101) minimizes noise, vibration, and harshness (NVH), prevents suspension overtravel, is lightweight and cost-effective. In particular, these advantages are attributed to the composite region (103) of the isolator (101), at least one MCU (102), and optionally a support region (105) obtained by overmolding at least one MCU (102) with the material of the composite region (103). Since the isolator (101) is fabricated to be complementary in shape to the spring seat regions (311) and (312), the isolator (101) can be easily adapted to changes in the suspension system (200). In addition, the use of the isolator (101) does not require any further structural changes to the spring (400) or the suspension system (200) or the vehicle (300).

[0203] Advantages :

[0204] The isolator (101) is associated with the following, compared to other helical spring isolators:

[0205] a. High load-bearing capacity, enabling it to support extremely high loads,

[0206] b. Low stiffness and high damping,

[0207] c. Lighter weight than rubber isolators with metal inserts,

[0208] d. No piercing conditions due to the unique properties of high wear resistance, toughness, elasticity, and flexibility of TPU, and

[0209] e. Reducing the cost of the suspension system (200) by combining other shock absorber components in one part.

[0210] The presently claimed invention is shown in more detail by the following embodiments and combinations of embodiments, which are generated by the corresponding dependent references and links:

[0211] Embodiments

[0212] I. An isolator (101) in a suspension system (201), the isolator (101) comprising:

[0213] a. At least one microcellular polyurethane (MCU) (102);

[0214] b. A composite region (103) that encapsulates the at least one MCU (102),

[0215] wherein the composite region (103) partially or completely encapsulates the at least one MCU (102), and

[0216] c. Optionally, at least one support region (105) attached to at least one surface (104) of the composite region (103).

[0217] II. The isolator (101) according to embodiment I, wherein the at least one MCU (102) is in a form selected from perforated disks, rings, half-rings, polygons, wires, wire meshes, files, inserts, and sheets.

[0218] III. The isolator (101) according to any one of embodiments I or II, wherein the isolator (101) comprises at least two MCUs (102a, 102b, 102bb) distributed across the composite region (103) or at least two MCUs (102c and 102cc) stacked coaxially with each other.

[0219] IV. An isolator (101) according to any one of embodiments I to III, wherein at least one MCU (102) is partially encapsulated by the composite region (103).

[0220] V. An isolator (101) according to any one of embodiments I to III, wherein at least one MCU (102E) is completely encapsulated by the composite region (103).

[0221] VI. An isolator (101) according to any one of embodiments I to V, wherein at least one MCU (102) comprises a porous elastomer, a porous polyisocyanate addition product, or any combination thereof.

[0222] VII. An isolator (101) according to any one of embodiments I to VI, wherein the composite region (103) comprises a thermoplastic composite, a polyamide, a copolyamide, an aromatic polyamide, a thermoplastic polyurethane (TPU), or any combination thereof.

[0223] VIII. An isolator (101) according to any one of embodiments I to VII, wherein at least one support region (105) comprises a material selected from: metal, steel, hard plastic, nylon fiber with glass filler, an additional layer of the composite region (103), or a combination thereof.

[0224] IX. An isolator (101) according to any one of embodiments I to VIII, wherein at least one support region (105) is in a form selected from hooks, sockets, inserts, rods, and half - rings, complementary coatings, and protrusions.

[0225] X. An isolator (101) according to any one of embodiments I to IX, wherein the support region (105) is a steel protrusion.

[0226] XI. An isolator according to any one of embodiments I to IX, wherein the support region (105) is an additional layer of the composite region (103).

[0227] XII. An isolator (101) according to any one of embodiments I to IX, wherein the support region (105) is a combination of a steel protrusion and an additional layer of the composite region (103).

[0228] XIII. A method of forming an isolator (101) according to any one of embodiments I to XII, wherein the method comprises:

[0229] a. Providing at least one MCU (102) in a mold for the isolator (101);

[0230] b. Optionally, provide at least one support area (105) in the mold for the isolator (101);

[0231] c. Inject the mixture for forming the composite area (103) into the mold and above the at least one MCU and optionally the at least one support area (105);

[0232] d. Optionally cure the mixture to form the isolator (101);

[0233] e. Release the isolator (101) from the mold.

[0234] XIV. The method according to embodiment XIII, wherein the mixture for forming the composite area (103) comprises polyurethane, thermoplastic composite, polyamide, copolyamide and aromatic polyamide, thermoplastic polyurethane or any combination thereof.

[0235] XV. A suspension system (200) for a vehicle (300), the vehicle having a body (301) and a movable part (302) capable of shifting relative to the body (301), the suspension system (200) comprising:

[0236] a. A spring (400), the spring including a first arm (401) hinged to a spring seat area (311) of the body (301) and a second arm (402) hinged to a spring seat area (312) of the movable part (302); and

[0237] b. At least one isolator (101) according to any one of claims 1 to 12,

[0238] wherein the at least one isolator is disposed between:

[0239] the first arm (401) of the spring (400) and the spring seat area (311) of the body (301) of the vehicle, or

[0240] the second arm (402) and the spring seat area (312) of the movable part (302) of the vehicle,

[0241] or both.

[0242] XVI. A vehicle (300), the vehicle comprising:

[0243] a. A body (301);

[0244] b. A movable part (302), the movable part being capable of shifting relative to the body (301); and

[0245] c. A suspension system (200) having at least one isolator (101) as described above.

