Composite Stabilizer One-Piece Construction for Vehicle Suspension

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Solution Overview

Problem

Existing stabilizers for vehicles made of metal are heavy, prone to breakage, and have complex production processes that limit the use of advanced fiber laying techniques, resulting in discontinuities that affect force transmission and damping properties.

Innovation Solution

A stabilizer with a composite structure of fiber-reinforced plastic, featuring a one-piece construction with adapted cross-sectional geometry and fiber orientation to optimize torsional and bending stresses, and integrated load introduction elements, produced using braiding or winding methods that allow for precise fiber placement and matrix material infiltration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal stabilizers are used, then strength and reliability are improved, but weight increases and breakage resistance worsens

Engineering Contradiction:

ImprovestrengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials by combining fiber-reinforced plastic (glass fiber, aramid, or carbon fibers) with a matrix material (duroplastic or thermoplastic) to create a stabilizer that achieves high strength-to-weight ratio, eliminating the need for heavy metal constructions while maintaining structural integrity and breakage resistance

Inventive Principle:

Principle #40Composite materials

2Reliability

If metal stabilizers are used, then reliability is improved, but ease of manufacture worsens due to complex production processes

Engineering Contradiction:

ImprovereliabilityVSAvoidease of manufacture

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-forming the core body with the desired stabilizer geometry before fiber placement, and by integrating load introduction means and connection elements into the mold structure beforehand, enabling their automatic incorporation during the composite manufacturing process without subsequent assembly steps

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges multiple manufacturing operations into a single composite molding process, combining fiber placement, matrix infiltration, and integration of load introduction means and connection elements into one continuous production step, thereby simplifying manufacturing while ensuring reliable one-piece construction

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If traditional fiber composite manufacturing is used, then ease of manufacture is improved, but manufacturing precision worsens due to fiber discontinuities

Engineering Contradiction:

Improveease of manufactureVSAvoidmanufacturing precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent applies continuity of useful action by implementing continuous fiber placement techniques where fibers are laid down without interruption or discontinuity throughout the stabilizer structure, ensuring optimal force transmission and eliminating weak points that would arise from segmented or discontinuous fiber courses

Inventive Principle:

Principle #20Continuity of useful action

4Ease of manufacture

If fiber orientation is not adapted, then ease of manufacture is improved, but strength worsens due to non-optimal stress distribution

Engineering Contradiction:

Improveease of manufactureVSAvoidstrength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent applies local quality by adapting fiber orientation locally to match the specific stress conditions at different locations within the stabilizer, with fibers oriented to optimize resistance against torsional stresses in the central region and bending stresses in the angled end pieces, thereby achieving maximum strength where needed

Inventive Principle:

Principle #3Local quality

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 provides a lightweight, high-strength stabilizer with improved damping and load-adapted properties, reducing the risk of breakage and simplifying production while maintaining optimal force transmission and damping performance.

Implementation Method 1

the fiber layers are infiltrated with a matrix material under application of pressure

Methodology Applied

Scientific EffectPressure infiltration: Pressure Increase

Implementation Method 2

a fiber-reinforced plastic, in particular glass fiber, aramid or carbon fibers which are embedded in a duroplastic or thermoplastic matrix material

Methodology Applied

Scientific EffectComposite material reinforcement: Composite Materials

Data Source

PatentEP2583815B1Stabilizer in fibre reinforced plastic composite and method for its production

Publication Date: 2015.10.14 LUHN & PULVERMACHER - DITTMANN & NEUHAUS

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Figure 4~5

AI summary

The invention relates to a composite stabilizer made of fiber-reinforced plastic, in particular glass fibers, aramid fibers, or carbon fibers embedded in a thermoset or thermoplastic matrix material, and to a method for its manufacture. To ensure better force transmission, the stabilizer is designed as a single piece without fiber interruptions. Furthermore, the cross-sectional geometry, wall thickness, and fiber orientation are adapted to the available installation space and the expected loads.