Fiber-Reinforced Plastic Axle Support with Integral Elastic Joints

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Solution Overview

Problem

Existing axle support structures for motor vehicles face challenges in economical series production due to complex mechanical requirements and inefficiencies, such as the need for additional rubber bearings and excess material at corners that require additional processing steps.

Innovation Solution

A single-shell or multi-shell frame element made of fiber-reinforced plastic with integral elastic connection points, designed to provide both elasticity and rigidity, eliminates the need for separate rubber bearings and simplifies production by integrating elastic properties directly into the frame element.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If axle supports are made from fiber-reinforced plastic, then material costs can be reduced and production simplified, but there is great deal of protruding material at the corners during production that has to be removed in additional process steps

Engineering Contradiction:

Improveproduction simplicityVSAvoidadditional processing time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent changes the geometric parameters of the frame element by providing recesses at the corners that exactly match the protruding material dimensions. This allows the protruding material to be retained and integrated into the final product, eliminating the need for additional cutting operations while maintaining production simplicity.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the previously harmful protruding material (which required additional removal steps) into a beneficial feature by designing recesses that accept and integrate this material. The protruding material that was considered waste or a production nuisance becomes an integral part of the final assembly, reducing processing time and costs.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Strength

If additional rubber bearings are added to meet mechanical requirements, then strength and rigidity can be improved, but device complexity and manufacturing costs increase

Engineering Contradiction:

Improvemechanical strengthVSAvoidstructural complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the function of separate rubber bearings into the frame element itself by providing recesses at the corners that directly receive and integrate the bearings. This integration eliminates the need for additional assembly steps and reduces structural complexity while maintaining the required mechanical strength through the optimized frame geometry and material distribution.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The frame element is designed to perform multiple functions: it provides structural support, incorporates elastic connection points for mounting, and integrates the rubber bearings directly into its structure. This multi-functionality eliminates the need for separate components and reduces overall device complexity while maintaining mechanical strength.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If elastic connection points are made integral with the frame element, then manufacturing steps are reduced and costs decreased, but achieving both elasticity and rigidity becomes more difficult

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidmechanical performance

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent applies local quality by providing recesses at specific corner locations of the frame element where elastic connection points are needed. The frame element has different properties in different locations: the recessed areas provide elasticity for mounting, while the rest of the structure maintains rigidity for load-bearing functions. This localized differentiation allows integral construction while achieving both elasticity and rigidity.

Inventive Principle:

Principle #3Local quality

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 cost-effective production while meeting mechanical demands, reducing jolting and improving driving comfort by allowing parallel shift along the vehicle's longitudinal axis and maintaining rigidity transverse to it, thus enhancing the overall efficiency and durability of the support structure.

Implementation Method 1

the at least one elastic connection point is essentially elastic in the direction of a longitudinal axis of the motor vehicle and is essentially rigid in a direction perpendicular to the longitudinal axis

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

a support structure, in particular an axle support for a motor vehicle, which is produced as a single-shell or multi-shell frame element made of fiber-reinforced plastic

Methodology Applied

Scientific EffectComposite materials: Composite Materials

Data Source

PatentEP2948362B1Support structure and method of producing a support structure

Publication Date: 2017.03.01 ZF FRIEDRICHSHAFEN AG

AI summary

The invention relates to a support structure (1), especially a cross-member for a motor vehicle, which support structure is produced as a single-shell or multi-shell fiber-reinforced plastics frame element (7). The frame element (7) comprises at least one elastic connection point (9, 9', 9", 9"') for connection to a unit, the at least one connection point (9, 9', 9", 9"') being designed as one piece with the frame element (7). The invention also relates to a method for producing support said structure (1).