Corrugated Composite Suspension Spring for NVH and Mass Production
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Solution Overview
Problem
Current methods for manufacturing corrugated plastic composite springs for vehicle suspensions face challenges in achieving high enough spring constants, durability, and Noise, Vibration, and Harshness (NVH) characteristics, while also being cost-effective and suitable for mass-production, due to differences in stiffness between metal and plastic materials.
Innovation Solution
A three-step process involving corrugated extrusion, braiding of three-dimensional woven fabric, and pultrusion with thermosetting resin is used to form a corrugated plastic composite spring, allowing for the use of different materials and continuous formation, which simplifies the manufacturing process and reduces weight by omitting components like dust covers and spring pads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high-stiffness materials are used to achieve sufficient spring constant, then the spring constant is improved, but the weight and material cost increase
Solution Approach 1:
The patent employs composite materials consisting of plastic matrix combined with reinforcement fibers (glass fiber, carbon fiber, or aramid fiber) to achieve the required spring constant while maintaining reduced weight. The composite structure provides both the stiffness needed for vehicle suspension and the weight advantage over solid metal springs.
Solution Approach 2:
The patent applies reinforcement fibers locally within the plastic matrix at strategic locations where strength is most needed. The corrugated structure itself provides stiffness in certain directions, and the fiber reinforcement complements this by providing localized strength enhancement without uniformly increasing weight throughout the entire spring.
2Strength
If corrugated plastic composite springs are manufactured using traditional methods (hand lay-up, filament winding), then the spring constant can be achieved, but the manufacturing cost increases and mass-production becomes difficult
Solution Approach 1:
The patent replaces traditional manual mechanical processes (hand lay-up, filament winding) with automated injection molding technology. The injection molding process automatically injects plastic material reinforced with fibers into a corrugated mold cavity, eliminating manual labor and enabling high-volume mass production at lower cost.
Solution Approach 2:
The patent changes the manufacturing parameters from low-volume artisanal processes to high-volume automated injection molding. By adjusting parameters such as injection pressure, temperature, and cycle time, the process achieves both the required mechanical properties and economical mass production.
3Ease of manufacture
If single material is used for manufacturing corrugated plastic composite springs, then the manufacturing process is simple, but the NVH characteristics deteriorate
Solution Approach 1:
The patent uses composite materials combining plastic matrix with reinforcement fibers to achieve both manufacturing feasibility and improved NVH characteristics. The composite structure provides vibration damping and noise reduction while maintaining structural integrity and spring performance.
Solution Approach 2:
The patent applies different material properties in different regions of the spring. The corrugated structure provides stiffness in compression directions while the plastic matrix provides vibration damping. This local differentiation of material functions improves NVH characteristics without complicating the overall manufacturing process.
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 process enhances NVH characteristics, increases productivity, and reduces fabrication costs, enabling the production of springs with improved vibration and noise isolation, while achieving a suitable spring constant for vehicle suspension applications.
Implementation Method 1
a corrugated extrusion part forming a pre-form having a hollow corrugated structure
Implementation Method 2
a pultrusion part impregnating the three-dimensional woven fabric with thermosetting resin
Data Source
AI summary
Disclosed is a corrugated plastic composite spring for a vehicle suspension and an apparatus and method for manufacturing the same. The apparatus includes a corrugated extrusion part, a braiding part, and a pultrusion part. The corrugated extrusion part forms a preform having a hollow corrugated structure. The braiding part weaves a three-dimensional woven fabric on the preform. The pultrusion part impregnates the three-dimensional woven fabric with thermosetting resin.