Composite Leaf Spring with Integral Elastic Inserts
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Solution Overview
Problem
Existing composite leaf springs for motor vehicles are heavy, complex, and require numerous components, with elastic joints complicating manufacturing and increasing costs, while also affecting kinematic properties due to the need for separate molding and elastomeric interfacial layers.
Innovation Solution
A composite leaf spring design featuring thermoplastic or thermosetting composite material reinforced with fibers, where inserts are integrated into the blade to provide elastic joints, reducing twisting and allowing for adjustable center of rotation, and eliminating the need for separate molding and interfacial layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If elastic joints are mounted on interfaces bonded to the upper face of the blade, then the blade can be connected to the chassis, but the manufacturing process becomes complicated and costs increase
Solution Approach 1:
The patent merges the elastic joint function directly into the blade structure by creating integral joints that are formed as one piece with the blade body during molding. This eliminates the need for separate elastic joint components and their associated bonding interfaces, thereby simplifying the manufacturing process while maintaining reliable connection to the chassis.
Solution Approach 2:
The blade is designed to perform multiple functions: it serves as both the structural leaf spring and the mounting structure for the elastic joints. The integral joints are formed directly from the blade material, making the blade a multi-functional component that eliminates the need for separate fastening elements and reduces assembly steps.
2Adaptability or versatility
If plates are attached around the composite blade to mount joints, then joints can be positioned, but separate molding operations and elastomeric interfacial layers are required
Solution Approach 1:
The patent combines the blade and joint mounting structures into a single integrated component. The integral joints are formed directly from the blade material through continuous molding, eliminating the need for separate plates and elastomeric interfacial layers. This reduces structural complexity while maintaining the ability to position joints appropriately for various kinematic requirements.
3Reliability
If elastomeric interfacial layers are used between plates and blade, then abrasion is avoided and forces are distributed, but kinematic properties are affected and complex shapes are required
Solution Approach 1:
The patent removes the elastomeric interfacial layer from the system by creating integral joints that are formed directly from the blade material. This eliminates the intermediate layer that was causing kinematic issues, while the joint design itself ensures proper force distribution through its structural geometry and direct material continuity with the blade.
4Adaptability or versatility
If a mold of large dimensions is designed to integrate the blade, then joints can be directly placed on the front axle, but manufacturing complexity increases
Solution Approach 1:
The patent segments the blade into multiple sections that can be molded separately in smaller, more manageable molds. The integral joints are formed in these smaller sections, which are then assembled to create the complete blade assembly. This segmentation approach reduces the complexity of individual molding operations while maintaining the benefit of integrated joint structures.
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
This design reduces weight, simplifies manufacturing, and enhances kinematic properties by integrating inserts directly into the blade, allowing for easier adjustment and minimizing bending stresses, thus improving the overall efficiency and cost-effectiveness of the leaf spring system.
Implementation Method 1
a blade (1 to 501) made of a thermoplastic or thermosetting composite material reinforced with fibers
Implementation Method 2
comprising elastic joints (10b to 511b) which are attached to these inserts
Data Source
Figure 1
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AI summary
The present invention relates to a composite spring leaf for the ground contact system of a motor vehicle, which spring leaf is intended to be mounted on a front or rear wheel set of the vehicle, to a method of manufacturing this leaf and to such a ground contact system incorporating it. This leaf (1) has two faces, upper (2) and lower (3), defining two longitudinal edges (4 and 5) connected to one another by the two ends of the leaf and is provided with two pairs (8 and 9) of chassis (12 and 13) bearers (10 and 11) respectively near to these ends, the bearers of each pair being respectively positioned near the longitudinal edges and having elastic articulations (10b and 11b) to be connected to the chassis. According to the invention, the two bearers of each pair respectively comprise two inserts (10a and 11a) which are made of a fibre-reinforced thermoset or thermoplastic composite which is identical or similar to that of the leaf, these inserts being incorporated directly into the leaf passing continuously or discontinuously transversely through it from one of its longitudinal edges to the other between its two faces and extending beyond the longitudinal edges.