Vehicle Stabilizer with Overmolded Metal Frame
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Solution Overview
Problem
Current stabilizers for vehicle suspension systems face challenges in balancing weight, volume, and rigidity, with metal stabilizers being heavy and prone to corrosion, aluminum stabilizers lacking rigidity, and polymeric stabilizers requiring larger volumes for equivalent rigidity.
Innovation Solution
A stabilizer design featuring a polymeric body overmolded on a metal frame, which reduces weight and volume while maintaining high rigidity and resistance, achieved by using a metal frame with two identical parts and strategically positioned holes and tabs for improved mechanical properties and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal stabilizer is used, then high rigidity is achieved, but weight increases and corrosion resistance decreases
Solution Approach 1:
The patent applies composite materials by combining a polymeric body with an internal metal frame structure. The polymeric material provides corrosion resistance and reduces weight, while the embedded metal frame maintains the required rigidity and structural strength. This composite approach resolves the contradiction between achieving high rigidity through metal while reducing weight and improving corrosion resistance.
2Weight of moving object
If an aluminum stabilizer is used, then weight is reduced, but rigidity decreases
Solution Approach 1:
The patent uses a composite structure with a polymeric body containing an internal metal frame. This allows the stabilizer to achieve weight reduction similar to aluminum while maintaining or exceeding the rigidity of traditional metal stabilizers through the reinforced frame structure embedded within the polymer matrix.
Solution Approach 2:
The stabilizer is segmented into distinct functional zones: the polymeric body providing overall form and corrosion resistance, and the internal metal frame providing structural rigidity. This segmentation allows each material to perform its optimal function, achieving light weight while maintaining high rigidity where needed.
3Weight of moving object
If a polymeric stabilizer is used, then weight and cost are reduced, but volume increases to achieve equivalent rigidity
Solution Approach 1:
The patent employs composite materials with a polymeric body and internal metal frame, allowing the stabilizer to maintain compact volume while achieving the required rigidity. The metal frame acts as a structural reinforcement that enables the polymeric body to achieve high stiffness without increasing volume, thus resolving the contradiction between weight reduction and volume control.
Data Source
AI summary
The present disclosure relates to a stabilizer for vehicle suspension, comprising a longitudinal polymeric body with a metal frame having two ends (3) and a central sector (2), having a hole (4) at each end (3) wherein there is housed a ball joint (7), where the frame is formed from two metal parts (1) having an open section which are arranged opposite one another on their open sides, the central sector (2) of each part (1) comprising two tabs (6) located in opposition on each side and facing the open side, and the ends (3) comprising rims (3′) such that the two opposing parts (1) rest on the tabs (6) and on the rims (3′) and are embedded in an overmolded body (5) which externally coats them and fills the inner space defined by the two opposing metal parts (1).