Polyamide-11 Coated Metal Anti-Noise Element for Leaf Spring

Solution Overview

Problem

Existing anti-noise elements for spring bundles in vehicle suspension systems have limited service life due to material wear and increased production costs, with previous solutions using polymeric or metal materials with rubber pads either failing to prevent noise effectively or being overly expensive and heavy.

Innovation Solution

An anti-noise element comprising a metallic plate with a polyamide-11 thermoplastic resin coating, featuring a median protrusion or side flaps to secure position between spring blades, reducing direct contact and wear, while being lightweight and cost-effective.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If polymeric or composite rubber anti-noise elements are used, then noise is reduced, but service life is limited due to material wear and friction

Engineering Contradiction:

ImprovenoiseVSAvoidservice life

Core Design Contradiction:

Object-affected harmful factorsVSDuration of action of moving object

Solution Approach 1:

The invention uses a composite structure combining polyamide-11 thermoplastic resin coating on a metallic plate substrate. The polyamide-11 layer provides noise reduction through friction dampening, while the metallic substrate provides structural strength and wear resistance, creating a composite material solution that addresses both noise reduction and durability requirements

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention changes the material parameter from traditional polymeric/rubber materials to polyamide-11 thermoplastic resin coating on metal. This parameter change provides both the friction characteristics needed for noise reduction and the mechanical properties needed for extended service life under workload and friction conditions

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If metal plate with rubber pad is used, then noise is reduced and positioning is secured, but production time increases and costs increase

Engineering Contradiction:

ImprovenoiseVSAvoidproduction time

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The invention changes the material parameter from traditional polymeric/rubber materials to polyamide-11 thermoplastic resin coating on metal. This parameter change provides both the friction characteristics needed for noise reduction and the mechanical properties needed for extended service life under workload and friction conditions

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses a simpler construction without requiring studs, nuts, or complex bonding processes. The anti-noise element can be directly positioned between spring blades using its geometry, eliminating the need for additional fastening components and reducing assembly time and cost

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Object-affected harmful factors

If steel blade with elastomeric coating is used, then noise is reduced, but weight increases and construction costs increase

Engineering Contradiction:

ImprovenoiseVSAvoidweight

Core Design Contradiction:

Object-affected harmful factorsVSWeight of moving object

Solution Approach 1:

The invention applies the polyamide-11 thermoplastic resin coating only on the surfaces of the metallic plate that contact the spring blades, rather than using a heavy steel blade throughout. This localized application provides noise reduction at the contact points while minimizing unnecessary weight

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The invention uses a composite structure combining polyamide-11 thermoplastic resin coating on a metallic plate substrate. The polyamide-11 layer provides noise reduction through friction dampening, while the metallic substrate provides structural strength and wear resistance, creating a composite material solution that addresses both noise reduction and durability requirements

Inventive Principle:

Principle #40Composite materials

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 durable, cost-effective anti-noise element with extended service life and reduced noise, ensuring secure assembly and preventing premature blade fracture, thus enhancing the overall performance and longevity of the spring bundle system.

Implementation Method 1

Each anti-noise element comprises a metallic plate, covered with a coating in the form of a layer of polyamide-11 thermoplastic resin

Methodology Applied

Scientific EffectLubrication: Lubrication

Data Source

PatentUS20220196101A1Noise-reducing element for a leaf spring

Publication Date: 2022.06.23 RASSINI NHK AUTOPECAS LTDA

AI summary

The anti-noise element (EAR) is applied to separate the end portions of each two spring blades (LM), superimposed and adjacent, of a spring bundle (FM) and comprises a metal plate (10) covered by a coating (20) in polyamide-11 thermoplastic resin and incorporating a median protrusion (12) to be fitted and retained into a corresponding hole (F) provided at the end portion of the spring blade (LM) against which the anti-noise element (EAR) is seated and retained.