Composite Coil Spring Fiber Layer Segmentation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Designing and fabricating composite coil springs with desired mechanical properties economically is challenging, as existing composite coil springs often fail to meet the requirements for vehicle suspension systems, particularly in terms of weight savings and durability.
Innovation Solution
A composite coil spring design featuring a coil body with a core and multiple fiber layers impregnated with a polymer material, where the fiber layers are arranged at oblique angles and different radial distances from the coiled axis, each having a number of fibers calculated as a product of a common base number multiplied by a positive integer, allowing for customizable strength profiles and efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite coil springs are designed to replace steel coil springs, then weight savings are achieved, but difficulty in designing with desired mechanical properties increases
Solution Approach 1:
The coil spring is segmented into multiple fiber layers with different fiber counts (multiples of a base number), allowing independent optimization of mechanical properties for each layer while maintaining overall weight reduction compared to steel springs
Solution Approach 2:
Different fiber layers are assigned different numbers of fibers (multiples of base number) to create local variations in strength and stiffness properties, enabling tailored mechanical performance in specific regions of the coil spring
2Reliability
If composite coil springs are designed with desired mechanical properties, then performance requirements are met, but fabrication cost increases
Solution Approach 1:
The fiber layer construction parameters are standardized around a common base number, allowing systematic variation (multiples of base number) that simplifies the fabrication process while maintaining the ability to meet specific mechanical property requirements through parameter selection
3Strength
If fiber layers are arranged at oblique angles, then strength profile is improved, but manufacturing precision requirements increase
Solution Approach 1:
The fiber reinforcement is segmented into discrete layers with standardized fiber counts (multiples of base number), which simplifies the winding and layup processes while maintaining the beneficial oblique angle strength characteristics
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 solution results in a strong and lightweight composite coil spring that effectively replaces metallic coil springs, offering weight reduction and improved fuel mileage by providing a tailored strength profile while maintaining economic fabrication.
Implementation Method 1
a plurality of fiber layers impregnated with a polymer material
Data Source
Figure 1~4
Figure 5~8
AI summary
A composite coil spring includes a coil body that extends along a coiled axis. The coil body includes a core and a plurality of fiber layers impregnated with a polymer material. The plurality of fiber layers are arranged around the core at different radial distances from the coiled axis. Each of the plurality of fiber layers extends around the coiled axis at an oblique fiber angle to the coiled axis. Each of the plurality of fiber layers includes a number of fibers that is a product of a common base number of fibers multiplied by a positive non-zero integer from a set of positive non-zero integers. The positive non-zero integer of at least one of the plurality of fiber layers is different from the positive non-zero integer of at least one other of the plurality of fiber layers. The plurality of fiber layers are selected from the group consisting of glass fibers, carbon fibers, and combinations thereof.