Composite Leaf Spring Bracket Structure Without Bolt Holes
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Solution Overview
Problem
The existing leaf spring devices for vehicle suspension systems face durability issues due to material differences between the leaf springs and brackets, leading to damage and vulnerability at hole portions.
Innovation Solution
A leaf spring device with center and side leaf springs made of glass fiber reinforced plastic (GFRP) and bracket modules that include center and side brackets with accommodation parts, shims, and covers, which support the leaf springs without direct fastening through holes, using fastening parts to secure the shims and prevent movement, thereby enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the leaf spring and bracket are connected by bolting through holes, then the assembly is secure and stable, but the material of the spring is damaged and the hole portion becomes vulnerable to durability issues
Solution Approach 1:
The patent introduces a bracket as an intermediary component that accommodates the leaf spring end without direct fastening to the spring. The bracket includes an accommodation part that holds the leaf spring end, and a separate fastening part that secures the bracket to the vehicle body, eliminating the need for holes in the leaf spring itself while maintaining secure connection.
Solution Approach 2:
The bracket is divided into distinct functional segments: an accommodation part that interfaces with the leaf spring end and a fastening part that attaches to the vehicle body. This segmentation allows the leaf spring to remain intact without holes while the bracket handles all fastening functions through its own integrated structure.
2Weight of moving object
If the leaf spring is made of composite material, then weight is reduced and corrosion resistance is improved, but the connection with metallic bracket becomes problematic due to material incompatibility
Solution Approach 1:
The bracket serves as a mediator between the composite leaf spring and the metallic vehicle body structure. The accommodation part of the bracket interfaces with the composite material leaf spring end without requiring holes or fasteners in the spring itself, while the fastening part provides secure metallic-to-metallic attachment to the vehicle body, thus resolving material incompatibility issues.
Solution Approach 2:
The bracket is designed with different local qualities: the accommodation part has features suitable for interfacing with composite material (such as molded-in channels or recesses), while the fastening part has features optimized for metallic attachment (such as bolt holes or weld points). This local differentiation allows the bracket to bridge different material types effectively.
Data Source
AI summary
A leaf spring device for a suspension system for a vehicle according to the present disclosure may include a center leaf spring, side leaf springs respectively disposed at two opposite sides of the center leaf spring, and bracket modules each including a center bracket configured to accommodate an end of the center leaf spring, and a side bracket connected to the center bracket and configured to accommodate an end of the side leaf spring.