Stabilizer Connection Plate Joining Through Alloy Oxide Regions

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Solution Overview

Problem

Conventional methods for manufacturing stabilizers result in the formation of Fe oxides on the inner surfaces of steel pipes, leading to gaps between base material portions due to the layered Fe oxides, which compromise the strength and integrity of the connection plate portions.

Innovation Solution

A stabilizer design featuring connection plate portions with alloy oxide regions where crystal grains from the base material portions straddle the alloy oxide region, ensuring a strong join between the base material portions, and a manufacturing process that includes simultaneous heating and oxygen reduction to minimize Fe oxide formation and scattering of alloy oxides, preventing gaps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional heating and forging methods are used to manufacture stabilizer connection plate portions, then the manufacturing process is simple and cost-effective, but Fe oxides form layered structures that create gaps between base material portions, compromising strength and integrity

Engineering Contradiction:
Improvestrength and integrity of connection plate portionVSAvoidmanufacturing process complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by performing oxygen reduction treatment before the forging step. The steel pipe is heated to form Fe oxides on the inner surface, then oxygen is reduced by introducing a reducing atmosphere or using a reducing agent before radial crushing. This preliminary removal of oxygen prevents the formation of harmful layered Fe oxide structures during subsequent forging, ensuring strong bonding between base material portions while maintaining the simplicity of the overall manufacturing process

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent changes the chemical and physical parameters during the heating and forging process. Specifically, it controls the oxidation state by adjusting the atmosphere composition (introducing reducing gases like nitrogen or carbon dioxide), temperature profiles, and timing of oxygen reduction. These parameter changes transform the Fe oxide layer from a harmful continuous structure into scattered alloy oxides embedded in the base material, eliminating gaps while maintaining manufacturing simplicity

Inventive Principle:
Principle #35Parameter changes

2Weight of moving object

If the stabilizer is made thinner to reduce weight, then weight reduction is achieved, but gaps between base material portions become more problematic and strength is compromised

Engineering Contradiction:
Improveweight of stabilizerVSAvoidstrength of connection plate portion
Core Design Contradiction:
Weight of moving objectVSStrength

Solution Approach 1:

By performing oxygen reduction treatment before forging, the patent eliminates the formation of continuous Fe oxide layers that would create gaps. This preliminary action ensures that even when the stabilizer is made thinner, the base material portions bond strongly without gap formation, maintaining strength while achieving weight reduction

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent converts the potentially harmful Fe oxides formed during heating into beneficial scattered alloy oxides through controlled oxygen reduction. Instead of forming continuous layers that create gaps, the oxides become dispersed particles embedded in the base material, which actually strengthen the structure. This allows thinner designs to maintain or even improve strength while reducing weight

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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 approach effectively prevents gaps between base material portions, ensuring the strength and integrity of the connection plate portions even when the stabilizer is made thinner, while maintaining cost-effectiveness by using common elements like Si, Mn, and Cr in the Fe alloy.

Implementation Method 1

a reduction step of causing a reduction reaction in the Fe oxides by using the easily oxidizable element as a reducing agent and removing oxygen from the Fe oxides

Methodology Applied
Scientific EffectReduction reaction: Reduction

Implementation Method 2

an oxygen reduction step of forming Fe oxides on inner peripheral surfaces of both end portions of the steel pipe

Methodology Applied
Scientific EffectOxidation: Oxidation

Data Source

PatentUS12179543B2Stabilizer and method for manufacturing stabilizer
Publication Date: 2024.12.31 NHK SPRING CO LTD
  • US12179543B2 patent drawing
  • US12179543B2 patent drawing
  • US12179543B2 patent drawing

AI summary

A stabilizer is a stabilizer including: a main body cylinder portion which is elastically deformable and a pair of connection plate portions respectively connected to a pair of left and right suspension devices, wherein the connection plate portion includes a pair of base material portions located on both sides in the connection plate portion in a plate thickness direction T and an alloy oxide region which is disposed between the pair of base material portions and in which alloy oxides are scattered, and wherein crystal grains constituting the pair of base material portions straddle the alloy oxide region in the plate thickness direction and the pair of base material portions are joined.