Hybrid Strut Weight Reduction via Composite Outer Shell
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Solution Overview
Problem
The existing shock absorbers in vehicles, made of metal materials like steel, are heavy and contribute to increased energy consumption and pollution, making it difficult to reduce weight while maintaining mechanical strength and stiffness.
Innovation Solution
A hybrid strut design is implemented, where a metal inner portion is combined with a composite material outer portion, featuring folded ends and a middle seat for supporting the suspension spring, enhancing engagement and reinforcement with stiffening ribs, to reduce weight while maintaining mechanical strength and stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the strut is manufactured in a monoblock manner using metal material, then mechanical strength and stiffness are maintained, but weight increases
Solution Approach 1:
The strut is constructed using composite materials, specifically a metal inner portion (such as aluminum alloy) combined with a composite outer portion (such as carbon fiber reinforced plastic). This composite structure maintains the necessary mechanical strength and stiffness while significantly reducing the overall weight compared to traditional monoblock metal construction.
Solution Approach 2:
The strut is divided into distinct segments: an inner portion and an outer portion. The inner portion provides structural support and houses the suspension spring, while the outer portion provides additional strength and aesthetic coverage. This segmentation allows each part to be optimized for its specific function, achieving weight reduction without compromising overall strength.
2Stability of the object's composition
If the strut is manufactured in a monoblock manner using metal material, then stiffness is maintained, but weight increases
Solution Approach 1:
The composite outer portion made of materials like carbon fiber reinforced plastic provides high stiffness-to-weight ratio. When properly designed and integrated with the metal inner portion, this composite structure maintains the necessary stiffness for wheel support and steering while dramatically reducing weight compared to solid metal construction.
Solution Approach 2:
Different portions of the strut are designed with different material properties and structural characteristics. The inner portion requires high strength for structural support, while the outer portion can be optimized for stiffness and aerodynamics. This local differentiation allows each region to contribute optimally to the overall performance without unnecessary weight.
3Weight of moving object
If the inner portion is folded and integrated with the outer portion, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The inner portion is pre-formed with folded ends before being integrated with the outer portion. This preliminary shaping allows the metal inner portion to be manufactured separately with optimized geometry, then assembled into the final configuration. This approach simplifies the overall manufacturing process compared to attempting to form the entire complex shape in a single operation.
Solution Approach 2:
The metal inner portion is nested within the composite outer portion, with the folded ends of the inner portion integrated into the outer portion's structure. This nesting arrangement allows both components to be manufactured separately using their optimal processes, then assembled together, reducing overall weight while maintaining structural integrity.
Data Source
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AI summary
A shock absorber mounted on a vehicle includes an inner portion that is made of a metal and has a first upper end and a first lower end, and an outer portion that is made of a composite material and is integrally formed with the inner portion. The outer portion has at least one of a second upper end on which the first upper end of the inner portion is folded and a second lower end on which the first lower end of the inner portion is folded, and a middle portion that has a seat for supporting a suspension spring.