Piezo-Resistive Elastomeric Suspension Support for Load Detection

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Solution Overview

Problem

Current suspension systems in motor-vehicles require complex and costly discrete displacement sensors for load detection, which are not compact and can be unreliable, failing to provide a simple and economical solution for improving comfort and grip.

Innovation Solution

Integration of a polymeric elastomeric material with carbon-based nanofillers, where piezo-resistive areas are created through laser irradiation for load detection, eliminating the need for additional sensors and logic circuitry, with conductive paths for electrical connection to an electronic control unit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If discrete displacement sensors are used for load detection in suspension systems, then load detection capability is achieved, but device complexity and installation cost increase

Engineering Contradiction:

Improveload detection capabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the load detection sensor functionality directly into the elastomeric support component itself by creating piezo-resistive areas within the material. This merging eliminates the need for separate discrete displacement sensors and their associated mounting hardware, thereby reducing device complexity and assembly steps while maintaining load detection capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The elastomeric support material serves multiple functions: it provides mechanical suspension support while simultaneously acting as a load sensor through its piezo-resistive properties. This multi-functionality reduces the overall system complexity by eliminating dedicated sensor components and simplifies installation while ensuring reliable load detection.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Measurement precision

If additional sensors and logic circuitry are used for load detection, then measurement accuracy is improved, but manufacturing cost and device complexity increase

Engineering Contradiction:

Improveload detection accuracyVSAvoidmanufacturing cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The sensing functionality is merged into the elastomeric material itself through laser-induced piezo-resistive areas. This eliminates the need for separate sensors and complex logic circuitry, reducing manufacturing costs while maintaining measurement precision through the material's inherent piezo-resistive response to applied loads.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces complex mechanical sensor systems and logic circuitry with a simpler electrical resistance-based detection method. The piezo-resistive areas provide direct electrical signals proportional to applied load, eliminating the need for additional mechanical components and complex electronic processing while maintaining measurement accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If piezo-resistive areas are created through laser irradiation in elastomeric material, then integration and reliability are improved, but manufacturing process complexity increases

Engineering Contradiction:

Improvesensor integration reliabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent uses laser irradiation to directly modify the elastomeric material's electrical properties, creating piezo-resistive areas without mechanical assembly steps. This substitution of traditional mechanical sensor installation with a direct material modification process improves integration reliability while the laser process itself, though advanced, consolidates multiple steps into a single manufacturing operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution provides a compact, reliable, and cost-effective means to detect load applied to suspension systems, enhancing vehicle comfort and grip by integrating load detection directly into the elastic support without additional sensors or unreliable circuitry.

Implementation Method 1

piezo-resistive areas where a polymeric material supplemented with carbon-based nanofillers of said body has been made locally piezo-resistive by laser irradiation, so as to define one or more electric deformation sensors capable of detecting the load applied on said elastic support

Methodology Applied

Scientific EffectPiezo-resistive effect: Piezoresistive Effect

Implementation Method 2

the body formed of polymeric elastomeric material supplemented with carbon-based nanofillers also comprises one or more conductive paths where the added polymeric material with carbon-based nanofillers has been made locally electrically conductive by means of laser irradiation

Methodology Applied

Scientific EffectLaser irradiation: Laser

Data Source

PatentUS10493814B2Elastic support with an integrated load sensor for suspension systems of a motor-vehicle

Publication Date: 2019.12.03 CENTRO RICERCHE FIAT SCPA

AI summary

An elastic support for on-board suspension systems of a motor-vehicle includes at least one body formed of polymeric elastomeric material supplemented with carbon-based nanofillers. An outer surface is provided with one or more piezo-resistive areas where a polymeric material supplemented with carbon-based nanofillers has been made locally piezo-resistive by laser irradiation so as to define one or more electric deformation sensors configured to detect the load applied on the elastic support.