[0246] The presently claimed invention is illustrated by the following non - limiting examples:

[0247] Raw materials

[0248]

[0249] Standard methods :

[0250]

[0251] Formation of an isolator

[0252] At least one MCU (102) is made of microporous polyurethane and the support surface (105) is made of stainless steel S430. The support surface (105) is prepared by a stamping process. The support surface (105) has a disk with a central hole. The at least one MCU (102) and the support surface (105) are placed in a mold / injection tool and injected with a mixture for the composite area (103), i.e., a mixture of TPU, to manufacture the isolator (101).

[0253] List of reference numerals

[0254] 101, 101E, 101a, 101b, 101c Isolator 102, 102E, 102a, 102b, 102c, 102cc MCU 103 Composite region 104 Surface of the isolator 105 Support region 200 Suspension system 211 Piston rod 212 Strut 300 Vehicle 301 Vehicle body 302 Movable part 311 Spring seat area on the vehicle body 312 Spring seat area on the movable part 400 Spring 401 First arm of the spring 402 Second arm of the spring

[0255] Obviously, many modifications and variations of the present invention are possible in light of the above teachings. The foregoing invention has been described in accordance with the relevant legal standards; thus, this specification is exemplary rather than restrictive in nature. Variations and modifications of the disclosed embodiments may be apparent to those skilled in the art and fall within the scope of the present invention. Accordingly, the legal protection scope of the present invention can only be determined by studying the following claims.

Claims

1. An isolator (101) in a suspension system (201), the isolator (101) comprising: a. At least one microcellular polyurethane (MCU) (102); b. A composite region (103) that encapsulates the at least one MCU (102), wherein the composite region (103) partially or completely encapsulates the at least one MCU (102), and c. Optionally, at least one support region (105) attached to at least one surface (104) of the composite region (103).

2. The isolator (101) according to claim 1, wherein the at least one MCU (102) is in a form selected from perforated disks, rings, half - rings, polygons, wires, wire meshes, files, inserts, spring coils, and sheets.

3. The isolator (101) according to any one of claims 1 or 2, wherein the isolator (101) comprises at least two MCUs (102a, 102b, 102bb) distributed across the composite region (103) or at least two MCUs (102c and 102cc) stacked coaxially with each other.

4. The isolator (101) according to any one of claims 1 to 3, wherein the at least one MCU (102b) is partially encapsulated by the composite region (103).

5. The isolator (101) according to any one of claims 1 to 3, wherein the at least one MCU (102bb) is completely encapsulated by the composite region (103).

6. The isolator (101) according to any one of claims 1 to 5, wherein the at least one MCU (102) comprises a porous elastomer, a porous polyisocyanate addition product, or any combination thereof.

7. The isolator (101) according to any one of claims 1 to 6, wherein the composite region (103) comprises a thermoplastic composite, a polyamide, a copolyamide, an aromatic polyamide, a thermoplastic polyurethane (TPU), or any combination thereof.

8. The isolator (101) according to any one of claims 1 to 7, wherein the at least one support region (105) comprises a material selected from: metal, steel, hard plastic, nylon fibers with glass fillers, an additional layer of the composite region (103), or a combination thereof.

9. The isolator (101) according to any one of claims 1 to 8, wherein the at least one support region (105) is in a form selected from hooks, sockets, inserts, rods, and half - rings, complementary coatings, and protrusions.

10. The isolator (101) according to any one of claims 1 to 9, wherein the support region (105) is a steel protrusion.

11. The isolator (101) according to any one of claims 1 to 9, wherein the support region (105) is an additional layer of the composite region (103).

12. The isolator (101) according to any one of claims 1 to 9, wherein the support region (105) is a combination of a steel protrusion and an additional layer of the composite region (103).

13. A method of forming an isolator (101) according to any one of claims 1 to 12, wherein the method comprises: a. providing at least one MCU (102) in a mold for the isolator (101); b. optionally, providing at least one support area (105) in the mold for the isolator (101); c. injecting a mixture for forming the composite area (103) into the mold and above the at least one MCU and optionally the at least one support area (105); d. optionally curing the mixture to form the isolator (101); e. releasing the isolator (101) from the mold.

14. The method according to claim 13, wherein the mixture for forming the composite area (103) comprises polyurethane, thermoplastic composite, polyamide, copolyamide and aromatic polyamide, thermoplastic polyurethane or any combination thereof.

15. A suspension system (200) for a vehicle (300), the vehicle having a body (301) and a movable component (302) displaceable relative to the body (301), the suspension system (200) comprising: a. a spring (400), the spring including a first arm (401) articulated to a spring seat area (311) of the body (301) and a second arm (402) articulated to a spring seat area (312) of the movable component (302); and b. at least one isolator (101) according to any one of claims 1 to 12, wherein the at least one isolator is disposed between: the first arm (401) of the spring (400) and the spring seat area (311) of the vehicle's body (301), or the second arm (402) and the spring seat area (312) of the vehicle's movable component (302), or both.

16. A vehicle (300), the vehicle comprising: a. a body (301); b. a movable component (302), the movable component being displaceable relative to the body (301); and c. a suspension system (200) having at least one isolator (101) according to the claim.

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