WO2019209199A2

WO2019209199A2 - Multi-material stabilizer bar and production method therof

Info

Publication number: WO2019209199A2
Application number: PCT/TR2018/050671
Authority: WO
Inventors: Mehmet Akif ÜNAL; Ferhunde Sedef KARAGÜL; Merve ERSOY; Nuri Bülent ERSOY; Semih ÇAKIL; Ayşe Meriç KARTAL BERKER; Yunus Emre ÖZÇELİK
Original assignee: Borusan Teknoloji̇ Geli̇şti̇rme Ve Arge A.Ş.; Boğazi̇çi̇ Üni̇versi̇tesi̇
Priority date: 2017-11-08
Filing date: 2018-11-08
Publication date: 2019-10-31
Also published as: WO2019209199A3

Abstract

The invention is related with a stabilizer component and a method of obtaining a stabilizer component which interconnects the short torque torsion bar with wheels, and which is located between the right and left wheels of the suspension system of the vehicle; which comprises reinforcement fibers arranged angularly with 90° to each other and +45° and -45° to the lateral, obtaining a torsion bar with a hollow core by using a unilateral fiber arrangement of 0° to said reinforcement fibers and by adding a resin; obtaining a bar by placing an inner bar with a diameter sufficient to contact the inner surface of said torsion bar, and obtained by installing the lever arms made of a metal, composite or polymer material on both ends of said bar.

Description

MULTI-MATERIAL STABILIZER BAR AND PRODUCTION METHOD THEROF

TECHNICAL FIELD

The invention within the automotive sector, is related with a suspension element which is also called a stabilizer bar, an anti roll bar, roll bar, anti-sway bar, sway bar which is located between the right and left wheels of the suspension system of a vehicle, and which interconnects the short torsion bar with the wheels of the vehicle.

The invention is particularly related with a hybrid stabilizer bar with reduced weight, which is manufactured with reinforced composite material.

PRIOR ART

The body of a vehicle sways outward at turns due to the centrifugal force. As a result of the sway, the suspension system respectively on the right and left of the vehicle becomes imbalanced and it changes the rotational angle of right and left wheels. By means of the stabilizer bar, the right and left wheels are balanced during sway, and steering control is increased as a result. The stabilizer bar is one of the key suspension elements that increase driving safety.

Particularly in order to prevent lateral swaying of the vehicle due to the centrifugal force while turning at a road bend, the stabilizer bar presses the wheel at the inner side of the turn, and enables a safe turn. During said action, the bar is subjected to torsion load, and the lever arms are exposed to a bending load. Therefore, the stabilizer bars are required to resist the forces determined by vehicle manufacturers.

Stabilizer bars are generally made of metal, and preferably made of steel; however, with the advancement of technology at present, they have started being made of different alloys or composite materials with a certain configuration. However, the metal stabilizer bars made of said steel or iron material cause extra weight on the vehicle. Meanwhile, the products developed with a composite material that enables reducing the weight, as an alternative to metal bars, fail to provide sufficient torsion force resistance and/or their production costs are high.

The European Patent Office document, with the publication number EP285737 describes the production method of a stabilizer bar, which consists of a steel, single component with a hollow core, which is lighter compared to the solid bars in the prior art, that was designed to increase resistance against fatigue and cracks. The scope of the invention aims at increasing resistance against fatigue cracks particularly. The method comprises the production steps of the thermal treatment of the stabilizer bar’s steel profile at a high temperature (1200°C), followed by a hot rolling step to narrow down the outer diameter. Said invention is a product with increased resistance against fatigue cracks, and it does not comprise composite forming within the scope of any weight reduction.

USPTO patent document, publication numbered US201501 15560 describes a type of carbon fiber composite stabilizer bar. The angle between the layers used during the production of said stabilizer bar is between 10° and 80°, preferably between 30° and 45°. The stabilizer bar is obtained by winding the layers with a resin from the inside out. The torsion resistance was increased and a kind of braiding method was suggested with the configuration comprising tubular form of layers with variable angles. The braiding angle between the innermost carbon fiber layer and the longitudinal axis is in the range of 42°-45° degrees. The braiding angle at the outermost layer is the lowest; therefore it has more bending resistance. As a result, the shear stresses between the sequences are minimized, and delamination of the layers is prevented. According to the invention with the following technical properties, the bar is braided with 45° and -45° angles between the composite layers, which is the level where the bar would exhibit the best resistance. Unidirectional fiber arrangement was also used to prevent the bar from losing its form. The invention described below with the embodiment herein is novel compared to the document with the publication number US201501 15560. It also meets the inventive step criteria due to its metal-composite configuration.

