Composite Elastomer-Metal Bushing for Lower Vehicle Bearing Weight
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Solution Overview
Problem
Existing elastomer-metal bushings used in vehicles are heavy, leading to reduced energy efficiency, particularly in large applications like commercial vehicles and railway bogies, where they contribute to increased weight and higher manufacturing costs.
Innovation Solution
The elastomer-metal bushing is designed with a stable inner part consisting of a combination of metal and plastic, where the inner flat steel part is surrounded by a plastic body, reducing overall weight and eliminating the need for machining and mechanical notches, allowing for a more compact, cost-effective, and stress-reduced design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the inner part is made entirely of metal to ensure strength and stability, then the load-bearing capability is improved, but the weight increases significantly
Solution Approach 1:
The inner part is constructed as a composite structure combining a metal core (for strength and load-bearing) with a plastic outer layer (for weight reduction and corrosion resistance). This composite design allows the component to achieve the required mechanical strength while significantly reducing the overall weight compared to a fully metallic construction.
2Reliability
If conventional metal machining is used to create connecting jaws, then the structural integrity is maintained, but manufacturing costs and complexity increase
Solution Approach 1:
The invention replaces traditional mechanical machining processes with injection molding technology. The connecting jaws are formed directly during the injection molding process through integrated cavity design, eliminating the need for subsequent machining operations, reducing manufacturing steps, and lowering production costs while maintaining structural integrity.
3Ease of operation
If mechanical notches are created in the metal part, then connection features are achieved, but stress concentration points are created reducing fatigue strength
Solution Approach 1:
The invention changes the geometric parameters of the connecting jaws by designing them with rounded transitions and optimized thickness variations directly in the injection molding process. This eliminates sharp notches and stress concentration points while maintaining the necessary connection capability, thereby improving fatigue strength.
4Reliability
If high-strength steel is used to ensure fatigue resistance, then the durability is improved, but the weight and material cost increase
Solution Approach 1:
The composite structure allows the use of a metal core that provides the necessary strength and fatigue resistance, while the plastic outer layer contributes to weight reduction. This enables the use of lower-grade, lighter metals compared to fully metallic designs, achieving durability requirements with reduced weight and material cost.
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
This design achieves a significant weight reduction of approximately 400 grams per bushing, enhancing energy efficiency and reducing production costs while maintaining load-bearing capabilities, and allows for the use of lower-strength, more cost-effective steel materials.
Implementation Method 1
An elastomer layer is firmly vulcanized between the inner and outer parts
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an elastomer-metal bushing (1), particularly for vehicles, comprising a stable inner part (2) with a circular cylindrical cross-section for attachment to a first bearing part with an outer tube (16), and a vulcanized elastomer layer (18) between the inner part (2) and the outer tube (16). The elastomer-metal bushing (1), in its fully assembled state, is pressed into a receiving eye for connection or as a component of a second bearing part, acting as a spherical bearing with a reduction in the diameter of the outer tube (16) and the creation of a preload in the elastomer layer (18). According to the invention, the stable, circular cylindrical inner part (2) consists of an inner flat steel part (3) surrounded by a plastic body (4) with a circular cylindrical outer shape.