Top mount for vehicle suspension system and method for manufacturing the same

Abstract

This invention is the result of research conducted under the 2023 Chungbuk-do Technical Development Support Project in the Materials, Parts and Equipment Field, specifically the project for the development of a lightweight insulator using the first application of laser welding, which is being carried out with the support of Chungcheongbuk-do Province and the Chungbuk-do Institute of Science and Technology Innovation in South Korea. The invention discloses a top mount for a vehicle suspension system and a method for manufacturing the same. The disclosed top mount for a vehicle suspension system includes a bracket that engages with the vehicle body and has a housing inside, a bush placed in the housing, an upper cap that is fixed to the upper side of the housing and provided on the bracket to support the upper surface of the bush, and a lower cup that is inserted to the lower side of the housing and engages with the bracket to support the lower surface of the bush. The bracket and the upper cap are integrally formed and made of plastic.

Description

Technical Field

[0001] The present invention relates to a top mount for a vehicle suspension device and a method for manufacturing the same, and more specifically, to a top mount for a vehicle suspension device that has been weight-reduced and a method for manufacturing the same.

Background Art

[0002] The present invention is the research result of the 2023 Chungbuk Material, Parts, and Equipment Technology Development Support Project, which is being carried out through the support of Chungbuk Province, South Korea, and the Chungbuk Institute of Science and Technology Innovation, and the research on the issue of developing a lightweight insulator with the first application of laser welding method.

[0003] A vehicle suspension device is provided between a vehicle body and an axle to absorb vibration and shock energy transmitted from the road surface, and many are equipped with a shock absorber and a suspension spring provided around the shock absorber.

[0004] The suspension spring alleviates the shock received from the road surface, and the shock absorber suppresses the free vibration of the suspension spring and further reduces the vibration applied to the vehicle body through the complementary action with the suspension spring.

[0005] The shock absorber includes a cylinder fixed to the wheel side, a piston slidably accommodated in the cylinder, and a piston rod whose one end is connected to the piston and the other end extends outside the cylinder and is fixed to the vehicle body side, and attenuates the vibration and shock transmitted from the road surface to the vehicle body while repeating the compression stroke and the rebound stroke during the running of the vehicle.

[0006] At this time, the vehicle suspension device includes a top mount and is mounted on the vehicle body. The top mount includes a bush that engages with an end portion by a piston rod of the shock absorber, and a bracket that supports the bush and is fixed to the vehicle body.

[0007] These top mounts dampen vibrations transmitted from the shock absorber's piston rod to the vehicle body through the elastic deformation of the bushing, while the piston rod is mounted to the vehicle body.

[0008] On the other hand, conventional top mounts for vehicle suspension systems have mainly consisted of brackets made of metal, but recently, in order to improve the fuel efficiency benefits associated with vehicle weight reduction, there has been a growing effort to offer top mounts made from a variety of materials. [Overview of the Initiative] [Problems that the invention aims to solve]

[0009] This embodiment aims to provide a lightweight top mount for vehicle suspension systems and a method for manufacturing the same.

[0010] This embodiment aims to provide a top mount for a vehicle suspension system and a method for manufacturing the same that maintains, complements, and improves durability.

[0011] This embodiment aims to provide a top mount for a vehicle suspension system and a method for manufacturing the same, which reduces the number of parts and improves productivity.

[0012] This embodiment aims to provide a top mount for a vehicle suspension system and a method for manufacturing the same, which improves ease of assembly.

[0013] This embodiment aims to provide a top mount for a vehicle suspension system and a method for manufacturing the same, which improves the vehicle's fuel efficiency and enhances its economic and marketability. [Means for solving the problem]

[0014] According to one aspect of the present invention, the present invention includes a bracket that engages with a vehicle body and has a housing inside it, a bush disposed in the housing, an upper cap provided on the bracket that is fixed to the upper side of the housing and supports the upper surface of the bush, and a lower cup that is inserted to the lower side of the housing and engages with the bracket to support the lower surface of the bush, wherein the bracket and the upper cap are integrally formed and made of plastic.

[0015] The bracket and the upper cap may be made of a plastic mixture of nylon-based plastic and glass fiber reinforced plastic.

