Fiber Composite Air Spring Carrier for Commercial Vehicle Axles
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Solution Overview
Problem
Conventional air spring carriers for commercial vehicles are heavy, have variable load-bearing capacity due to weld seam quality, require complex tools, and are difficult to manufacture reliably, especially for vehicles with demanding applications.
Innovation Solution
An air spring carrier made from a fiber composite material with a base body and support arms, featuring integrated fastening means and optional reinforcement elements, produced using methods like winding or laminating, which allows for customizable properties and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metal air spring carriers are used, then high strength and load-bearing capacity are achieved, but the component weight increases significantly
Solution Approach 1:
The patent applies composite materials by constructing the air spring carrier from multiple layers of fiber-reinforced plastic materials (such as carbon fiber or glass fiber reinforced polymers) arranged in different orientations. This layered composite structure provides high strength and load-bearing capacity comparable to metal while significantly reducing the component weight, directly resolving the contradiction between strength and weight.
2Strength
If welded metal half-shells are used to manufacture air spring carriers, then structural integrity is achieved, but variable load-bearing capacity due to weld seam quality issues occurs
Solution Approach 1:
The patent eliminates welding by using composite material construction where multiple fiber-reinforced plastic layers are bonded together through resin matrices. This approach ensures uniform and consistent load-bearing capacity across all components, as the composite bonding process provides predictable and controllable joint strength without the variability inherent in weld seam quality.
Solution Approach 2:
The patent merges the functions of multiple metal half-shells and welded brackets into a single integrated composite component. The fiber reinforcement and resin matrix work together as a unified structure, eliminating the need for separate welded connections and ensuring consistent structural integrity throughout the entire air spring carrier.
3Shape
If complex metal forming tools are used for manufacturing half-shells, then component shape is achieved, but manufacturing complexity and effort increase
Solution Approach 1:
The patent changes the manufacturing parameters from complex metal forming processes to composite material layup and curing processes. Fiber-reinforced plastic materials can be shaped using simpler tooling where layers are laid up in molds and then cured, allowing for complex geometries to be achieved with less sophisticated and less expensive manufacturing equipment compared to precision metal forming.
Solution Approach 2:
The use of composite materials enables the air spring carrier to achieve complex shapes through the flexibility of fiber placement and layering in molds, eliminating the need for complex metal forming tools and reducing manufacturing effort while maintaining the required component geometry.
4Strength
If welded brackets are added to metal air spring carriers, then load-bearing capacity is improved, but manufacturing reliability decreases due to weld seam variability
Solution Approach 1:
The patent merges the brackets and main body into a single integrated composite component where fiber reinforcement continues uninterrupted through what would have been separate welded parts. This integration eliminates welding operations entirely, ensuring consistent manufacturing quality and reliability while maintaining or improving load-bearing capacity through the continuous fiber structure.
Solution Approach 2:
The composite material construction allows brackets to be formed as an integral part of the air spring carrier through the same layup and curing process, eliminating variable weld seam quality and ensuring consistent manufacturing precision and process reliability across all produced components.
Data Source
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AI summary
The invention relates to an air spring support (1) for an air-sprung axle (11) of a motor vehicle, preferably a commercial vehicle, comprising a base body (2) having a central section (3) and two support arms (4) arranged on opposite sides of the central section (3); a first fastening means (5, 5', 6) for connecting the air spring support to the axle, which is arranged on the central section (3); and a second fastening means (7) for holding an air spring (10) and/or a damping element (9), which is provided on each arm (4). According to general principles of the invention, the central section (3) and the support arms (4) form a single component, and the base body (3) is made of a fiber composite material.