Hybrid Suspension Member with Embedded Inserts
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Solution Overview
Problem
Existing wheel-carrying members for vehicle suspensions with hybrid structures are complex, time-consuming, and costly to manufacture, with metal inserts primarily functioning as load transfer elements rather than contributing to overall strength and stiffness.
Innovation Solution
A wheel-carrying member with a hybrid structure featuring a fibre-reinforced thermoplastic matrix body, embedded metal inserts, and a thermoplastic matrix laminate shell element, where the inserts are securely connected without adhesives and designed to function as load-bearing elements, reducing manufacturing time and increasing strength and stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a hybrid structure with metal inserts and thermoset polymeric matrix is used, then strength and stiffness are improved, but manufacturing cycle time increases due to curing step
Solution Approach 1:
The patent changes the polymeric matrix from thermoset to thermoplastic material. This parameter change eliminates the curing step required for thermoset materials, significantly reducing manufacturing cycle time while maintaining the hybrid structure's strength and stiffness through the fibre reinforcement and metal inserts.
Solution Approach 2:
The patent uses a composite material structure combining thermoplastic matrix with fibre reinforcement (such as carbon fibre or glass fibre). This composite approach provides the necessary strength and stiffness while allowing faster processing compared to thermoset materials, as thermoplastics can be molded and processed more quickly without curing requirements.
2Ease of manufacture
If metal inserts are designed only as load transfer elements, then manufacturing is simpler, but overall strength and stiffness of the wheel-carrying member are reduced
Solution Approach 1:
The patent designs the metal inserts to serve dual functions: as load transfer elements connecting the wheel-carrying member to other suspension components, and as load-bearing elements that contribute to the overall strength and stiffness of the structure. This multi-functionality eliminates the need for separate reinforcement elements, maintaining manufacturing simplicity while enhancing structural performance.
Solution Approach 2:
The patent merges the functions of load transfer and structural reinforcement into a single metal insert component. By integrating these functions, the design achieves both manufacturing simplicity and enhanced overall strength and stiffness without requiring additional separate elements or complex assembly steps.
3Ease of manufacture
If conventional materials (steel, aluminium, cast iron) are used, then manufacturing is straightforward, but weight of the wheel-carrying member increases
Solution Approach 1:
The patent employs composite materials consisting of a thermoplastic polymeric matrix reinforced with fibres (such as carbon fibre or glass fibre). This composite construction achieves a high strength-to-weight ratio, significantly reducing the weight of the wheel-carrying member compared to conventional metallic materials while maintaining ease of manufacture through molding processes.
Solution Approach 2:
The patent changes the material composition from dense metallic materials (steel, aluminium, cast iron) to a composite material system with a polymeric matrix and fibre reinforcement. This parameter change in material composition dramatically reduces weight while preserving manufacturability through thermoplastic processing techniques.
Data Source
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AI summary
The wheel-carrying member (10) has a hybrid structure comprising a body (30) in a composite material with a fibre reinforced thermoplastic matrix, at least one shell element (28, 28', 28", 28"') formed by a laminate with a thermoplastic matrix and fixed on an external side of the body (30), and a plurality of metal inserts (32, 34, 36, 38, 52) for connecting or fixing the wheel-carrying member (10) to other components (18, 22) of the suspension or of the vehicle, said metal inserts (32, 34, 36, 38, 52) being at least partially embedded in the body (30) so that they are firmly connected to the body (30) without the use of adhesive means.