Composite Shock Absorber Cup Mounting with Metal Support Plate
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Solution Overview
Problem
Composite materials used in motor vehicle body components, such as shock absorber cups, degrade under permanent static forces, leading to issues like cracking, delamination, and loss of tightening torque over time due to creep effects.
Innovation Solution
A device with a shock absorber cup made of composite material integrated into the vehicle body, featuring a support plate interposed between the shock absorber and the cup, with spacer elements like welded nuts and screws that distribute compression forces and apply torque without directly stressing the composite material, ensuring the cup is not prestressed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a shock absorber cup is made of composite material to lighten the vehicle body while preserving resistance, then the weight of the body is reduced and strength is maintained, but the composite material degrades under permanent static forces causing cracking, delamination, and loss of tightening torque
Solution Approach 1:
A support plate made of metal material is introduced as an intermediary component between the shock absorber and the composite cup. This support plate bears the compression forces and distributes them over the entire contact interface, preventing direct stress application to the composite material. The support plate thus mediates the force transmission, protecting the composite cup from degradation while maintaining the weight reduction benefits.
Solution Approach 2:
The shock absorber mounting system is divided into separate functional components: the composite cup integrated into the body, the metal support plate for force distribution, and fixing elements (screws with washers) for secure attachment. This segmentation allows each component to perform its specific function optimally - the composite cup provides lightweight structural integration, while the metal support plate handles mechanical loading.
2Strength
If fixing elements are directly attached to the composite shock absorber cup to secure the shock absorber, then the shock absorber is firmly fixed, but the composite material experiences permanent static forces leading to creep effects and loss of tightening torque over time
Solution Approach 1:
The support plate serves as a mediator that prevents direct attachment of fixing elements to the composite cup. Instead, screws pass through the support plate and are secured with washers and nuts, ensuring that the composite cup is not subjected to permanent static forces from the fixing elements. This intermediary arrangement maintains both strong fixing and long-term torque retention.
Solution Approach 2:
The support plate is positioned beforehand to distribute compression forces before they can concentrate on the composite material. This preventive measure protects the composite cup from degradation before it can occur, ensuring long-term durability of the tightening torque without requiring frequent maintenance.
3Object-affected harmful factors
If the support plate distributes compression forces over the entire contact interface with the shock absorber cup, then the composite material is protected from stress concentration, but the device complexity increases due to additional components
Solution Approach 1:
The support plate performs multiple functions simultaneously: it distributes compression forces to protect the composite cup, provides a mounting surface for fixing elements, and maintains proper positioning of the shock absorber. By combining these functions into a single component, the overall device complexity is minimized while still achieving force distribution protection.
Data Source
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AI summary
Assembly of a damper on a cup made of a composite material with a support plate. A device for mounting a damper on the body of a motor vehicle comprises a damper cup (10) made of a composite material built into the body, and a support plate (11) to be inserted between the damper and the damper cup (10). The support plate (11) comprises fastening elements (12) allowing an end of the damper to be fastened to the support plate (11), and is designed so as to absorb the compression efforts of the damper and to press against the damper cup (10) in such a way that said efforts are distributed over the entire contact interface between the support plate (11) and the damper cup (10).