Nested Shell Suspension Arm for Compact Chassis Packaging

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing suspension arms for vehicles require significant installation space and weight, leading to potential collisions and suboptimal kinematic properties during jounce and rebound movements.

Innovation Solution

A suspension arm design featuring two shell elements with open cross-sections, where the second shell element is partially arranged within the first, reducing installation space and weight while maintaining advantageous kinematic properties through a closed cross-section configuration and strategic connection of side wall sections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If traditional solid cross-section suspension arm design is used, then strength and rigidity are sufficient, but installation space and weight increase significantly

Engineering Contradiction:

Improveinstallation spaceVSAvoidstructural strength

Core Design Contradiction:

Volume of moving objectVSStrength

Solution Approach 1:

The patent applies nesting by placing the second shell element inside the first shell element, creating a nested configuration where one structural component is housed within another. This nested arrangement significantly reduces the overall volume and installation space requirements while maintaining the structural integrity needed for strength and rigidity.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent uses composite construction by combining two shell elements with different cross-sectional configurations (one open, one closed) to create a composite structural system. This composite design achieves optimal strength-to-volume ratio, providing sufficient structural strength while minimizing installation space requirements.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If traditional solid cross-section suspension arm design is used, then structural rigidity is maintained, but weight increases

Engineering Contradiction:

Improvesuspension arm weightVSAvoidstructural rigidity

Core Design Contradiction:

Weight of moving objectVSStability of the object's composition

Solution Approach 1:

The nested configuration of the second shell element within the first shell element reduces material usage and overall weight while the closed cross-section of the inner element provides structural rigidity. This nesting approach achieves weight reduction without compromising the stability and rigidity required for suspension arm functionality.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent applies local quality by giving different cross-sectional characteristics to different parts of the suspension arm structure. The first shell element has an open cross-section for weight reduction, while the second shell element has a closed cross-section for localized rigidity enhancement, creating an optimized distribution of structural properties throughout the component.

Inventive Principle:

Principle #3Local quality

3Volume of moving object

If compact suspension arm design is implemented, then installation space is reduced, but risk of collisions during jounce and rebound movements increases

Engineering Contradiction:

Improveinstallation spaceVSAvoidcollision prevention

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The nested configuration allows the suspension arm to achieve a compact overall envelope that reduces installation space, while the concentric arrangement of the two shell elements maintains adequate clearance and structural integrity during dynamic movements, preventing collisions with surrounding components during jounce and rebound cycles.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Strength

If open cross-section design is used for both shell elements, then manufacturing is simplified, but structural efficiency and rigidity decrease

Engineering Contradiction:

Improvestructural efficiencyVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent applies local quality by assigning different cross-sectional characteristics to different shell elements based on their specific functional requirements. The first shell element uses an open cross-section that is easier to manufacture, while the second shell element uses a closed cross-section that provides enhanced structural efficiency, creating an optimized balance between manufacturability and structural performance.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11820196B2Suspension arm for a chassis of a vehicle, in particular a motor vehicle, and vehicle, in particular a motor vehicle

Publication Date: 2023.11.21 AUDI AG

AI summary

A suspension arm for a chassis of a vehicle, having a first shell element which has a first open cross-section and having a second shell element which is connected to the first shell element and has a second open cross-section. The second shell element is arranged at least in part in the first open cross-section, and the open cross-sections are open in the same direction.