Integrated Resilient Control Arm for Vehicle Suspension
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Solution Overview
Problem
Conventional vehicle suspensions, such as helical spring or compressed air systems, occupy valuable space and increase weight, limiting utility and passenger space, and require multiple components.
Innovation Solution
A control arm with a resilient flex-element formed from a metal shell and a carbon-fiber reinforced plastic reinforcement, which acts as a spring to absorb kinetic energy during jounce and rebound, eliminating the need for conventional suspensions and reducing component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional helical spring or compressed air suspension is used, then the suspension provides adequate shock absorption, but the vehicle occupies more space and has increased weight
Solution Approach 1:
The patent combines the control arm structural component with a resilient flex-element into a single integrated unit. The control arm shell and flex-element work together as one component to provide both structural support and shock absorption functions, eliminating the need for separate spring and damper assemblies. This merging reduces the number of parts and overall vehicle weight while maintaining suspension performance.
Solution Approach 2:
The control arm in this patent serves multiple functions simultaneously: it provides structural support for the wheel assembly, acts as a suspension link connecting the wheel to the vehicle body, and functions as a spring through its resilient flex-element. This multi-functionality eliminates the need for dedicated spring components, reducing weight and complexity.
2Volume of moving object
If conventional helical spring or compressed air suspension is used, then the suspension provides adequate shock absorption, but less utility space is available for passengers or loads
Solution Approach 1:
By integrating the resilient flex-element directly into the control arm structure, the patent eliminates the need for separate spring assemblies that would occupy vertical space above the wheel well. This space-saving design allows for increased utility space or passenger space in the vehicle interior.
3Ease of manufacture
If conventional suspension components are used, then adequate shock absorption is provided, but more components need to be installed increasing cost
Solution Approach 1:
The integration of multiple functions into a single control arm component reduces the total part count, which directly lowers manufacturing costs through fewer components to produce, inventory, and assemble. The patent achieves this by making the control arm itself resilient through its flex-element design.
Solution Approach 2:
The control arm is divided into functional zones: a rigid shell portion for structural support and connection points, and a resilient flex-element portion for shock absorption. This segmentation allows each zone to be optimized for its specific function while being manufactured as an integrated component.
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
This solution provides a lightweight, cost-effective, and space-efficient suspension system that maintains the necessary strength and rigidity, allowing for improved driving properties and increased utility space without the need for additional suspension components.
Implementation Method 1
a resilient flex-element that is formed integrally with the reinforcement and extends therefrom to be supported or guided by a portion of the vehicle structure... the resilient flex-element serves as a spring, providing the control arm with a resilient, shock-absorbing function
Data Source
AI summary
There is provided a control arm comprising a shell-like shell of a first material and a reinforcement of a plastic material, wherein the reinforcement has a flex-element which protrudes therefrom and which can be supported or guided by means of a vehicle structure in order in the event of jounce and/or rebound of the suspension to produce a resilient action equivalent to a conventional spring.