As a result, all problems described above have necessitated an innovation in the related field. OBJECTIVE OF THE INVENTION

The present invention has been required to eliminate the foregoing problems and to provide a technical innovation in the related field.

The main objective of the invention is to reduce power consumption in production processes, to ensure a lighter stabilizer bar as one of the suspension components of a vehicle, and to increase its resistance.

Another objective of the invention is to better maintain stability compared to other composite stabilizer bars during operation owing to the unilateral fiber arrangement it contains.

Another objective of the invention is to provide high resistant stabilizer embodiment thanks to its metal-composite hybrid structure.

Another objective of the invention is to reduce the weight of the stabilizer and to provide ease of transportation and installation.

Another objective of the invention is to ensure reducing weight on the vehicle where the stabilizer is used, and to ensure that the vehicle saves fuel.

BRIEF DESCRIPTION OF THE INVENTION

The present invention is a type of stabilizer which achieves all of the objectives mentioned above and is detailed as follows.

The method of obtaining a stabilizer component which interconnects the short torque torsion bar with wheels, and which is located between the right and left wheels of the suspension system of the vehicle; which comprises reinforcement fibers arranged angularly with 90° to each other and +45° and -45° to the lateral, obtaining a torsion bar (12) with a hollow core by using a unilateral fiber arrangement of 0° to said reinforcement fibers and by adding a resin; obtaining a bar (10) by placing an inner bar (1 1 ) with a diameter sufficient to contact the inner surface of said torsion bar (12), and obtained by installing the lever arms (20) made of a metal, composite or polymer material on both ends of said bar (10). The invention comprises a torsion bar made of a composite material; a bar which comprises a hollow inner bar with an outer diameter to contact the inner diameter of said torsion bar; and a lever arm which comprises at least one connector bushing fixed by means of a connection housing to the end points of said bar.

In another preferred embodiment of the invention, the torsion bar is obtained by using carbon fiber with [0° / +45° / -45°] arrangement.

In another preferred embodiment of the invention, the torsion bar is obtained by using glass fiber with [0° / +45° / -45°] arrangement.

In another preferred embodiment of the invention, the torsion bar is obtained by using aramid fiber with [0° / +45° / -45°] arrangement.

In another preferred embodiment of the invention, the torsion bar is obtained by using kevlar fiber with [0° / +45° / -45°] arrangement.

In another preferred embodiment of the invention, the torsion bar is obtained by using thermoset and reinforcing fiber with [0° / +45° / -45°] arrangement.

In another preferred embodiment of the invention, the torsion bar is obtained by using thermoplastic and reinforcing fiber with [0° / +45° / -45°] arrangement.

In another preferred embodiment of the invention, the torsion bar is obtained by using elastomeric and reinforcing fiber with [0° / +45° / -45°] arrangement.

In another preferred embodiment of the invention, the stabilizer is obtained by attaching the lever arms tightly on both ends of the bar.

In another preferred embodiment of the invention, the stabilizer is obtained by gluing the lever arms on both ends of the bar.

In another preferred embodiment of the invention, the stabilizer is obtained by attaching the lever arms on both ends of the bar in certain geometry.

In another preferred embodiment, the invention comprises an installation housing on the connection bushing which enables installing the stabilizer on the vehicle.

In another preferred embodiment, the invention comprises two inner radii at the section towards the connection housing of the indent located on the lever arm. In another preferred embodiment, the invention comprises an inner bar made of metal material.

The protection scope of the invention is described in the claims, and may not certainly be restricted with those described in this brief and detailed description for illustration. Obviously, a person specialized in the art may suggest similar embodiments under the light of those described above, without diverging from the main theme of the invention.

BRIEF DESCRIPTION OF DRAWINGS

Figure 1 A provides a perspective view of the invention.

Figure 1 B provides an exploded view of the invention.

Figure 2 A provides a perspective view of the torsion bar of the invention.

Figure 2 B provides a perspective view of the lever arm of the invention.

