Hollow Metal Pipe Stabilizer Link With Resin Insert Molding
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Solution Overview
Problem
Conventional stabilizer links made of resin have significant displacement under axial load due to lower stiffness compared to steel, which can lead to failure in meeting elastic lift requirements, and there is a need for reduced weight while maintaining strength.
Innovation Solution
A link arm member with a support bar made from a hollow metal pipe sealed at both ends, integrated with resin housings formed by insert molding, featuring flat plate parts and recesses for enhanced strength and sealing, and reinforced with fiberglass for improved material properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If an all-resin support bar is used to reduce weight, then weight is reduced, but the flexural modulus becomes too low (approximately 6 GPa) causing excessive stretch under axial load and failure to meet elastic lift requirements
Solution Approach 1:
The patent uses a composite structure combining resin and metal materials. The support bar has a hollow metal pipe core (providing high flexural modulus of approximately 210 GPa) surrounded by resin material (providing damping and corrosion resistance). This composite structure achieves both weight reduction and sufficient strength by leveraging the complementary properties of both materials.
Solution Approach 2:
The patent applies different materials to different regions of the support bar. The hollow metal pipe is positioned in the core region where high strength is most needed, while the resin material surrounds it providing additional structural support and environmental protection. This local differentiation of material properties optimizes the overall performance.
2Manufacturing precision
If the width of the resin support bar is increased to equalize Iy and Ix, then the second moment of area is improved, but the stretch under axial load remains excessive due to the inherently low flexural modulus of resin
Solution Approach 1:
Instead of relying on geometric modifications alone, the patent uses composite materials to fundamentally solve the strength issue. The metal core provides the necessary stiffness to prevent excessive stretch, while the resin surrounding it provides additional structural support and allows for optimized cross-sectional geometry.
3Strength
If a hollow metal pipe is used for the support bar to increase strength, then the flexural modulus increases (approximately 210 GPa), but weight reduction benefits are diminished compared to all-resin construction
Solution Approach 1:
The hollow metal pipe structure concentrates metal material where it is most needed - in the core region providing primary structural support - while leaving the outer regions for resin material. This localized use of metal minimizes weight while maintaining necessary strength.
Solution Approach 2:
The composite structure allows the metal component to provide high strength where needed while the resin component provides additional support and environmental protection, achieving an optimal balance between weight and strength that neither material could achieve alone.
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 achieves a balance of reduced weight and high strength, with minimal displacement under load, effectively addressing the limitations of resin stabilizer links by integrating metal and resin components for enhanced performance.
Implementation Method 1
a support bar (1a) which is sealed by plastically deforming a hollow metal pipe at both ends thereof
Implementation Method 2
a housing part (1b) made of resin which is arranged at each end of the support bar (1a) and has a receiving hole (1b3) for receiving a ball part (10b) of a ball stud (10), wherein the housing part is formed by insert molding with the support bar
Data Source
AI summary
A link arm member of the present invention is used in a vehicle for connecting a suspension and a stabilizer, and includes: a support bar that is sealed by plastically deforming a hollow metal pipe at both ends thereof; and a housing part made of resin that is arranged at each end of the support bar and has a receiving hole for receiving a ball part of a ball stud to which the suspension or the stabilizer is fixed, wherein the housing part is formed by insert molding with the support bar.