Composite Suspension Triangle Structure for Lightweight Rigidity
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Solution Overview
Problem
Existing mechanical connecting and transmission parts, particularly in the automobile and aeronautics industries, face challenges in achieving reduced weight, high strength and rigidity, and low manufacturing costs, with existing solutions like metal alloys being costly and composite materials lacking sufficient stress resistance and automation difficulty.
Innovation Solution
A method involving a composite rod made of unidirectional fibers embedded in a plastic matrix, shaped by deformation and surface treatment, combined with a digital wire bending machine for automated production, creating a robust mechanical part with integrated interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal alloys are used to manufacture mechanical parts, then strength and rigidity are improved, but weight increases and manufacturing cost increases
Solution Approach 1:
The patent uses composite materials consisting of a plastic matrix reinforced with unidirectional or multidirectional fibers (glass, carbon, or other reinforcing fibers). This composite structure provides high strength-to-weight ratio, achieving the required mechanical strength while significantly reducing weight compared to traditional metal alloys.
2Weight of moving object
If composite materials are used to manufacture mechanical parts, then weight is reduced, but stress resistance shows limits and manufacturing difficulty increases
Solution Approach 1:
The patent implements local quality by using unidirectional fiber layers in areas subjected to high tensile or compressive stresses, while using multidirectional or random fiber layers in areas requiring isotropic properties or lower stress resistance. This localized optimization ensures adequate stress resistance throughout the part while maintaining weight reduction benefits.
Solution Approach 2:
The patent changes material parameters by selecting different fiber types (glass, carbon, basalt), different fiber orientations (unidirectional, multidirectional, random), and different plastic matrix materials to optimize stress resistance for specific application requirements while maintaining lightweight characteristics.
3Weight of moving object
If composite materials are used to manufacture mechanical parts, then weight is reduced, but manufacturing automation difficulty increases and cost increases
Solution Approach 1:
The patent uses preimpregnated tapes (prepregs) where the plastic matrix is already impregnated with fibers before molding. This preliminary preparation allows for easier automated handling, positioning, and molding compared to traditional wet layup methods, thereby improving manufacturing automation capability.
Solution Approach 2:
The patent replaces traditional manual craftsmanship with automated molding systems that can automatically position, layer, and compress the composite materials. This substitution of mechanical systems enables scalable production while maintaining the lightweight benefits of composite materials.
4Ease of manufacture
If traditional molding methods are used, then manufacturing simplicity is maintained, but manufacturing cost remains high due to craftsmanship requirements
Solution Approach 1:
The patent employs self-aligning features in the mold design and self-curing properties of the plastic matrix that automatically position and secure the fiber layers during molding. This self-service mechanism reduces the need for skilled manual intervention and craftsmanship, thereby lowering manufacturing costs while maintaining simplicity.
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 method produces a lightweight, rigid, and cost-effective mechanical part suitable for connecting structures, such as suspension triangles, with enhanced stress resistance and automated manufacturing capabilities.
Implementation Method 1
a composite rod (30, 31) made of unidirectional fibers embedded in a plastic matrix (2)
Implementation Method 2
its conformation is achieved by deformation
Data Source
Figure 1~2
Figure 3~5
AI summary
A method for manufacturing a mechanical connection and/or transmission part (1) arranged between two structures, which consists in carrying out the following operations in succession: - creating a rigid framework (3), by means of operations of shaping at least one pipe length or the like (30, 31), in order to recreate the three-dimensional shape of the part (1), and creating, at specific locations, segments whose shapes are suited to optimizing the strength and rigidity of the part (1), - incorporating into the framework (3) at least one element (4, 5) that is suitable for creating an interface of the part (1) with one or other of the structures, - moulding a plastic matrix (2) around the framework (3).