IN the quest for ultra-lightweight vehicles, manufacturers are targeting all components, including the conventional coil spring. Audi, in conjunction with patent holder SOGEFI, has developed a fibre-reinforced-plastic (FRP) spring for weight-saving purposes. Compared with a steel spring found in an Audi A4, the FRP spring is 40 per cent lighter, thicker in diameter with fewer turns and delivers equal or better performance. The spring is constructed from long glass fibres twisted together and impregnated with epoxy resin. Additional fibres are then wrapped around the core at 45-degree angles to the longitudinal axis to support the core by acting in either compression or tension. The production process of the FRP spring is more energy efficient than conventional steel springs because no heat treatment (450 to 1 000 degrees Celsius) is necessary. Furthermore, no surface treatment is required to protect the FRP spring against oxidation. To address any durability concerns, Audi is subjecting the FRP spring to marathon cycles on a test rig to simulate loads equal to about 300 000 km of driving by the average customer. The new FRP suspension springs will debut in the 2012 Audi R8 e-tron electric sportscar and should reach mainstream production in 2013.
Plastic springs
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