Auxiliary Rubber Spring Arc-Shape Fatigue Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current automobile suspension rubber springs experience fatigue failure, leading to a relatively short service life of less than 5,000 km due to crack formation at the outer edge of rubber layers, resulting in reduced durability and comfort.
Innovation Solution
An auxiliary rubber spring design featuring arc-shaped metal and rubber layers with a transitional chamfer and encapsulated bonding, where the arc lengths and thicknesses increase gradually, reducing stress concentration and enhancing fatigue resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flat-structured rubber springs are used, then manufacturing is simple, but stress concentration occurs at the outer edges leading to fatigue failure and short service life
Solution Approach 1:
The patent applies curvature by designing the metal partitions and rubber layers with arc-shaped cross-sections instead of flat structures. This curved geometry distributes stress more evenly across the components, eliminating stress concentration at outer edges and preventing fatigue failure, thereby extending service life from less than 5,000 km to over 20,000 km.
Solution Approach 2:
The patent implements local quality by creating a transitional chamfer at the connecting edges between metal partitions and rubber layers. This localized geometric feature gradually transitions the thickness from the metal partition to the rubber layer, reducing stress concentration at the bonding interface and preventing crack initiation in high-stress regions.
2Reliability
If uniform thickness rubber layers are used, then manufacturing is easy, but stress distribution is uneven causing crack formation at outer edges
Solution Approach 1:
The patent applies local quality by varying the thickness of rubber layers at different positions. The rubber layers have different thicknesses in the thickness direction, with gradual changes not exceeding 30% between adjacent layers. This non-uniform thickness distribution optimizes stress distribution throughout the component, preventing crack formation while maintaining manufacturing feasibility.
Solution Approach 2:
The patent changes the geometric parameters of the rubber layers by progressively increasing arc lengths and thicknesses from the supporting plate to the connecting plate. This parameter variation creates a gradient structure that distributes stress more evenly, enhancing fatigue resistance without creating abrupt transitions that would complicate manufacturing.
3Reliability
If abrupt thickness transitions are used at bonding interfaces, then manufacturing is simpler, but stress concentration increases leading to crack propagation
Solution Approach 1:
The patent applies the nesting principle by encapsulating the bonding interface between metal partitions and rubber layers within a transitional chamfer structure. This nested geometric configuration creates a gradual thickness transition zone that protects the bonding interface from stress concentration, preventing crack propagation while maintaining structural integrity.
Solution Approach 2:
The transitional chamfer introduces a curved geometric transition at the bonding interface instead of an abrupt angle. This curvature distributes stress more evenly across the interface between metal and rubber components, eliminating stress concentration points that would lead to fatigue failure and crack propagation.
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 design significantly extends the service life of the rubber spring by 400% and improves driving smoothness and passenger comfort by reducing dynamic load and stress concentration.
Implementation Method 1
the rubber layers act as a buffer and a connection
Implementation Method 2
absorb and eliminate vibration
Implementation Method 3
arc lengths of sections of respective rubber layers gradually increase in a thickness direction from the supporting plate to the connecting plate, such that surface areas of the rubber layers gradually increase
Data Source
AI summary
An auxiliary rubber spring for an automobile suspension, comprising: N layers of metal partitions, N being an integer greater than or equal to 1, and a transverse section of each metal partition being arc-shaped; N+1 rubber layers, the rubber layers being alternately lapped with the metal partitions, and a transversal section of each rubber layer being arc-shaped; a supporting plate provided with a first convex arc surface on one side thereof, the first convex arc surface being bonded to a first concave arc surface of an outermost rubber layer; and a connecting plate provided with a second concave arc surface on one thereof, the second concave arc surface being bonded to a second convex arc surface of another outermost rubber layer. The auxiliary rubber spring for an automobile suspension according to the present invention may increase fatigue resistance of the rubber spring and effectively extend service life thereof.