Composite leaf spring development  
Challenge
  • Volume UK manufacturer of world class composite leaf springs (GKN) sought global business opportunities in passenger car applications
  • Composite materials typically offer specific strain energy capacity and fatigue life many times that of their steel counterparts
  • Leaf springs have not seen significant application in this field since 1950’s, and steel coil springs are ubiquitous
Approach
  • Apply concept thinking which could offset the higher spring cost by offering the OEM customer a range of other features
  • A flat, low profile spring lends itself to a larger interior package, and to modular assembly with linkages in an isolated subframe: benefits include greater occupant space, easier ‘stuff up’ assembly and quieter NVH
  • A slender, lightweight transverse leaf reduces unsprung mass and can be 4-point mounted to displace the anti-roll bar function
Benefits
  • Modular, lightweight and refined passenger
    car rear suspension systems built and tuned
    for US and Japanese vehicle OEMs
  • Technology licensed to Japanese Tier
    1 supplier
  • GKN and many of its global customers
    gained access to a technology which could
    fulfil future product and
    manufacturing requirements

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