Composite Coil Spring Layering for Lightweight Fatigue Resistance
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Solution Overview
Problem
Composite coil springs face challenges in matching the mechanical properties, durability, and size of steel coil springs while maintaining an acceptable cost.
Innovation Solution
A composite coil spring design featuring a carbon fiber core surrounded by alternating layers of carbon and glass fiber layers with a polymer matrix, including silica nanoparticles, to enhance mechanical properties and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite coil springs are used to reduce weight, then weight is reduced, but mechanical properties and durability are difficult to match with steel coil springs
Solution Approach 1:
The patent employs a composite structure consisting of a polymer matrix composite beam with embedded steel wire reinforcement. This combination allows the spring to achieve both weight reduction (approximately two-thirds lighter than steel) and maintained mechanical properties through the synergistic effect of the polymer matrix and steel reinforcement elements.
Solution Approach 2:
The invention applies different material properties to different regions of the spring structure. The polymer matrix provides lightweight characteristics and corrosion resistance, while embedded steel wire reinforcement provides localized strength and durability where needed, creating a non-uniform but optimized material distribution throughout the spring body.
2Weight of moving object
If composite materials are used to reduce weight, then weight is reduced, but size and durability are difficult to match with steel coil springs
Solution Approach 1:
The patent uses a composite construction combining polymer matrix material with embedded steel wire reinforcement. This composite approach enables the spring to be approximately two-thirds lighter than traditional steel springs while maintaining durability through the reinforcing steel elements that provide structural integrity and resistance to fatigue and degradation.
Solution Approach 2:
The invention modifies the material parameters by transitioning from solid steel to a polymer-steel composite structure. The polymer matrix provides corrosion resistance and lightweight properties, while the steel reinforcement maintains mechanical strength and durability, effectively changing the material parameters to achieve both weight reduction and reliability.
3Strength
If composite coil springs are designed with multiple fiber layers, then mechanical properties are improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the spring structure into distinct functional layers: a polymer matrix composite layer and embedded steel wire reinforcement layers. This segmentation allows each layer to be optimized for its specific function while simplifying the manufacturing process, as each layer can be applied and cured independently rather than requiring complex integration of multiple fiber types.
Solution Approach 2:
The invention applies different material compositions to different regions of the spring structure. The polymer matrix composite provides lightweight and corrosion-resistant properties, while embedded steel wire reinforcement provides localized strength. This local differentiation of material properties optimizes mechanical performance without requiring uniform complexity throughout the entire structure.
Data Source
AI summary
A composite coil spring includes a coil body that extends along a coiled axis. The coil body includes a polymer matrix and, disposed in the polymer matrix, a carbon fiber core and a plurality of fiber layers wrapped around the carbon fiber core in alternating oblique fiber angles to the coiled axis. The fiber layers include, from inside-out starting from the carbon fiber core, at least two consecutive carbon fiber intermediate fiber layers of alternating oblique fiber angles to the coiled axis, immediately followed by at least two consecutive glass fiber intermediate fiber layers of alternating oblique fiber angles to the coiled axis, and immediately followed by a carbon fiber outermost fiber layer.