Bump Stop Assembly Notch Fracture Mechanism
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Solution Overview
Problem
Existing bump stop assemblies for motor vehicles do not effectively manage large applied loads, as they either fail to break away or are not robust enough to absorb such loads without fracturing during normal operation.
Innovation Solution
A bump stop assembly with a base featuring a notch or V-shaped groove that allows the flange to fracture under high load conditions, enabling the assembly to move downward and absorb the load, while maintaining stability during normal operation through a combination of a shaft and a base with a central bore for vertical adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the bump stop assembly is made robust to prevent fracture during normal operation, then reliability is improved, but the assembly cannot effectively break away under large applied loads
Solution Approach 1:
The base is segmented by introducing a notch that creates a predetermined fracture location. This segmentation allows the base to remain intact during normal operation while enabling controlled breakage under excessive load, resolving the contradiction between reliability and strength by creating a weak point that only activates when needed.
Solution Approach 2:
A notch is pre-formed in the base during manufacturing to establish a predetermined fracture location. This preliminary action prepares the structure in advance so that when excessive load is applied, the fracture occurs at the intended location rather than randomly, ensuring reliable load management while maintaining normal operational integrity.
2Force
If the base is made frangible to break away under large loads, then load absorption is improved, but the assembly becomes unstable during normal operation
Solution Approach 1:
The base has non-uniform structure with a localized notch creating a specific weak region. The majority of the base maintains full strength and stability for normal operation, while the localized notch area provides controlled frangibility for load absorption, resolving the contradiction between stability and load absorption capability.
3Force
If the notch is positioned to enable easy fracture, then load absorption is improved, but manufacturing precision becomes more difficult to control
Solution Approach 1:
The notch is pre-formed during manufacturing with precise positioning relative to the opening perimeter. This preliminary action establishes the exact fracture location in advance, ensuring that the notch position is controlled and repeatable across production, thereby maintaining manufacturing precision while enabling effective load absorption.
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 solution provides a robust, compact, and aesthetically appealing bump stop assembly that effectively breaks away under high loads, ensuring the hood can absorb large applied forces without fracturing during normal closure conditions, while maintaining stability and ease of manufacturing.
Implementation Method 1
the base includes a notch configured to provide a fracture location of the base
Data Source
AI summary
This disclosure relates to a bump stop assembly for a motor vehicle. An example assembly includes a head configured to contact a hood of the motor vehicle when the hood is closed, a shaft, and a base configured to fit in an opening in a panel of the motor vehicle. The shaft supports the head relative to the base. Further, the base includes a notch configured to provide a fracture location of the base.