Composite Suspension Arm Mounting Structure for High-Load Rigidity
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Solution Overview
Problem
Existing suspension arms for vehicles, particularly those made from carbon fiber reinforced plastic, face issues with damage and reduced rigidity due to high loads concentrated at mounting portions, leading to potential cracks and warping.
Innovation Solution
A suspension arm design where mounting portions are formed separately from the body portion and coupled in a surface-contact state, incorporating a bushing coupling portion, fastening portion with coupling plates, and a slip prevention mechanism to prevent slipping and enhance rigidity, with the body portion made of a lightweight carbon-based material and mounting portions made of a metallic material like aluminum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the suspension arm is made from carbon fiber reinforced plastic to reduce weight, then weight is reduced, but rigidity and resistance to concentrated loads at mounting portions deteriorate
Solution Approach 1:
The suspension arm is divided into two distinct parts: a body portion made of carbon fiber reinforced plastic for weight reduction, and mounting portions made of metallic material for strength. These parts are separately manufactured and then coupled together, allowing each part to be optimized for its specific function without compromise.
Solution Approach 2:
Different materials are used in different locations of the suspension arm. The body portion uses lightweight carbon fiber reinforced plastic where weight reduction is critical, while the mounting portions use strong metallic material where load-bearing capacity is critical. This local differentiation of material properties resolves the contradiction between overall weight reduction and localized strength requirements.
2Ease of manufacture
If mounting portions are integrated into the body portion, then manufacturing is simpler, but rigidity under high loads deteriorates due to material limitations
Solution Approach 1:
The mounting portions are separated from the body portion and manufactured as independent components. This segmentation allows the mounting portions to be made from metallic material with superior load-bearing properties, while the body portion can be manufactured using carbon fiber reinforced plastic through processes like resin transfer molding or autoclave curing.
Solution Approach 2:
The suspension arm employs a composite structure combining carbon fiber reinforced plastic and metallic material. The metallic mounting portions provide the necessary rigidity and strength to withstand high concentrated loads, while the carbon fiber body portion provides lightweight structural support. This composite approach resolves the contradiction between manufacturing simplicity and structural performance.
3Weight of moving object
If carbon fiber reinforced plastic is used for the entire suspension arm, then weight is reduced, but resistance to cracking and warping under concentrated loads deteriorates
Solution Approach 1:
The suspension arm uses different materials in different locations based on local stress requirements. The metallic mounting portions are placed specifically at locations where high concentrated loads are applied, providing local reinforcement against cracking and warping. The carbon fiber body portion maintains weight reduction in areas where loads are less concentrated.
Solution Approach 2:
By separating the mounting portions from the body portion and using different materials for each, the design protects the carbon fiber structure from the high stresses that would cause cracking and warping. The metallic mounting portions act as protective elements that absorb and distribute concentrated loads, preventing them from reaching the carbon fiber body.
Data Source
AI summary
There is provided a suspension arm for a vehicle used in a suspension device of a vehicle. The suspension arm may include: a body portion constituting a basic body of the suspension arm; and a plurality of mounting portions configured to connect the suspension arm to a wheel-side member or a vehicle-body-side member. At least one of the plurality of mounting portions may be configured to include a bushing coupling portion and a fastening portion formed to extend from the bushing coupling portion to one side, such that the fastening portion may be coupled to a coupling portion provided on one side of the body portion in surface-contact with state.