Undulating Fibre-Composite Leaf Spring Ends
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Solution Overview
Problem
Conventional leaf spring arrangements made of fibre-composite materials face issues with relative movement between the leaf spring and bearing eye holder under dynamic loads, leading to wear and potential shifting, which requires material reworking at the ends for secure accommodation.
Innovation Solution
A leaf spring arrangement with fibre-composite material ends configured in an undulating shape to fit seamlessly into corresponding receptacles of the bearing eye holder, maintaining a homogeneous fibre volume ratio along the entire length without material addition or removal, ensuring secure retention and preventing shifting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical fastening means (clamping sleeves or through-bolts) are used to connect the leaf spring to the bearing eye holder, then the leaf spring can be connected in a force-fitting manner, but relative movements occur under dynamic loads resulting in increased wear and potential shifting
Solution Approach 1:
The end regions of the leaf spring are formed with undulating contours (curved surfaces) that complement corresponding recesses in the bearing eye holder, creating a form-fitting connection that prevents relative movement while distributing loads evenly across the curved contact surfaces
2Reliability
If the ends of the leaf spring are provided with additional elements for form-fitting accommodation, then secure retention in the bearing eye holder is achieved, but the fibre composite structure becomes non-homogeneous due to material addition or removal
Solution Approach 1:
The undulating form-fitting features are integrated directly into the existing fibre composite structure of the leaf spring end regions, allowing localized shape modification without adding or removing material, thus maintaining homogeneous fibre distribution and composite integrity throughout the entire component
Solution Approach 2:
The contour of the end regions is modified by changing the geometric parameters of the fibre reinforcement layout during manufacturing, creating undulating surfaces that achieve form-fitting accommodation while preserving the homogeneous fibre composite structure through controlled variation of fibre orientation and density
3Reliability
If the leaf spring ends are reworked by inclusion or removal of material to achieve form-fitting accommodation, then secure accommodation in the bearing eye holder is achieved, but production complexity and manufacturing time increase
Solution Approach 1:
The undulating form-fitting contours are pre-formed in the end regions of the leaf spring during the initial composite manufacturing process (such as RTM or autoclave curing), eliminating the need for subsequent material addition, removal, or post-processing operations to achieve proper accommodation in the bearing eye holder
Data Source
AI summary
The invention relates to a leaf spring arrangement having a leaf spring made of a fibre-composite material and at least one bearing eye holder, wherein at least one end of the leaf spring is accommodated in a retaining element of the at least one bearing eye holder in a form-fitting manner in a longitudinal direction of the leaf spring, wherein the leaf spring has a length and a central longitudinal plane, wherein the leaf spring has, along its length, perpendicularly to the central longitudinal plane, a cross section in which both a depth and a height are constant along the entire length of the at least one end of the leaf spring, wherein the at least one end of the leaf spring is formed in an undulating manner, wherein the retaining element of the at least one bearing eye holder has a receptacle with a matching undulating shape, wherein the at least one end of the leaf spring has at least one undulation, wherein the receptacle of the at least one bearing eye holder is configured to accommodate the at least one undulation of the leaf spring. The leaf spring arrangement is distinguished by the fact that the at least one end of the leaf spring has at least two undulations, wherein the receptacle of the at least one bearing eye holder is configured to accommodate the at least two undulations of the leaf spring in a form-fitting manner.