Elastic Loop with Woven Ribbon for Exhaust Suspension
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Solution Overview
Problem
Existing elastic loops for suspending motor vehicle exhaust systems are costly to produce while maintaining performance, particularly due to complex constructions that increase production costs without effectively achieving a two-stage spring characteristic.
Innovation Solution
An elastic loop with a basic body made of elastomeric material, featuring two receiving eyes and two sets of supporting bands, and a ring made of a pre-cut tear-resistant ribbon woven in consecutive one-layer and two-layer areas, which provides a two-stage spring characteristic and increased lateral stability at reduced production costs by using narrower ribbons and minimizing additional materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex construction with integrated loss safety in the basic body is used, then the reliability is improved, but the manufacturing cost increases
Solution Approach 1:
The elastic loop is divided into separate functional components: the basic body made of elastomeric material and the loss safety made of a pre-cut tear-resistant ribbon. This segmentation allows each component to be manufactured independently using optimized processes, reducing overall manufacturing cost while maintaining reliability through the dedicated loss safety function.
Solution Approach 2:
The loss safety function is extracted from the basic body and implemented as a separate pre-cut ribbon component. This extraction simplifies the basic body manufacturing process and allows the loss safety to be produced using cost-effective pre-cut ribbon technology, thereby reducing total production costs while preserving the reliability function.
2Ease of manufacture
If a pre-cut ribbon with consecutive one-layer and two-layer areas is used, then the manufacturing cost is reduced, but the structural complexity increases
Solution Approach 1:
The ribbon exhibits local quality variations with consecutive one-layer areas providing flexibility and two-layer areas providing strength and stability. This localized structural differentiation allows the ribbon to achieve optimal performance characteristics in different regions, enabling cost-effective manufacturing while managing structural complexity through functional zoning.
3Ease of manufacture
If narrower ribbons are used, then the production cost is reduced, but the strength may be compromised
Solution Approach 1:
The ribbon functions as a composite structure combining elastomeric material with tear-resistant ribbon material. This composite construction allows narrower ribbon dimensions to achieve the required strength and tear resistance by leveraging the complementary properties of the combined materials, thereby reducing production cost without compromising structural integrity.
Solution Approach 2:
The strength requirement is addressed by transitioning from increasing ribbon width to optimizing ribbon construction through consecutive one-layer and two-layer weaving areas. This dimensional approach allows narrower ribbons to achieve adequate strength through structural configuration rather than simply increasing cross-sectional area, reducing material cost while maintaining performance.
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 achieves a progressive spring characteristic and enhanced lateral stability while significantly reducing production costs by using a simpler weaving technique and narrower ribbons, ensuring durability under dynamic loads without the need for additional reinforcement or complex manufacturing steps.
Implementation Method 1
an elastic loop having a basic body made of an elastomeric material, the basic body comprising at least two elastic supporting bands
Implementation Method 2
a ring made of a pre-cut piece of a tear-resistant ribbon which is continuously woven in consecutive one-layer and two-layer areas
Data Source
AI summary
An elastic loop 1 is provided for suspending an exhaust system of a motor vehicle at a vehicle floor of the motor vehicle. The elastic loop 1 has a basic body 4 made of an elastomeric material 5, the basic body 4 enclosing two receiving eyes 6 and 7, one of which being provided for receiving a supporting part, and the other of which being provided for receiving a part to be supported, and the basic body 4 comprising at least two elastic supporting bands 8 and 9 which run from the one receiving eye 6 to the other receiving eye 7 in a main plane of extension and operation of the loop. Further, the elastic loop 1 has a ring 21 enclosing the basic body 4 in the main plane, the ring 21 being a pre-cut piece 24 of a ribbon 20 which is continuously woven in consecutive one-layer and two-layer areas, i.e. once in a single closed layer and once in two separate layers, the pre-cut piece 24 including an entire two-layer area and at least parts of both adjacent one-layer areas.