[0016] The bracket may include a main body portion in which the housing is provided, and flange portions that extend inclined from both sides of the main body portion.

[0017] The main body portion may include a plurality of first projections that protrude outward from the outer peripheral surface, extend vertically, and are arranged spaced apart along the outer peripheral surface.

[0018] The upper cap may include a plurality of second projections that are formed to protrude upward from the upper surface, extend radially from an opening provided in the center, and are spaced apart along the periphery of the opening.

[0019] The flange portion is formed to protrude downward from the lower surface, extends in the longitudinal direction of the flange portion, and may include a plurality of third projections that are spaced apart along the outer circumferential surface of the main body portion that is in contact with the flange portion.

[0020] The first projection extends around the upper cap toward the lower end of the main body, and the portion where the main body and the flange portion come into contact may extend to the portion that comes into contact with the flange portion.

[0021] The lower cup may include an insertion portion whose outer circumferential surface is inserted into a lower side of the container, and a stepped portion that protrudes from a lower end portion of the insertion portion to support a lower end of the bracket.

[0022] The bush may include an inner pipe that is positioned at the center of the container and fixedly installed at an upper end portion of the piston rod, an outer pipe that is press-fitted and fitted into the container of the bracket, and a vibration isolation rubber interposed between the inner pipe and the outer pipe.

[0023] The flange portion may include a bolt engagement hole that is formed to penetrate obliquely.

[0024] It may further include a washer coupled to one side of the bolt engagement hole.

[0025] According to another aspect of the present invention, there is provided a method for manufacturing a top mount for a vehicle suspension device, which integrally forms a bracket made of plastic and engaged with a vehicle body and provided with a container therein, and an upper cap seated on an upper side of the container and provided on the bracket, inserts a bush into the container by inserting it from a lower side of the container, inserts a lower cup engaged with the bracket from a lower side to an upper side of the container so as to support a lower surface of the bush, and welds and engages the bracket and the lower cup.

[0026] The lower cup includes an insertion portion whose outer circumferential surface is inserted into a lower side of the container, and a stepped portion that protrudes from a lower end portion of the insertion portion to support a lower end of the bracket. The lower cup is inserted from a lower side to an upper side of the container such that a lower end of the bracket is seated and supported by the stepped portion, and includes welding and engaging the bracket and the insertion portion. A method for manufacturing a top mount for a vehicle suspension device may be provided.

[0027] A method for manufacturing a top mount for a vehicle suspension device in which the bracket and the upper cap are injection molded may be provided.

Effects of the Invention

[0028] This embodiment provides a top mount for a suspension device of a vehicle with reduced weight and a method for manufacturing the same.

[0029] This embodiment provides a top mount for a suspension device of a vehicle that maintains, complements, and improves durability, and a method for manufacturing the same.

[0030] This embodiment provides a top mount for a suspension device of a vehicle that reduces the number of parts and improves productivity, and a method for manufacturing the same.

[0031] This embodiment provides a top mount for a suspension device of a vehicle that improves the ease of assembly, and a method for manufacturing the same.

[0032] This embodiment provides a top mount for a suspension device of a vehicle that improves the fuel efficiency of the vehicle, and also improves the economy and commerciality, and a method for manufacturing the same.

Brief Description of the Drawings

[0033] [Figure 1] It is a perspective view showing a state of looking at a top mount for a suspension device of a vehicle according to an embodiment of the present invention from above. [Figure 2] It is a perspective view showing a state of looking at a top mount for a suspension device of a vehicle according to an embodiment of the present invention from below. [Figure 3] It is a perspective view showing a state of looking at a part of a top mount for a suspension device of a vehicle according to an embodiment of the present invention after cutting from above. [Figure 4] It is a cross-sectional view showing a state in which a top mount for a suspension device of a vehicle according to an embodiment of the present invention is assembled. [Figure 5] It is a perspective view showing a state before a top mount for a suspension device of a vehicle according to an embodiment of the present invention is assembled.

