Bolster Spring Flange Design for Reduced Axle Translation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle suspensions with bolster springs face challenges in optimizing design for reduced spring rates, axle translation during braking and acceleration, and tire clearance, often relying on acute apex angles and numerous fasteners.
Innovation Solution
The design incorporates bolster springs with a reduced apex angle of 37 degrees, direct mounting with common fasteners, and a unique flange configuration to enhance shear operation, reduce spring rates, and increase tire clearance, while using fewer and smaller fasteners for a lighter, more optimized structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional acute apex angles and numerous fasteners are used in bolster spring mounting, then structural strength and retention integrity are improved, but device complexity and weight increase
Solution Approach 1:
The patent combines multiple fastening functions into a single integrated flange structure. The flange incorporates mounting surfaces, attachment points, and structural reinforcement in one component, eliminating the need for multiple separate fasteners and mounting elements while maintaining retention integrity through the unified structural design.
Solution Approach 2:
The flange structure serves multiple functions simultaneously: it provides structural reinforcement, creates mounting surfaces for bolster springs, enables attachment to the vehicle frame, and maintains retention integrity. This multi-functional design replaces what would traditionally require multiple specialized components.
2Force
If reduced apex angle is used for bolster springs, then shear operation is improved and spring rates are reduced, but structural complexity increases
Solution Approach 1:
The flange structure incorporates localized geometric features including specific apex angles, mounting surface orientations, and reinforcement patterns positioned at critical stress points. This local optimization allows the reduced apex angle configuration to achieve improved shear operation and spring rates without requiring complex modifications throughout the entire structure.
3Weight of moving object
If direct mounting of bolster springs with fewer fasteners is implemented, then weight is reduced and design is optimized, but manufacturing precision requirements increase
Solution Approach 1:
The flange structure is pre-configured with precisely positioned mounting surfaces and attachment points during manufacturing. This preliminary precision work enables the direct mounting approach with fewer fasteners, as the critical alignment and positioning are established in advance rather than requiring high precision during assembly.
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 configuration results in lower primary and secondary suspension spring rates, reduced axle translation, and increased tire clearance, achieving improved stability and efficiency during braking and acceleration with a more compact and lightweight design.
Implementation Method 1
elastomeric material positioned between the base plate and the top plate
Implementation Method 2
an apex angle between the bolster springs has been reduced allowing them to operate more in shear thereby providing for a decrease in the primary and secondary suspension spring rates
Data Source
AI summary
A bolster spring for a vehicle suspension including a base plate, a top plate, elastomeric material positioned between the base plate and the top plate, a first flange comprising a pair of ears having a bottom mounting surface upwardly extending from a first end of the base plate at an angle ½α, and one or more mounting holes positioned in the pair of ears in the first flange adapted for attachment to a pair of ears on an upwardly extending flange on a second bolster spring.