Composite Lower Cap for Suspension Thrust Bearing
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Solution Overview
Problem
Existing suspension thrust bearings in motor vehicle suspension systems face issues with radial deformation of shock absorber bump stops under high axial forces, leading to potential breakage and increased production costs due to the need for complex metal components and costly anticorrosion treatments.
Innovation Solution
A suspension thrust bearing design featuring a lower cap with a reinforcing metal insert buried in a plastic synthetic material body, which includes axial and radial portions to enhance stiffness and absorb radial forces, allowing for cost-effective production and high resistance to shocks without the need for entirely metal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an entirely metal lower cap is used to withstand high radial forces from shock absorber bump stop deformation, then strength and reliability are improved, but manufacturing cost increases due to costly materials and anticorrosion treatments
Solution Approach 1:
The lower cap is constructed as a composite structure combining plastic synthetic material for the main body with a metal reinforcing insert embedded in the tubular portion. This composite approach provides the necessary strength to withstand radial forces from bump stop deformation while avoiding the high costs associated with entirely metal construction and anticorrosion treatments.
2Ease of manufacture
If a plastic synthetic material lower cap is used to reduce manufacturing cost, then ease of manufacture is improved, but strength and reliability deteriorate under high radial forces from shock absorber bump stop deformation
Solution Approach 1:
The lower cap features a metal reinforcing insert specifically positioned in the tubular portion where radial forces from bump stop deformation are transmitted. This localized reinforcement provides strength exactly where needed while maintaining plastic material for the rest of the cap body, optimizing both strength and manufacturing cost.
3Reliability
If complex metal components are used to ensure high resistance to shocks, then reliability is improved, but device complexity increases leading to more difficult assembly
Solution Approach 1:
The metal reinforcing insert is integrated directly into the plastic lower cap during the molding process, combining two materials and functions into a single unified component. This integration maintains high shock resistance while simplifying assembly compared to separate metal components that would require additional fastening operations.
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, cost-effective suspension thrust bearing capable of handling normal and shock-induced forces, reducing production costs and avoiding deformation issues, while maintaining structural integrity and ease of assembly.
Implementation Method 1
the tubular portion includes a reinforcing insert located at the level of this axial contact surface... able to support forces encountered in normal use and forces caused by shocks transmitted by the shock absorber bump stop
Implementation Method 2
The suspension thrust bearing includes at least one rolling bearing forming an axial thrust bearing... allowing relative angular movement between the rolling bearing cup of the spring, which is mobile in rotation, and the fixed support block
Data Source
AI summary
A suspension thrust bearing including at least one rolling bearing forming an axial thrust bearing disposed on a lower cap is provided. The lower cap includes a body with an annular rolling bearing portion for a spring and a tubular portion including a bore in which a shock absorber bump stop is inserted. An axial contact surface is defined on the lower portion of the bore of the tubular portion against which the shock absorber bump stop when deformed exerts a radial force. The tubular portion includes a reinforcing insert located at the level of this axial contact surface.