Figure 3 shows the force directions that the invented stabilizer is exposed to.

DESCRIBING THE REFERENCE NUMBERS OF THE FIGURES

10. Bar

11. Inner bar

12. Torsion bar

20. Lever arm

201. Connection housing

21. Connection bushing

211. Outer radius

212. Installation housing

22. Indent 221 . Inner radius

S. Stabilizer

DETAILED DESCRIPTION OF THE INVENTION

The invented type of stabilizer embodiment is described in this detailed description with the examples only to facilitate understanding the invention and without having any restrictive effect.

The subject of the invention is related with a hybrid suspension element in the automotive industry, with reduced weight and reinforced with a composite material, and a stabilizer (S) that interconnects the wheels and the short torsion bar, and located between the right and left wheels in the suspension system of the vehicle.

The invention comprises a torsion bar (12) made of a composite material; a bar (10) which comprises a hollow inner bar (1 1 ) with an outer diameter to contact the inner diameter of said torsion bar (12); and a lever arm (20) which comprises at least one connector bushing (21 ) fixed by means of a connection housing (201 ) to the end points of said bar (10).

Figure 1 A provides a perspective view and Figure 1 B an exploded view of the invention.

The invented stabilizer (S) comprises a bar (10) in the middle part of the stabilizer (S) and two lever arms (20) connected to both ends of said bar (10). The stabilizer can be installed on the vehicle by means of the connection bushing (21 ) comprised by said lever arms.

The directions of force that the stabilizer (S) is exposed to when the vehicle is running are provided on Figure 3. Particularly, the relocation in axis z on the stabilizer (S) is distributed as a bending force on the lever arms (20) and as a torsional load on the bar (10). The resistance level of the stabilizer (S) is determined with the reaction forces shown in the opposite direction of the relocation in the axis z, which occurs on the lever arms (20). Most of the reaction force is covered by means of a torsion arm (12) on the rod (10). During turns, the force on the car wheels makes an effect in opposite direction to the lever arms (20). It causes a torsion bend on the bar (10). In order to ensure vehicle stabilization, the lever arms (20) are required to ensure resistance against torque on the z axis, and the bar (10) is required to satisfy the foreseen resistance level.

Figure B provides an illustration on which the lever arms of the invention are shown. The lever arms (20) can be connected on the rod (10) by means of the connection housing (201 ) it has. Installation can be with minimum one bolt, and it can be realized with tight fitting or form fitting in certain geometry.

The lever arms (20) comprise a connection bushing (21 ) at their lower part, which enables installing the stabilizer (S) on the vehicle. A soft form is obtained at the end point of the lever arm (20) thanks to the outer radius (21 1 ) at the end point of said connection bushing. As a result, resistance against forces to effect outward from the installation housing (212) has been optimized, and the use of materials has been minimized. The lever arms (20) are preferably made of aluminum materials.

There is an indent (22) at the inner part of said lever arms (20). Said indent (22) embodiment supports the triangular form of the lever arm (20), and it has enabled reducing the weight of the product, without changing its torque resistance. There are two inner radii (221 ) embodiments at the point near to the connection housing (201 ) of said indent (22). As a result, sharp lines are eliminated and the force on the edges is distributed and the surface tensions are reduced to the optimum level.

The lever arms (20) can be made of metal, polymer and/or composite materials in the preferred embodiments of the invention. Furthermore, according to the type of the material used, it can be produced with cast, forged, injection molding or machined production.

The bar (10) that the invention has, preferably comprises a torsion bar (12) made of fiber reinforced composite material at is outer part, and an inner bar (1 1 ) with a hollow round profile the inner part. The torsion bar (12) has a fiber arrangement structure of [0° / +45° / -45°]. The bar (10), particularly enables that the form of the torsion bar (12) is not lost by means of the unidirectional fiber arrangement in the direction of the inner bar (1 1 ). The fibers arranged to make 90° angle with each other and 45° with the lateral enable the resistance of the tension bar (12) of the bar (10) to be at the optimum level.

In the production of said torsion bar (12), one or more of carbon fiber, glass fiber, aramid fiber, and kevlar fiber can be used as the reinforcement fiber in different combinations. The torsion bar (12) is obtained from composite material by using said reinforcement fibers with thermoset, thermoplastic or elastomeric resin.