Mode for Carrying Out the Invention

[0034] Hereinafter, this embodiment will be described in detail with reference to the accompanying drawings. The following embodiments are presented to fully convey the idea of ​​the present invention to those who have ordinary skill in the art to which the present invention pertains. The present invention is not limited to the embodiments presented herein and can be embodied in other forms. In order to clarify the present invention, the drawings may omit illustrations of parts not relevant to the description and may exaggerate the size of components to some extent to aid understanding.

[0035] The vehicle suspension system employing the vehicle suspension top mount 10 is for damping vibrations and shocks transmitted from the road surface to the vehicle body, and comprises a shock absorber (not shown) and a coil spring (not shown) provided around a shock absorber (not shown).

[0036] A shock absorber (not shown) comprises a cylinder fixed to the wheel side, a piston slidably housed within the cylinder, and a piston rod with one end connected to the piston and the other end extending outside the cylinder and fixed to the vehicle body side.

[0037] Therefore, the shock absorber (not shown) dampens vibrations and shocks transmitted from the road surface to the vehicle body by repeatedly performing compression and rebound strokes in response to the reciprocating motion of a piston sliding against a cylinder while the vehicle is in motion.

[0038] A coil spring (not shown) is provided around the shock absorber (not shown) to elastically support it in the direction away from the cylinder and piston rod, thereby increasing the vibration damping effect of the shock absorber (not shown).

[0039] The suspension system of this vehicle is fixed at the lower end to the wheel side, and the upper end is attached to the vehicle body via a top mount. In other words, the top mount dampens vibrations transmitted from the piston rod of the shock absorber (not shown) to the vehicle body while ensuring that the piston rod is attached to the vehicle body.

[0040] Figure 1 is a perspective view of the top mount 10 for a suspension system according to one embodiment of the present invention, viewed from above, and Figure 2 is a perspective view of the top mount 10 for a suspension system according to one embodiment of the present invention, viewed from below.

[0041] Referring to Figures 1 and 2, a top mount 10 for a vehicle suspension system according to one embodiment of the present invention includes a bracket 100, an upper cap 300, a lower cup 400, and a washer 500.

[0042] The bracket 100 is configured to form the external frame of the top mount and is connected to the vehicle body.

[0043] Conventional brackets 100 were typically made of metal materials such as aluminum. While this has the advantage of ensuring high rigidity of the bracket 100, it increased the weight and contributed to the vehicle's fuel efficiency.

[0044] As a result, the bracket 100 according to one embodiment of the present invention is made of plastic material instead of metal, achieving weight reduction of the top mount, further improving the vehicle's fuel efficiency through weight reduction, and maintaining and enhancing durability by improving the shape of the bracket 100 itself.

[0045] The bracket 100 includes a centrally located main body portion 110 and a flange portion 120 that extends laterally from the main body portion 110, and both the main body portion 110 and the flange portion 120 are made of plastic.

[0046] The main body portion 110 is provided in a cylindrical shape, but may include a housing 111 inside and a first projection 112 that protrudes outward from the outer surface.

[0047] The housing 111 houses the bush 200. The bush 200 will be described in more detail later.

[0048] Multiple first projections 112 are provided, each extending vertically and arranged spaced apart along the outer circumferential surface.

[0049] The first projection 112 can be extended to the point where the main body 110 and the flange portion 120 (described later) come into contact. That is, when the lateral outer surface of the main body 110 comes into contact with the inclined flange portion 120 as shown in Figure 1, the first projection 112 can be extended from around the upper cap 300 (described later) toward the lower end of the main body 110, and also extended to the point where the main body 110 and the flange portion come into contact, so that its vertical length gradually decreases.

[0050] Therefore, the bracket 100 can be made more rigid by providing the first projection 112 on the main body 110 against vertical external forces acting by a shock absorber (not shown) that moves up and down.

[0051] The flange portion 120 is formed to extend inclined on both sides of the main body and may include bolt engagement holes 122 formed in the outer casing and a third projection 121 that protrudes downward from the lower surface.

[0052] The bolt engagement holes 122 can be formed at an angle and penetrate the outer casing of the flange portion 120. Therefore, the bracket 100 can be fixed to the vehicle body by fastening bolts inserted into the bolt engagement holes 122.

