Vehicle Chassis Spring Assembly With Intermediate Layer Sealing
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Solution Overview
Problem
Existing spring assemblies are susceptible to corrosion and breakage due to dirt penetration, which damages the paint and weakens the helical springs, particularly under environmental influences.
Innovation Solution
A spring assembly with a coating, a spring support, and an intermediate layer connected via a positive connection, such as a positive element and negative receptacle, to prevent dirt ingress and reduce paint damage, using an elastic adhesive layer to absorb energy and reduce stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the spring is directly supported on the spring support, then the structure is simple, but dirt penetrates between the spring and spring support causing paint damage and corrosion
Solution Approach 1:
An intermediate layer is introduced between the spring and spring support to prevent direct contact. This intermediate layer acts as a mediator that seals the gap, preventing dirt penetration while maintaining structural integrity and reducing corrosion risk without significantly complicating the overall structure.
2Strength
If an adhesive layer is used to bond the spring to the spring support, then connection strength is improved, but the manufacturing process becomes more complex and less stable
Solution Approach 1:
The connection system is segmented into distinct functional elements: a positive element on the spring support and a corresponding negative receptacle. This segmentation eliminates the need for adhesive layers while maintaining strong mechanical connection, thereby simplifying the manufacturing process and improving production stability.
Solution Approach 2:
The chemical bonding mechanism (adhesive) is replaced with a mechanical bonding mechanism (positive connection with interlocking elements). This substitution eliminates variability in adhesive application and curing, resulting in more consistent and reliable manufacturing.
3Volume of moving object
If the spring is directly supported on the spring support, then the assembly is compact, but paint abrasion occurs due to dirt ingress
Solution Approach 1:
The intermediate layer serves as a protective mediator between the spring coating and the external environment. It prevents dirt from reaching the paint surface while maintaining compact assembly dimensions, thereby protecting against abrasion and corrosion without increasing overall volume significantly.
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 assembly is protected against environmental influences, reducing paint damage and spring breakage, while allowing for a faster, optimized, and automated manufacturing process.
Implementation Method 1
the intermediate layer includes an elastic adhesive; wherein the intermediate layer is at least materially connected to the coating on a side facing the spring
Data Source
AI summary
A spring assembly for a vehicle chassis may include a spring that features a coating, a spring support, and an intermediate layer. The intermediate layer can be arranged between the spring and the spring support. The intermediate layer may be at least materially connected to the spring, in particular to the coating on a side facing the spring. The intermediate layer lies entirely or partially against the spring support on a side facing away from the spring and is connected to the spring support by a connection other than a material connection.