The torsion bar (12) is supported by means of the inner bar (1 1 ) made of hollow round profile of the invention, thus the stabilizer (S) is made lighter and the performance values are increased.

The torsion bar (12) can be manufactured with the pultrusion method in a preferred embodiment of the invention.

In another preferred embodiment of the invention, obtaining a bar (10) with optimum level of resistance is ensured with the fibers arranged on the inner bar (1 1 ) in [0° / +45° / -45°] form, and with the resin.

The outer diameter of the inner bar (1 1 ) of the invention is dimensioned to contact the inner surface of the torsion bar (12) and it is preferably made of metal or composite material.

In a preferred embodiment of the invention, the torsion bar (12) is wound with the filament winding method.

In another preferred embodiment of the invention, the torsion bar (12) is manufactured with prepreg laying or braiding method.

In another preferred embodiment of the invention, the torsion bar (12) is obtained with resin transfer method.

The fiber arrangement must be [0° / +45° / - 45°] while using the foregoing filament winding, pultrusion, prepreg laying, braiding and resin transfer method during the production of the torsion bar (12) included in the bar of the invention (10).

Claims

1. The method of obtaining a stabilizer component which interconnects the short torque torsion bar with wheels, and which is located between the right and left wheels of the suspension system of the vehicle; which comprises reinforcement fibers arranged angularly with 90° to each other and +45° and -45° to the lateral, obtaining a torsion bar (12) with a hollow core by using a unilateral fiber arrangement of 0° to said reinforcement fibers and by adding a resin; obtaining a bar (10) by placing an inner bar (11 ) with a diameter sufficient to contact the inner surface of said torsion bar (12), and obtained by installing the lever arms (20) made of a metal, composite or polymer material on both ends of said bar (10).

2. Method of obtaining a stabilizer component according to Claim 1 , through which a torsion bar (12) is obtained by using carbon fiber with [0° / +45° / -45°] arrangement.

3. Method of obtaining a stabilizer component according to Claim 1 , through which a torsion bar (12) is obtained by using glass fiber with [0° / +45° / -45°] arrangement.

4. Method of obtaining a stabilizer component according to Claim 1 , through which a torsion bar (12) is obtained by using aramid fiber with [0° / +45° / -45°] arrangement.

5. Method of obtaining a stabilizer component according to Claim 1 , through which a torsion bar (12) is obtained by using kevlar fiber with [0° / +45° / -45°] arrangement.

6. Method of obtaining a stabilizer component according to Claim 1 , through which a torsion bar (12) is obtained by using reinforcement fiber with [0° / +45° / -45°] arrangement and thermoset resin.

7. Method of obtaining a stabilizer component according to Claim 1 , through which a torsion bar (12) is obtained by using reinforcement fiber with [0° / +45° / -45°] arrangement and thermoplastic resin.

8. Method of obtaining a stabilizer component according to Claim 1 , through which a torsion bar (12) is obtained by using reinforcement fiber with [0° / +45° / -45°] arrangement and elastomeric resin.

9. Method of obtaining a stabilizer component according to Claim 1 , which is obtained by tightly fixing the lever arms (20) on both ends of the bar (10).

10. Method of obtaining a stabilizer component according to Claim 1 , which is obtained by sticking the lever arms (20) on both ends of the bar (10).

11. Method of obtaining a stabilizer component according to Claim 1 , which is obtained by fitting the lever arms (20) with a certain geometry on both ends of the bar (10).

12. Embodiment of a kind of stabilizer which interconnects the short torque torsion bar and the wheels, and which is located between the right and left wheels on a suspension system of the vehicle, characterized with a torsion bar (12) made of a composite material; a bar (10) which comprises a hollow inner bar (11 ) with an outer diameter to contact the inner diameter of said torsion bar (12); and a lever arm (20) which comprises at least one connector bushing (21 ) fixed by means of a connection housing (201 ) to the end points of said bar (10).

13. A stabilizer embodiment according to Claim 12, which comprises an installation housing (212) on the connection bushing (21 ) which enables installing the stabilizer (S) on the vehicle.

14. A stabilizer (S) embodiment according to Claim 12, which comprises two inner radii (221 ) in the direction of the connection housing (201 ) of the indent (22) positioned on the lever arm (20).

15. A stabilizer (S) embodiment according to Claim 12, which comprises an inner rod (11 ) made of a metal component.