[0053] Multiple third projections 121 are provided, each extending in the longitudinal direction of the flange portion 120 and being arranged at intervals along the outer circumferential surface of the main body portion 110 that contacts the flange portion 120.

[0054] As shown in Figure 2, the third projection 121 may be formed to start from the outer circumferential surface of the main body 110 and extend to the portion where the bolt engagement hole 122 is provided or to a point where it is recessed around the bolt engagement hole 122, and may be formed so that their horizontal lengths differ from each other.

[0055] Therefore, the bracket 100 can be made more rigid by providing a third projection 121 on the main body 110 against horizontal external forces acting on it by a shock absorber (not shown) that moves up and down in the bolt engagement hole 122.

[0056] The upper cap 300 is mounted on the bracket 100 so as to be fixed to the upper side of the housing 111 and support the upper surface of the bush 200. The upper cap 300 is made of plastic, just like the bracket 100.

[0057] The upper cap 300 may include a second projection 310 that has an opening 320 in the center and protrudes upward from the upper surface.

[0058] Multiple second projections 310 are provided, each extending radially from the opening 320 and being spaced apart along the periphery of the opening 320.

[0059] The second projection 310 may be formed in a manner similar to that in Figure 1, with its height decreasing towards the opening 320 and increasing in height and sloping away from the opening 320.

[0060] Therefore, the upper cap 300 can be made rigid by providing a second projection 310 to withstand horizontal external forces acting on the bolt engagement hole 122 by a shock absorber (not shown) that moves up and down.

[0061] The upper cap 300 is formed integrally with the bracket 100. Generally, conventional upper caps 300 are not only made of metal, but are also provided in a separate configuration from the bracket 100, requiring an assembly process with the bracket 100. As a result, the upper cap 300 according to one embodiment of the present invention is made of plastic together with the bracket 100 and is formed integrally, reducing the weight of the top mount and reducing the assembly process.

[0062] The bracket 100 and upper cap 300 may be made of a plastic mixture of nylon-based plastic and glass fiber reinforced plastic. For example, the bracket 100 may be a plastic mixture of PA66 and GF50. However, the plastic of the bracket 100 and upper cap 300 of the present invention is not limited to these, and includes plastics made of materials that are lighter than metal materials, as well as plastics mixed in various proportions other than nylon-based plastic and glass fiber reinforced plastic.

[0063] The lower cup 400 is inserted into the lower side of the housing 111 and is configured to engage with the bracket 100 to support the lower surface of the bush 200.

[0064] The lower cup 400 is provided in a hollow cylindrical shape. Specifically, the lower cup 400 has cup openings on its upper and lower surfaces, with the upper cup opening having a smaller diameter than the lower cup opening, and the upper surface may have multiple recessed holes on the lower side. The sides of the lower cup 400 are provided with an insertion portion 410 and a stepped portion 420, and at least a portion of them may be provided so as to be in close contact with the inner circumferential surface of the container 111. The insertion portion 410 and the stepped portion 420 will be described in detail later.

[0065] The washer 500 is coupled to one side of the bolt engagement hole 122, and when the fastening bolt engages with the bolt engagement hole 122, it widens the area over which the force is applied, distributing the pressure and thereby improving the durability of the flange portion 120. The washer 500 may be made of a metal material, for example, aluminum.

[0066] Figure 3 is a perspective view showing a portion of a top mount 10 for a vehicle suspension system according to one embodiment of the present invention, cut off and viewed from above, and Figure 4 is a cross-sectional view showing the assembled top mount 10 for a vehicle suspension system according to one embodiment of the present invention.

[0067] Referring to Figures 3 and 4, a top mount 10 for a vehicle suspension system according to one embodiment of the present invention includes a bush 200.

[0068] The bush 200 is positioned inside a housing 111 provided on the bracket 100 and is configured to elastically support the end of the piston rod of a shock absorber (not shown), and includes an inner pipe 210, an outer pipe 230, and vibration-damping rubber.

