Adapter Assembly for Composite Trailer Suspension Attachment

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Solution Overview

Problem

The challenge lies in joining a suspension assembly to a composite cargo vehicle structure, such as a trailer, without damaging the composite structure, as forming holes for mechanical fasteners can damage the fibers and compromise the structural integrity.

Innovation Solution

An intermediate adapter assembly is permanently coupled to the composite floor assembly and removably coupled to the suspension assembly, allowing for secure attachment without direct fastening into the composite material, thereby preserving its integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If mechanical fasteners are used to join the suspension assembly to the composite floor assembly, then the suspension assembly can be securely attached, but the composite structure is damaged due to hole formation and fiber damage

Engineering Contradiction:

Improveattachment strengthVSAvoidcomposite structure damage

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

An intermediate adapter assembly is introduced as a mediator component that couples to the composite floor assembly through a bonding surface without requiring holes or fasteners in the composite material. The adapter assembly then provides attachment points for the suspension assembly, thereby enabling secure attachment while preserving the integrity of the composite structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the suspension assembly is permanently attached to the composite floor assembly, then structural integrity is maintained, but the suspension assembly cannot be easily removed or replaced

Engineering Contradiction:

Improvestructural integrityVSAvoidsuspension assembly removal

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The attachment system is segmented into three distinct components: the composite floor assembly, the intermediate adapter assembly, and the suspension assembly. The adapter assembly serves as a separate intermediate component that can be permanently bonded to the composite floor while providing removable attachment points for the suspension assembly, enabling both structural integrity and ease of repair.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If holes are formed in the composite floor assembly for fasteners, then the suspension assembly can be attached, but the fibers in and around the holes are damaged compromising structural integrity

Engineering Contradiction:

Improveattachment process simplicityVSAvoidcomposite structure integrity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The intermediate adapter assembly eliminates the need to form holes in the composite floor assembly by providing its own attachment surface. This mediator component can be bonded to the composite floor using surface preparation and adhesive bonding, avoiding fiber damage while maintaining manufacturing simplicity and composite integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS10710423B2Joining a suspension assembly to a composite trailer structure

Publication Date: 2020.07.14 WABASH NATIONAL CORP

AI summary

A cargo vehicle includes a composite floor assembly configured to support cargo, at least one wheel assembly configured to transport the cargo on the composite floor assembly, a suspension assembly associated with the at least one wheel assembly, and an intermediate adapter assembly. The intermediate adapter assembly is permanently coupled to the composite floor assembly and removably coupled to the suspension assembly such that the composite floor assembly is removably coupled to the suspension assembly.