Composite Tubular Spring Structure for Corrosion-Free Linear Compression
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Solution Overview
Problem
Metallic helical springs used in vehicle suspensions are susceptible to corrosion and torsional bias during manufacturing, affecting their linear movement and durability.
Innovation Solution
A composite spring made from a fiber-reinforced material with a tubular structure, featuring a resilient member that can be a coil with defined openings, is manufactured using a subtractive process like water jet cutting, which reduces torsional stress and enhances corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic wire is used to form wound helical springs, then the spring can provide mechanical energy storage and shock absorption, but the spring becomes susceptible to corrosion and torsional bias affecting linear movement
Solution Approach 1:
The patent applies composite materials by constructing the spring from multiple layers of fiber-reinforced composite materials (e.g., carbon fiber, glass fiber) embedded in a polymer matrix. This composite structure provides superior corrosion resistance compared to metallic springs, as the non-metallic materials do not rust or degrade from exposure to road salt and moisture, directly resolving the corrosion susceptibility issue while maintaining mechanical performance.
2Productivity
If traditional winding manufacturing process is used for metallic springs, then the spring can be formed efficiently, but torsional stress is imparted causing bias in deflection axis and affecting linear movement
Solution Approach 1:
The patent applies segmentation by constructing the spring from multiple discrete layers of fiber-reinforced composite materials that are stacked and cured together. Each layer can be independently manufactured and positioned, allowing precise control over the final spring geometry. This layered approach eliminates the torsional stress inherent in traditional single-step winding processes, ensuring the spring maintains true linear movement without deflection axis bias.
Solution Approach 2:
The patent applies parameter changes by transitioning from metallic material to fiber-reinforced composite material, which fundamentally changes the manufacturing process from cold-forming/winding to curing. This parameter change in material properties allows the spring to be formed without imparting torsional stress, as the composite layers are cured in their final positions rather than being mechanically deformed during formation, thereby achieving precise linear movement characteristics.
3Weight of moving object
If fiber-reinforced composite material is used for the spring tube, then corrosion resistance and weight reduction are achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies merging by combining multiple layers of fiber-reinforced composite materials into a single integrated spring structure through curing. The individual layers, which may have different fiber orientations and properties, are merged together in a controlled curing process to form a unified component. This merging approach achieves weight reduction and corrosion resistance while consolidating what could be a complex multi-step process into an integrated manufacturing sequence.
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 composite spring provides improved corrosion resistance, reduced weight, and more linear compression characteristics compared to traditional metallic springs, with tailored mechanical properties and noise isolation capabilities.
Implementation Method 1
a tube made from a fiber-reinforced composite material... a portion of the wall adjacent the one or more openings defining a resilient member of the spring
Implementation Method 2
using a subtractive manufacturing process to form one or more openings through a wall of the tubular precursor
Data Source
AI summary
Composite springs and methods for manufacturing such composite springs are provided. A spring includes a tube made from a fiber-reinforced composite material and having a longitudinal axis. The tube includes a first axial end having a closed shape that completely surrounds the longitudinal axis, a second axial end axially opposite the first axial end relative to the longitudinal axis, and one or more openings formed through a wall of the tube. The one or more openings define a resilient member of the spring.