[0069] The inner pipe 210 is located in the center of the housing 111 and is fixedly installed to the upper end of the piston rod. The inner pipe 210 is a hollow cylindrical shape with a through hole formed in the center through which the piston rod of a shock absorber (not shown) is inserted, and the lower end has a flat portion that is fixed to the vibration-damping rubber 220 and may be formed in a "⊥" shape. The inner pipe 210 may be made of a metal material, which is cold-headed carbon steel.

[0070] The outer pipe 230 is provided in a hollow cylindrical shape and is press-fitted into the housing 111 of the bracket 100. The outer pipe 230 may be made of plastic. For example, the outer pipe 230 may be a plastic mixture of PA66 and GF35. However, the outer pipe 230 of the present invention is not limited to this, and includes plastics made of a material that is lighter than metal, such as nylon-based plastics and glass fiber reinforced plastics, as well as plastics mixed in various proportions.

[0071] The vibration-damping rubber 220 is interposed between the inner pipe 210 and the outer pipe 230. The vibration-damping rubber 220 is provided in a hollow cylindrical shape, and in order to increase the effect of the cushioning action performed when compressed in the vertical direction, the upper surface may have an uneven shape in which concave and convex portions are repeated along the circumference. The vibration-damping rubber 220 may be made of a rubber material, and in particular may be made of natural rubber which has high elasticity, flexibility and high tensile strength.

[0072] The lower cup 400 is provided with an insertion portion 410 and a stepped portion 420 on its side in order to engage with the bracket 100 that houses the bush 200.

[0073] The insertion portion 410 has its outer circumferential surface inserted into the lower side of the housing 111, and the stepped portion 420 is formed to protrude from the lower end of the insertion portion 410 and support the lower end of the bracket 100. In this case, the insertion portion 410 is made relatively thicker than the other parts of the lower cup 400, and the part of the bracket 100 that contacts the insertion portion 410 corresponding to the position of the insertion portion 410 may be made thinner than the other parts of the main body portion 110 of the bracket 100.

[0074] The lower cup 400 can be welded and engaged with the bracket 100. That is, the insertion portion 410 of the lower cup 400 can be welded and engaged with the bracket 100. As an example of the welding method, a laser welding method using a laser can be applied, and by welding and engaging the lower cup 400 and the bracket 100 in this way, the assembly of the top mount can be improved.

[0075] The following describes how to manufacture the top mount 10 for a vehicle suspension system according to this embodiment.

[0076] Figure 5 is a perspective view showing a top mount 10 for a vehicle suspension system according to one embodiment of the present invention, before assembly.

[0077] Referring to Figure 5, one embodiment of the present invention can be manufactured by sequentially assembling a bracket 100, a bush 200, and a lower cup 400, which are made of plastic and integrally formed with the upper cap 300.

[0078] First, a bracket 100, which is attached to the vehicle body and has a storage compartment 111 inside, and an upper cap 300, which is attached to the upper side of the storage compartment 111 and provided on the bracket 100, are integrally formed, and all of these are made of plastic. At this time, the bracket 100 and the upper cap 300 can be formed by injection molding. Therefore, the first projection 112 and the third projection 121 provided on the bracket 100 and the second projection 310 provided on the upper cap 300 can also be formed by injection molding when the bracket 100 and the upper cap 300 are integrally formed.

[0079] Subsequently, the lower cup 400, which engages with the bracket 100, is inserted from the bottom to the top of the housing 111 so as to support the lower surface of the bush 200. At this time, the insertion portion 410 of the lower cup 400 can be inserted from the bottom to the top of the housing 111 so that the lower end of the bracket 100 is firmly attached to and supported by the stepped portion 420.

[0080] Subsequently, the bracket 100 and the lower cup 400 can be welded together and engaged. At this time, the bracket 100 and the insertion part 410 can be welded together and engaged, and a laser welding method using a laser can be applied.

[0081] Thus, the suspension top mount 10 according to one embodiment of the present invention, together with the upper cap 300, is made of plastic, achieving a lighter top mount compared to conventional ones made of metal, and consequently contributing to a lighter vehicle and improved fuel efficiency. Furthermore, instead of making the bracket 100 and upper cap 300 from relatively less durable plastic, the unique shape of the configuration can be improved via the first projection 112, second projection 310, and third projection 121 to maintain, complement, or improve durability. In addition, the bracket 100 and upper cap 300 can be integrally formed and manufactured through injection molding to reduce the number of parts and assembly steps, improving productivity, and assembly can be improved by fusing and engaging the bracket 100 and lower cup 400. This, of course, improves the economic and marketability of the vehicle.

