Corrugated Plastic Composite Spring for Vehicle Suspension
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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 impregnation is used to form a corrugated plastic composite spring, allowing for continuous formation and the use of different materials to enhance NVH characteristics and simplify the suspension module.
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 uses composite materials consisting of plastic matrix combined with reinforcement fibers (glass fiber, carbon fiber, or aramid fiber) to achieve high spring constant while maintaining low weight. The composite structure provides both the necessary stiffness and weight reduction compared to using high-stiffness metals alone.
Solution Approach 2:
The patent employs corrugated (waved) geometry in the spring structure to enhance the spring constant. The curved and folded configuration of the plastic composite material provides mechanical leverage that increases stiffness without requiring additional material or weight.
2Ease of manufacture
If corrugated plastic composite spring is manufactured using single material, then the manufacturing process is simplified, but the NVH characteristics deteriorate
Solution Approach 1:
The patent uses multi-material composite construction where an inner layer of thermoplastic resin provides vibration damping and noise isolation, while an outer layer of thermosetting resin composite provides structural strength. This layered composite approach improves NVH characteristics while maintaining manufacturing feasibility.
Solution Approach 2:
The patent applies different materials to different layers of the spring structure: the inner layer uses thermoplastic resin for vibration absorption and noise reduction, while the outer layer uses thermosetting resin composite for structural integrity. Each layer performs its specific function optimally.
3Strength
If hand lay-up process and filament winding process are used to manufacture corrugated plastic composite spring, then the spring constant is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent replaces complex manual lay-up and filament winding processes with automated pultrusion manufacturing. The pultrusion process uses a die and pulling mechanism to continuously form the corrugated composite spring, eliminating the need for manual fiber placement and complex winding equipment.
Solution Approach 2:
The pultrusion process is a self-service manufacturing method where the material itself (resin-impregnated fibers) is pulled through a shaped die that automatically forms the corrugated geometry and cures the material, eliminating the need for separate forming and curing steps.
4Ease of manufacture
If typical blow molding process is used to manufacture corrugated plastic composite spring, then the manufacturing process is simplified, but the spring constant and durability are insufficient
Solution Approach 1:
The patent uses fiber-reinforced composite materials (plastic matrix with glass fiber, carbon fiber, or aramid fiber reinforcement) instead of plain thermoplastic resin. This composite construction provides the necessary spring constant and durability while maintaining the simplicity of the pultrusion 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
This approach enables the production of corrugated plastic composite springs with improved NVH characteristics, increased productivity, reduced component costs, and lower vehicle weight by forming a spring with a hollow corrugated structure using thermoplastic polymer materials and three-dimensional woven fabrics impregnated with thermosetting resin.
Implementation Method 1
a corrugated extrusion part (10) forming a pre-form (15) having a hollow corrugated structure
Implementation Method 2
a pultrusion part (30) impregnating the three-dimensional woven fabric (24) with thermosetting resin
Implementation Method 3
impregnating the three-dimensional woven fabric (24) with thermosetting resin and hardening the three-dimensional woven fabric
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.