Leaf Spring Stop Mechanism Aluminum Extrusion
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Solution Overview
Problem
Existing stop devices for limiting vertical deflection of leaf springs in motor vehicles are heavy due to their steel construction, leading to reduced payload and increased CO2 emissions, and require extensive machining and installation space for cable lines.
Innovation Solution
A stop device featuring a support structure made of extruded aluminum with a guide device for cable management, allowing for a lighter, cost-effective design that intercepts bending moments and supports the stop torque-free, thereby increasing payload and reducing emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a stop device with rubber buffer is attached to a vehicle carrier using a steel construction, then the stop device provides reliable support for the leaf spring, but the weight of the stop device increases significantly
Solution Approach 1:
The patent changes the material parameter from steel to aluminum for the support structure, reducing density and weight while maintaining structural integrity. The aluminum extruded profile is designed with optimized geometry to compensate for the lower material strength, achieving the same load-bearing capacity with reduced weight.
Solution Approach 2:
The patent uses a composite construction combining aluminum extruded profile with rubber buffer elements. The aluminum provides the structural framework and mounting capability, while the rubber buffers provide the damping and stopping function, creating a hybrid structure that optimizes both weight and performance.
2Strength
If a steel girder is used to attach the rubber buffer to the vehicle side member, then the stop device can withstand high bending moments, but the manufacturing cost increases due to forging and subsequent machining
Solution Approach 1:
The patent replaces the traditional forged steel beam construction with an aluminum extruded profile system. The extrusion process creates complex cross-sections directly during forming, eliminating the need for subsequent machining operations. The structural strength is achieved through optimized geometric design of the extruded profile rather than material selection alone.
Solution Approach 2:
The patent changes the manufacturing process parameters from forging and machining to extrusion. This process substitution reduces manufacturing steps, tooling requirements, and post-processing operations, thereby lowering production costs while maintaining the ability to withstand bending moments through design optimization.
3Ease of operation
If the support plate is directly attached to the vehicle carrier, then the installation is simple, but the installation space for cable lines is restricted
Solution Approach 1:
The patent segments the support structure into multiple functional components: the aluminum extruded profile provides structural support and mounting, while separate cable management elements (such as cable clips, conduits, or routed channels integrated into the extrusion) handle the cable lines. This segmentation allows independent optimization of each function without compromise.
Solution Approach 2:
The patent utilizes the three-dimensional space around and within the support structure by integrating cable management features into the extruded profile geometry. Cables are routed through channels, along surfaces, or secured with clips positioned in spaces that would otherwise be unused, effectively adding cable accommodation capability without increasing the footprint or compromising simplicity.
Data Source
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Figure 5~6
AI summary
The invention relates to a stop mechanism (10) for limiting a vertical spring deflection of a motor vehicle leaf spring that is mounted on an axle member, said stop mechanism (10) comprising a stop (12) that limits a vertical movement of the at least one leaf spring, a support structure (14) for supporting and mounting the stop (12) on a vehicle support (16), and a guiding device (18) for receiving and guiding at least one cable, a line (20) and/or a holder (48); according to the invention, the guiding device (18) is secured to the support structure (14).