Modular Spring Hanger Structure for Stronger Trailer Frame Mounting
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Solution Overview
Problem
Existing spring hangers used in vehicle frames, particularly trailer frames, lack sufficient stiffness and strength, and their attachment methods to frame rails are not optimized for improved structural integrity and component mounting.
Innovation Solution
A spring hanger assembly comprising an inner and outer hanger section with perpendicular tabs and fingers, joined via fasteners or welding, featuring assembly holes and recesses for secure attachment to frame rails, allowing for enhanced stiffness and strength while accommodating various suspension components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If simple one piece braces are welded directly to the frame, then manufacturing is simple, but stiffness and strength are insufficient
Solution Approach 1:
The spring hanger is divided into multiple sections (inner hanger section and outer hanger section) that can be manufactured separately and then assembled together using fasteners. This segmentation allows each section to be optimized for strength while maintaining manufacturing simplicity through modular construction.
Solution Approach 2:
The spring hanger combines different structural elements (inner and outer sections with tabs and fingers) into a composite assembly that achieves superior strength and stiffness compared to a simple one-piece design, while still using common materials and manufacturing processes.
2Ease of manufacture
If simple one piece braces are welded directly to the frame, then manufacturing is simple, but structural integrity is compromised
Solution Approach 1:
By segmenting the spring hanger into multiple sections connected by fasteners, the design achieves reliable structural integrity through distributed connection points while maintaining ease of manufacture through modular assembly.
Solution Approach 2:
The inner and outer hanger sections are pre-formed with specific geometries (tabs, fingers, mounting holes) that enable reliable assembly and secure attachment to the frame rail, ensuring structural integrity is built into the design from the outset.
3Reliability
If frame rail attachment is optimized for improved structural integrity, then reliability improves, but device complexity increases
Solution Approach 1:
The segmented design with inner and outer sections provides multiple attachment points and pathways for securing the spring hanger to the frame rail, improving reliability while the modular nature keeps complexity manageable through standardized connection methods.
Solution Approach 2:
The spring hanger design incorporates multiple features (tabs for suspension component mounting, fingers for frame rail attachment, mounting holes) that serve different functions within a unified structure, achieving reliable multi-point attachment without proportionally increasing complexity.
Data Source
AI summary
A spring hanger assembly may be formed pieces shaped to increase the stiffness and strength. The spring hanger assembly may comprise separate pieces, such as an inner section and an outer section. The spring hanger assembly may be attached to a frame using fasteners or hucks.