Fiber-Reinforced Bending Spring With Variable Fiber Volume
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Solution Overview
Problem
Conventional flexible spring elements made of fiber-plastic composite materials face challenges in cost-effectiveness and adaptability to varying stresses, often resulting in oversized designs with excessive weight and manufacturing complexity.
Innovation Solution
The solution involves a flexible spring element with varying volume fractions of spiral spring fibers in functional layers, where the volume fraction is higher in longitudinal sections and lower in curvature sections, utilizing a matrix material removal layer to control fiber distribution and reduce material usage, and incorporating a distance expansion element in curved sections to enhance deformation resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the bending spring element is designed with a uniform thickness to withstand maximum tensile and compressive loads in curved sections, then the strength and reliability are improved, but the weight and material usage increase excessively in longitudinal sections where loads are significantly lower
Solution Approach 1:
The patent implements local quality by varying the thickness of the bending spring element along its length. The element has greater thickness in curved sections where tensile and compressive loads are highest, and reduced thickness in longitudinal sections where loads are significantly lower. This is achieved through a molding process that allows different thickness regions to be formed in a single operation, optimizing both strength and weight by matching material distribution to actual load requirements.
2Reliability
If several bending spring elements are combined into a bending spring assembly to distribute loads, then the reliability and load distribution are improved, but the device complexity and manufacturing effort increase
Solution Approach 1:
The patent merges multiple functional elements into a single integrated bending spring element. By forming the element with varying thickness in one piece using a molding process, it achieves the load-distributing benefits of multiple elements while eliminating the complexity of assembly, fasteners, and alignment that would be required for separate components.
3Weight of moving object
If the bending spring element has varying thickness to optimize weight, then the weight and material usage are reduced, but the manufacturing precision and production complexity increase
Solution Approach 1:
The patent applies parameter changes by varying the thickness parameter of the bending spring element along its length. The molding process allows continuous or stepped variation of thickness to optimize weight while maintaining manufacturing feasibility. The process controls dimensional accuracy through standard molding techniques, avoiding the need for complex post-processing or assembly operations.
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
This approach allows for cost-effective production of high-quality flexible spring elements with optimized spring properties, reduced weight, and improved resistance to environmental conditions, while minimizing material expenditure and manufacturing effort.
Implementation Method 1
a functional layer section arranged in the curvature section facing outwards is subjected to tensile stress
Implementation Method 2
a functional layer section opposite and facing inwards in the curvature section is subjected to compressive stress
Implementation Method 3
during a deflection of the bending spring element as intended
Data Source
Figure 1~3
Figure 4
Figure 5~6
AI summary
The invention relates to a flexible spring element (1) made of a fibre-reinforced plastics composite material (4, 23), a functional layer (2, 3) made of a fibre-reinforced plastics composite material (4) being located on each of two mutually opposite sides (9, 10) of a central plane of the flexible spring element (1). At least one matrix material discharge layer (17) extending parallel to the two functional layers (2, 3) and in a longitudinal direction (7) is arranged in at least one longitudinal portion (14) and has at least a fraction of discharge layer fibres (18) which are oriented differently from the longitudinal direction (7) of the flexible spring element (1). Within at least one curved portion (13) of the flexible spring element (1) a first volume fraction of flexible spring fibres (5) in the functional layers (2, 3) is smaller, preferably smaller by several % than a second volume fraction of flexible spring fibres (5) in the functional layers (2, 3) within the at least one longitudinal portion (14).