Composite Vehicle Axle with Metallic Web Connectors
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Solution Overview
Problem
Conventional non-driven rear vehicle axles are heavy due to their steel construction, and existing lightweight solutions face challenges in achieving high strength and fatigue resistance with compact connection points.
Innovation Solution
A vehicle axle design featuring composite material carriers with integrated reinforcing fibers, formed from multiple parallel partial carriers connected by webs, which increases the adhesive surface area for shear forces and incorporates metallic reinforcement inserts for enhanced strength and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive connections are used to connect composite material carriers and metal connection parts, then the connection strength can be sufficient, but the connection points require large surface area and occupy much space
Solution Approach 1:
The patent uses composite material carriers made of fiber-reinforced plastic (pultruded beams) combined with metal connection parts. The composite material provides high strength-to-weight ratio, allowing strong connections with reduced material volume. The fiber orientation and composite structure enable high adhesive bonding strength without requiring large connection surfaces.
Solution Approach 2:
The patent changes the geometric parameters of the connection design by using I-shaped or T-shaped cross-sections of the pultruded beams. This cross-sectional geometry provides optimized adhesive bonding surfaces that achieve sufficient connection strength with compact dimensions. The parameter optimization includes beam height, wall thickness, and connection surface area to meet strength requirements while minimizing space occupation.
2Strength
If conventional steel construction is used for non-driven rear axles, then the structural strength and durability are sufficient, but the axle becomes relatively heavy
Solution Approach 1:
The patent replaces conventional steel construction with composite material carriers made of fiber-reinforced plastic. These pultruded beams provide equivalent or superior structural strength while significantly reducing weight. The fiber reinforcement (glass, carbon, or aramid fibers) embedded in the plastic matrix creates a high strength-to-weight ratio structure suitable for axle applications.
Solution Approach 2:
The axle is segmented into multiple functional components: composite material carriers for structural support, metal connection parts for mounting, and reinforcement inserts for stress concentration areas. This segmentation allows each component to be optimized for its specific function, with the composite carriers providing lightweight structural strength and metal parts providing durable connection points.
3Area of stationary object
If compact connection points are used to reduce space occupation, then the space efficiency improves, but the adhesive surface area decreases reducing connection strength
Solution Approach 1:
The patent applies local quality optimization by concentrating adhesive bonding surfaces in specific locations on the I-shaped or T-shaped cross-sections of the pultruded beams. The connection parts are designed to interface with these localized bonding areas, providing sufficient connection strength through optimized local geometry rather than requiring large overall connection surfaces.
Solution Approach 2:
The composite material structure of the pultruded beams provides inherent strength enhancement at connection points. The fiber reinforcement and composite construction allow for compact connection geometries that maintain high bonding strength, as the composite material can be tailored to provide localized strength where connection parts are attached.
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 achieves high strength and resistance to fatigue failure while maintaining a compact and lightweight construction, ensuring robust connections that absorb bending moments and vertical loads effectively.
Implementation Method 1
the connection parts having webs which are arranged between the partial carriers and are glued to them
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
The invention relates to a vehicle axle (1) for a wheel suspension, comprising a carrier (2) made of composite material formed from plastic and reinforcing fibers integrated therein, and connecting elements (3) made of metal, preferably light metal, wherein the connecting elements (3) are connected to the carrier (2) and are configured for connecting a wheel carrier and for connecting at least one spring component and/or damper component. To create a vehicle axle of this type that exhibits high strength with respect to the connection between the carrier and the connecting elements, while maintaining a compact design of the connection points and being robust against fatigue failure, the invention provides that the carrier (2) is formed from at least two parallel sub-carriers (2.1, 2.2) made of the composite material of said type, wherein the connecting elements (3) have webs (3.1) that are arranged between the sub-carriers (2.1, 2.2) and are bonded to them.