Composite Material Bush Uniform Strength Design
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Solution Overview
Problem
Conventional trailing arm bush cores exhibit non-uniform strength between the center and end portions due to cooling differences during casting, leading to inconsistent performance in vibration and shock absorption.
Innovation Solution
A composite material bush design featuring a center plate with an outer foam made of different materials, where the center plate is produced using press molding or extrusion molding and the outer foam is injection molded, with features like offset fastening holes, varying corner radii, and a bonding material to ensure uniform strength and improved bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a core is produced by casting alloys, then the core can be manufactured with complex shape, but the center and end portion cannot have uniform strength due to cooling time differences
Solution Approach 1:
The core is divided into two separate components: a center plate and an outer foam. The center plate is produced by press molding or extrusion molding to ensure uniform strength, while the outer foam is injection molded to form the remaining core structure. This segmentation allows each component to be manufactured with optimal strength characteristics.
Solution Approach 2:
The core is constructed as a composite structure combining a metal center plate with a plastic outer foam. This composite material approach enables the center plate to provide uniform strength through controlled molding processes while the outer foam provides the necessary structural form, resolving the strength uniformity issue inherent in traditional casting.
2Strength
If the center plate and outer foam are made of different materials, then uniform strength can be achieved, but bonding between the two materials becomes difficult
Solution Approach 1:
A bonding material with specific properties is applied locally at the interface between the center plate and outer foam. This bonding material has a melting point lower than both the center plate and outer foam, allowing it to be melted during injection molding to create strong adhesion between the dissimilar materials without damaging either component.
Solution Approach 2:
The bonding material's melting point is specifically controlled to be lower than both the center plate and outer foam materials. This parameter change enables the bonding material to melt during the injection molding process, facilitating bonding between the metal center plate and plastic outer foam through thermal softening and adhesion.
Data Source
AI summary
A composite material bush may include a center plate; and an outer foam which is arranged outside the center plate to surround the center plate and is made of different kinds of materials.