Fiber-Reinforced Four-Point Link for Vehicle Suspension
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Solution Overview
Problem
Existing four-point links for vehicle wheel suspensions, particularly in commercial vehicles, face challenges in mass production and cost reduction while maintaining performance, with previous solutions either being heavy and costly or disadvantageous in large-scale production.
Innovation Solution
A four-point link made of fiber-reinforced plastic materials, featuring a core element, pre-impregnated thread, and support arms, where the thread is non-positively connected to the core and support arms, providing defined torsional rigidity and lateral stiffness, and allowing for efficient production through robotic winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a four-point link is made of metal or welded sheet metal/cast iron, then strength and durability are ensured, but weight increases and production costs rise
Solution Approach 1:
The patent applies composite materials by combining a metal core element with fiber-reinforced plastic thread wound around it. This creates a hybrid structure that leverages the strength of metal where needed (core element) and the weight-saving properties of composites (thread wrapping), thereby reducing overall weight while maintaining required strength levels.
Solution Approach 2:
The invention implements local quality by using a metal core element only where structural strength is critical, while the fiber-reinforced plastic thread provides strength and stability in other areas. This localized material distribution optimizes the weight-strength ratio by applying each material where it is most effective.
2Weight of moving object
If a four-point link is made of fiber-reinforced plastic with integral design, then weight is reduced, but suitability for mass production deteriorates
Solution Approach 1:
The patent segments the four-point link into two main components: a metal core element and fiber-reinforced plastic thread. These can be manufactured separately using optimized processes (core element by casting or stamping, thread by winding) and then assembled, significantly improving mass production suitability compared to integral molding while maintaining weight advantages.
Solution Approach 2:
The metal core element acts as an intermediary that facilitates mass production. It provides a stable, easily manufactured substrate that can be produced in high volumes through casting or stamping, while the fiber thread is applied in a controlled winding process. This intermediary structure enables efficient assembly and automation in mass production environments.
3Weight of moving object
If fiber-reinforced plastic material is used, then weight is reduced and roll stabilization is enhanced, but production time and costs increase
Solution Approach 1:
The patent implements continuous useful action through the robotic winding process, where the fiber-reinforced plastic thread is continuously wrapped around the metal core element without interruption. This continuous process, as opposed to discrete step-by-step assembly, significantly reduces production time while maintaining the weight and performance benefits of fiber-reinforced plastic materials.
4Manufacturing precision
If complex assembly of multiple components is used, then manufacturing precision is improved, but device complexity and production costs increase
Solution Approach 1:
The patent merges the core element and the fiber-reinforced plastic thread into a integrated hybrid structure. The thread is wound directly around the core element and bonded to it, creating a unified component that achieves high manufacturing precision through the winding and bonding process itself, rather than requiring complex post-assembly operations. This merging reduces assembly complexity while maintaining precision.
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 design enhances roll stabilization, lateral guidance, and comfort by setting a defined kinematics, reducing the load on bearing elements and enabling high-volume production with reduced production time and costs.
Implementation Method 1
a fiber-reinforced plastic material, featuring a core element, pre-impregnated thread, and support arms, where the thread is non-positively connected to the core and support arms
Implementation Method 2
the thread being pre-impregnated with a resin
Implementation Method 3
The torsion element serves to stabilize the four support arms against pivoting. The support arms and the torsion element are arranged in such a way that pivoting of the respective support arm, ie twisting of the respective support arm about the torsion axis, is accompanied by torsion of the torsion element.
Implementation Method 4
defined torsional rigidity and lateral stiffness
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The invention relates to a four-point link (1) for a wheel suspension of a vehicle, comprising a core element (2), a thread (3), and four bushings (6). The thread (3) is pre-impregnated with a resin, and the core element (2) has a torsional element (4) and four support arms (5) which are integrally connected to the torsional element (4). Each bushing (6) is arranged on a respective distal end of each support arm (5) in order to receive a respective bearing element. The core element (2) and each bushing (6) is at least partly wound with the thread (3) in order to connect each bushing (6) and the thread (3) together at least in a formfitting manner. The invention also relates to a method for producing the aforementioned four-point link (1).