Vehicle Stabilizer Bar with Injection-Molded Pendulum Support

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Solution Overview

Problem

The assembly of existing vehicle stabilizers is complex and time-consuming due to the need for multiple individual components, particularly in connecting the stabilizer body and pendulum supports.

Innovation Solution

A stabilizer design featuring a curved torsion spring body with injection-molded connecting elements that integrate with pendulum supports, providing both articulated and solid connections to simplify assembly and reduce component count, utilizing fiber-plastic composite materials for weight and design advantages.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If separate pendulum supports are used and connected to the stabilizer body, then the stabilizer can be assembled with standardized components, but the assembly process becomes complex and time-consuming

Engineering Contradiction:

Improveassembly simplicityVSAvoidnumber of components

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines the pendulum support and connecting element into a single integrated component. The connecting element is directly connected to the pendulum support, eliminating the need for separate assembly steps and reducing the total number of components while maintaining the same functional capabilities.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connecting element is pre-connected to the pendulum support during manufacturing, creating a prefabricated assembly. This preliminary action simplifies the final installation process as the pre-assembled unit requires fewer steps to install compared to assembling individual components on-site.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If multiple individual components are used for the stabilizer assembly, then each component can be optimized independently, but the overall assembly cost and installation time increase

Engineering Contradiction:

Improveassembly speedVSAvoidnumber of components

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent merges multiple components (pendulum support and connecting element) into a single integrated unit, directly reducing the number of parts that need to be handled, transported, and assembled, thereby increasing assembly speed and productivity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

By pre-assembling the pendulum support and connecting element into a single component during manufacturing, the patent eliminates the need for time-consuming on-site assembly operations, significantly reducing installation time and improving overall productivity.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If traditional connection methods are used between stabilizer body and pendulum support, then assembly flexibility is maintained, but assembly costs and effort increase

Engineering Contradiction:

Improveassembly costVSAvoidinstallation effort

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The integration of the connecting element with the pendulum support creates a single component that eliminates the need for separate connection operations, reducing both assembly costs and installation effort while maintaining the same flexibility in assembly approaches.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connecting element is pre-attached to the pendulum support during manufacturing, converting a complex multi-step assembly operation into a simple single-step installation process, thereby reducing both cost and effort.

Inventive Principle:

Principle #10Preliminary action

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 design reduces assembly costs and time by creating a prefabricated composite component that simplifies installation, enhances weight efficiency, and optimizes space usage in vehicle chassis, while maintaining effective force transfer and stability.

Implementation Method 1

a first end of the connecting element is injection-molded onto an end of a pendulum support

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

a curved stabilizer body that forms a torsion spring

Methodology Applied

Scientific EffectTorsion spring: Torsion Spring

Implementation Method 3

a curved stabilizer body that forms a torsion spring

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11351836B2Stabilizer bar for a chassis of a motor vehicle, and method for producing such a stabilizer bar

Publication Date: 2022.06.07 ZF FRIEDRICHSHAFEN AG

AI summary

A stabilizer (1) for a chassis of a vehicle. The stabilizer has a curved stabilizer body (2) that forms a torsion spring, a pendulum support (5, 6) and a connecting element (7, 8). The connecting element (7, 8) connects the stabilizer body (2) and the pendulum support (7, 8) to one another. To reduce the cost and complexity of assembly. The stabilizer is characterized in that a first end (11) of the connecting element (7, 8) is injection-molded onto a pendulum support end (9).