Wavy Leaf Spring Structure for Asymmetric Load Damping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing leaf springs in vehicle suspension systems face challenges in providing enhanced ride comfort and increased durability, particularly under asymmetric loads and heavy-duty conditions.
Innovation Solution
A leaf spring design featuring a wavy middle leaf plate with a longitudinally elongated center bolt aperture and a slidable arrangement, allowing relative movement between the middle leaf plate and adjacent plates, combined with roller bearings and guiding structures to reduce friction and guide longitudinal sliding, thereby improving load distribution and reducing stress concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional leaf spring with rigidly connected leaf plates is used, then structural simplicity is maintained, but ride comfort and durability are insufficient under asymmetric loads
Solution Approach 1:
The patent applies the dynamics principle by transforming the rigid connection between leaf plates into a dynamic, movable connection. The middle leaf plate is designed with a wavy structure that allows it to slide relative to the upper and lower leaf plates along the longitudinal direction, enabling the suspension system to adapt dynamically to asymmetric loads and improve durability
Solution Approach 2:
The patent applies segmentation by dividing the leaf spring into distinct functional segments: the upper leaf plate, the wavy middle leaf plate, and the lower leaf plate. This segmentation allows each component to perform its specific function independently, with the middle plate handling load distribution and sliding movements
2Ease of manufacture
If the leaf spring structure is simplified, then manufacturing ease is improved, but load distribution and stress management are insufficient
Solution Approach 1:
The patent applies curvature by designing the middle leaf plate with a wavy structure featuring crests and troughs. This curved geometry creates multiple contact points with the upper and lower leaf plates, significantly improving load distribution across the spring assembly while maintaining manufacturing feasibility
Solution Approach 2:
The patent applies local quality by concentrating the wavy structure specifically in the middle leaf plate rather than throughout the entire assembly. This localized modification optimizes load distribution at critical stress points while keeping the overall manufacturing process simple
3Reliability
If a fixed connection between leaf plates is used, then structural stability is maintained, but damping effect and ride comfort are reduced
Solution Approach 1:
The patent resolves this contradiction by introducing controlled movement through the slidable connection. The middle leaf plate can slide along the longitudinal direction while maintaining vertical stability, providing enhanced damping effects for ride comfort without compromising overall structural stability
Solution Approach 2:
The wavy middle leaf plate acts as an intermediary element between the upper and lower leaf plates. It mediates the interaction between these components by distributing loads through multiple contact points and allowing controlled sliding movements, thereby improving ride comfort while maintaining structural integrity
4Productivity
If the center bolt aperture is circular and uniform across all leaf plates, then manufacturing simplicity is maintained, but relative movement and load distribution are limited
Solution Approach 1:
The patent applies local quality by giving the middle leaf plate a distinct elongated aperture shape compared to the circular apertures in other leaf plates. This localized differentiation enables the middle plate to slide relative to adjacent plates while maintaining manufacturing efficiency through standardized hole shapes for most components
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 enhances damping effects, reduces vertical movement, and increases durability by optimizing load distribution and minimizing stress concentration, particularly beneficial for vehicles under asymmetric loads and heavy-duty applications.
Implementation Method 1
the middle leaf plate has a wavy structure in the longitudinal direction where troughs and crests of waves of the wavy structure form longitudinally distributed contact points for transfer of load between the middle leaf plate and the upper and lower leaf plates
Implementation Method 2
combined with roller bearings and guiding structures to reduce friction and guide longitudinal sliding
Implementation Method 3
when a load is transferred between the middle leaf plate and the upper or lower leaf plate via one or more of the contact points and the waves of the middle leaf plate thereby are stretched
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The invention concerns a leaf spring (1, 2) for a vehicle suspension system, the leaf spring (1, 2) comprising a middle leaf plate (4) located between an upper leaf plate (5) and a lower leaf plate (3) and a center bolt (6) extending through an aperture (8a, 8b, 8c) of each of the leaf plates (3, 4, 5) at a central region (9) of the leaf spring (1, 2), wherein the middle leaf plate (4) has a wavy structure in the longitudinal direction where troughs and crests of waves (20) of the wavy structure form longitudinally distributed contact points (21) for transfer of load between the middle leaf plate (4) and the upper and lower leaf plates (3, 5), wherein the center bolt aperture (8b) of the middle leaf plate (4) has an elongation in the longitudinal direction that is greater than that of the center bolt aperture (8a, 8c) of the upper and lower leaf plates (3, 5) so as to allow the middle leaf plate (4) to move in the longitudinal direction relative to the upper and lower leaf plates (3, 5), wherein the middle leaf plate (4) is slidably arranged relative to the upper and lower leaf plates (3, 5) in the longitudinal direction.