Composite Leaf Spring Abrasion Protection for U-Bolt Mounting
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Solution Overview
Problem
Composite leaf springs used in vehicle suspension systems, formed from glass fiber and resin, suffer from low abrasion resistance, leading to reduced axial force of U-bolts and decreased durability, especially when mounted on rough surfaces.
Innovation Solution
Integration of a protective member made from aramid fabric and an abrasion-preventing pad formed from polyamide material, which are stacked on the composite leaf spring to enhance abrasion resistance and prevent slippage, maintaining the axial force of U-bolts and increasing the durability of the composite leaf spring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a composite leaf spring is formed in a unitary body using glass fiber and resin, then weight is reduced and fuel efficiency is improved, but abrasion resistance decreases
Solution Approach 1:
The patent applies composite materials by combining glass fiber and resin to form the leaf spring body, achieving weight reduction while maintaining structural integrity. This composite structure allows the spring to be formed as a unitary body with optimized strength-to-weight ratio, directly addressing the weight reduction goal while managing the inherent abrasion resistance limitation through protective measures.
Solution Approach 2:
The patent implements local quality by applying protective members specifically at the U-bolt mounting portions where abrasion occurs most severely. Instead of uniformly protecting the entire leaf spring, the solution targets critical areas with enhanced abrasion-resistant materials, optimizing the balance between protection and weight considerations.
2Reliability
If the composite leaf spring is vulnerable to friction, then it cannot be manufactured using multiple plates, but must be formed in a unitary body, which reduces manufacturing flexibility
Solution Approach 1:
The use of composite materials enables the leaf spring to be manufactured as a unitary body through molding processes, eliminating the need for multiple plate assemblies. This approach simplifies the manufacturing process while inherently providing better abrasion resistance compared to traditional multi-plate steel constructions, as the composite material can be cured into a monolithic structure with consistent properties throughout.
3Force
If a portion of the composite leaf spring to which the U-bolt is mounted is excessively worn, then the axial force of the U-bolt greatly decreases, but adding protective measures increases device complexity
Solution Approach 1:
The patent applies local quality by placing protective members specifically at the U-bolt mounting portions where wear would compromise axial force. This targeted approach prevents excessive wear at critical locations without adding protective structures to the entire leaf spring, thereby maintaining axial force while minimizing the increase in device complexity.
Solution Approach 2:
The protective members act as intermediaries between the U-bolt and the composite leaf spring body. These protective elements absorb the wear and friction, preventing direct contact between the U-bolt and the composite material, thus maintaining the axial force of the U-bolt while the protective members gradually wear instead of the critical mounting portions.
Data Source
AI summary
A suspension system for a vehicle includes: a composite leaf spring having a protective member which covers an outer surface of the composite leaf spring; and an abrasion-preventing pad coupled to the composite leaf spring and shielding. The protective member and the abrasion-preventing pad are disposed at a portion of the composite leaf spring to which a U-bolt is mounted.