Suspension Spring Seat Bonding to Prevent Adhesive Crack-Off
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Solution Overview
Problem
In existing spring devices, adhesive overflow from the coil spring to the holding member can lead to cracks and early damage due to vehicle vibrations and changes over time, causing the adhesive to break away and rub against the coil spring, damaging the coating layer.
Innovation Solution
A spring device with a metal wire coated in a resin layer, integrated with an elastically deformable seat section featuring a groove for the wire, where the adhesive forms a thicker overflow portion to prevent excessive thinness and breakage, using an adhesive accumulation portion to restrict adhesive flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied to the holding member and the coil spring is placed on the adhesive-applied position, then the coil spring can be adhered to the holding member, but the adhesive is extremely likely to overflow from the adhered surfaces
Solution Approach 1:
The patent applies local quality by creating a protrusion with a specific shape on the holding member that locally controls adhesive distribution. The protrusion has a top surface that is inclined relative to the bottom surface, creating different adhesive thickness zones: a first adhesive layer on the inclined top surface and a second adhesive layer on the bottom surface, with the first layer being thinner than the second layer.
2Ease of manufacture
If the adhesive overflow part is thin, then the adhesive can flow smoothly, but cracks occur between the overflow part and the adhesion layer due to vibration and time
Solution Approach 1:
The patent implements beforehand cushioning by designing the protrusion shape and adhesive layer configuration in advance to prevent future failure. The first adhesive layer on the inclined top surface is designed to be thinner than the second adhesive layer on the bottom surface, creating a gradual transition that prevents stress concentration and crack formation during vehicle vibrations and time-dependent degradation.
3Device complexity
If the boundary between overflow part and adhesion layer is too thin, then adhesive application is simple, but the overflow part breaks away and rubs against the coil spring
Solution Approach 1:
The patent applies local quality by creating a protrusion with a specific shape on the holding member that locally controls adhesive distribution. The protrusion has a top surface that is inclined relative to the bottom surface, creating different adhesive thickness zones: a first adhesive layer on the inclined top surface and a second adhesive layer on the bottom surface, with the first layer being thinner than the second layer.
Solution Approach 2:
The patent implements beforehand cushioning by designing the protrusion shape and adhesive layer configuration in advance to prevent future failure. The first adhesive layer on the inclined top surface is designed to be thinner than the second adhesive layer on the bottom surface, creating a gradual transition that prevents stress concentration and crack formation during vehicle vibrations and time-dependent degradation.
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 configuration suppresses the early damage of the spring by maintaining a sufficient thickness of the adhesive overflow portion, preventing breakage and extending the lifespan of the spring.
Implementation Method 1
adhered to the wire by an adhesive
Implementation Method 2
seat section made of an elastically deformable material, bearing load acting on the spring section
Data Source
AI summary
This spring used for a suspension device for a vehicle is provided with: a metal wire material which constitutes a spring section and which has a cover layer provided on the surface thereof; and a seat section which is subjected to a load acting on the spring section, is formed from an elastically deformable material, has a groove section into which the wire material fits, and is bonded to the wire material by an adhesive. The minimum thickness of the portion of the adhesive, which protrudes from the groove section, is greater than or equal to the thickness of an adhesion layer formed in the groove section.