[0082] Although the present invention has been described by limited embodiments and drawings, the present invention is not limited thereto, and various modifications and variations are possible by persons with ordinary skill in the art to which the present invention pertains, within the equivalent scope of the technical concept of the present invention and the claims set forth below.

Claims

1. A bracket that engages with the vehicle body and has a storage device inside, A bush arranged in the aforementioned housing, An upper cap is provided on the bracket so as to be fixed to the upper side of the housing and to support the upper surface of the bush, Includes a lower cup inserted into the lower side of the housing and engaging with the bracket to support the lower surface of the bush, The bracket and the upper cap are integrally formed and made of plastic, forming a top mount for a vehicle suspension system.

2. The bracket and the upper cap are, A top mount for a vehicle suspension system according to claim 1, comprising a plastic mixture of nylon-based plastic and glass fiber reinforced plastic.

3. The aforementioned bracket is The main body portion in which the aforementioned storage device is provided, The top mount for a vehicle suspension system according to claim 1, further comprising flange portions that are inclined and extended on both sides of the main body.

4. The main body is, The top mount for a vehicle suspension system according to claim 3, comprising a plurality of first protrusions that are formed to protrude outward from the outer peripheral surface, extend vertically, and are spaced apart along the outer peripheral surface.

5. The aforementioned upper cap is A top mount for a vehicle suspension system according to claim 1, comprising a plurality of second projections formed to protrude upward from the upper surface, extending radially from an opening provided in the center, and arranged spaced apart along the periphery of the opening.

6. The flange portion is The top mount for a vehicle suspension system according to claim 3, comprising a plurality of third projections formed to protrude downward from the lower surface, extending in the longitudinal direction of the flange portion, and arranged spaced apart along the outer circumferential surface of the main body portion that contacts the flange portion.

7. The first projection is, The top mount for a vehicle suspension system according to claim 4, wherein the upper cap is extended towards the lower end of the main body, and the portion where the main body and the flange portion contact is extended to the portion that contacts the flange portion.

8. The aforementioned lower cup is The outer surface is an insertion portion that is inserted into the lower side of the housing, A top mount for a vehicle suspension system according to claim 1, comprising a stepped portion that protrudes from the lower end of the insertion portion and supports the lower end of the bracket.

9. The aforementioned bush, An inner pipe located at the center of the housing and fixedly installed at the upper end of the piston rod, The outer pipe is press-fitted and fitted into the housing of the aforementioned bracket, A top mount for a vehicle suspension system according to claim 1, comprising vibration-damping rubber interposed between the inner pipe and the outer pipe.

10. The flange portion is A top mount for a vehicle suspension system according to claim 3, comprising a bolt engagement hole formed at an angle and through.

11. The top mount for a vehicle suspension system according to claim 10, further comprising a washer coupled to one side of the bolt engagement hole.

12. A bracket made of plastic, which engages with the vehicle body and has a storage device inside, and an upper cap which is fixed to the upper side of the storage device and provided on the bracket are integrally formed. Insert the bush into the lower side of the housing and place it inside the housing. The lower cup that engages with the bracket is inserted from the bottom to the top of the housing so as to support the lower surface of the bush, A method for manufacturing a top mount for a vehicle suspension system, comprising welding and engaging the bracket and the lower cup.

13. The lower cup includes an insertion portion whose outer circumferential surface is inserted into the lower side of the housing, and a stepped portion which is formed to protrude from the lower end of the insertion portion and supports the lower end of the bracket. The lower cup is inserted from the bottom to the top of the housing so that the lower end of the bracket is secured and supported by the stepped portion. A method for manufacturing a top mount for a vehicle suspension system according to claim 12, comprising welding and engaging the bracket and the insertion portion.

14. The method for manufacturing a top mount for a vehicle suspension system according to claim 12, wherein the bracket and the upper cap are injection molded.

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