Hollow-Core Multipoint Link for Lighter Vehicle Undercarriages

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Solution Overview

Problem

Existing multipoint links for vehicle undercarriages, particularly those with solid core elements, have high mass due to high-density foamed materials, leading to increased production costs and complexity, and are not optimized for high-volume production.

Innovation Solution

A multipoint link with a core element constructed as a hollow body comprising two shell elements, allowing for reduced material input and mass, with preimpregnated rovings for increased winding speed and selective placement, and internal supporting structures for enhanced load absorption and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a solid core element made from high-density foamed material is used, then the multipoint link achieves sufficient structural strength and shape stability, but the mass of the component increases significantly

Engineering Contradiction:

Improvestructural strengthVSAvoidmass

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The core element is divided into multiple shell elements (first shell element, second shell element, etc.) that are joined together to form a hollow body structure. This segmentation reduces material usage and mass while maintaining the necessary structural strength through the distributed framework of shell elements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The core element is constructed as a hollow body with porous or cellular structure formed by joining multiple shell elements, rather than using solid high-density foam. This porous construction reduces mass while the shell elements provide the necessary structural support.

Inventive Principle:

Principle #31Porous materials

2Shape

If a solid core element is used, then the multipoint link maintains its shape during the winding process, but the production cost and complexity increase

Engineering Contradiction:

Improvecomponent contourVSAvoidproduction complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The core element is segmented into multiple shell elements that can be produced separately and then joined. This reduces the complexity of producing a single large solid core while maintaining shape stability during winding through the distributed structural support of multiple shells.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The hollow body core element with multiple shells is designed as a cost-effective alternative to solid cores, using less material and enabling simpler production processes. The reduced material input and modular construction lower both material costs and production complexity.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Force

If high-density foamed material is used for the core element, then the multipoint link achieves sufficient load-bearing capacity, but the material cost and mass increase

Engineering Contradiction:

Improveload-bearing capacityVSAvoidmaterial input

Core Design Contradiction:

ForceVSQuantity of substance

Solution Approach 1:

The core element is segmented into multiple shell elements that collectively provide load-bearing capacity without requiring high-density foam. The distributed shell structure efficiently carries loads while using significantly less material than a solid core would require.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The multipoint link uses a composite construction combining the hollow body core element made from multiple shell elements with the outer layer of at least one roving. This composite structure achieves sufficient load-bearing capacity with reduced material input compared to using high-density foam alone.

Inventive Principle:

Principle #40Composite materials

4Weight of moving object

If a disposable core element is used, then the mass is reduced, but the production expenditure and removal complexity increase

Engineering Contradiction:

ImprovemassVSAvoidproduction expenditure

Core Design Contradiction:

Weight of moving objectVSEase of manufacture

Solution Approach 1:

The core element is segmented into multiple shell elements that form a permanent hollow body structure, eliminating the need for disposable cores. This segmented permanent structure reduces mass compared to solid cores while avoiding the high production expenditure and removal complexity associated with disposable cores.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention rejects the disposable core approach in favor of a permanent hollow body structure made from multiple shells. This permanent structure, while requiring initial production investment, eliminates ongoing removal costs and complexity, making it more economical for high-volume production.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS12138983B2Multi-point link for an undercarriage of a vehicle

Publication Date: 2024.11.12 ZF FRIEDRICHSHAFEN AG

AI summary

The invention is directed to a multipoint link (1) for an undercarriage of a vehicle, comprising a core element (5) formed from a foamed material and at least one roving (10) of bundled continuous filaments wound around the core element (5), wherein the at least one roving (10) winding around the core element (5) in at least one layer forms an outer layer of the multipoint link (5), wherein the core element (5) is constructed as a hollow body which comprises at least two shell elements (11, 12).