Integrated Engine Mount Case Bracket Folded Edge

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Solution Overview

Problem

Integrated type engine mounts face issues with stress concentration, durability, and rust prevention due to incomplete edges and electro-deposition coating problems, leading to potential damage and reduced commercial value.

Innovation Solution

The engine mount features a case bracket with a folded and rubber-covered edge to secure a sufficient bonding surface, reducing stress concentration and preventing paint peeling, while ensuring a hermetic seal to prevent foreign substances from entering.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the insulator and case bracket are forcibly fitted after electro-deposition coating, then the assembly is completed, but the paint on the base bracket is peeled off and rust prevention is compromised

Engineering Contradiction:

Improveassembly completionVSAvoidrust prevention

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent applies preliminary action by performing the fitting operation before electro-deposition coating. The insulator and case bracket are fitted into the base bracket first, then the entire assembly undergoes electro-deposition coating. This sequence prevents paint peeling because the fitting is done on the bare metal surface, and the coating is applied afterward as a unified layer, eliminating the harmful interaction between fitting and painted surfaces.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the insulator is expanded due to movement, then the insulator may be damaged by interference with the housing bracket edge, but restricting movement reduces functional flexibility

Engineering Contradiction:

Improveinsulator durabilityVSAvoidmovement flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent applies beforehand cushioning by providing a buffer zone or protective structure between the insulator and the housing bracket edge. This cushioning element prevents direct contact and damage when the insulator expands during operation, while still allowing the insulator to move and expand within the protected space, maintaining functional flexibility without compromising durability.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Reliability

If the edge of the case bracket is incomplete or sharp, then stress concentration occurs leading to separation and cracks, but adding protective structures increases complexity

Engineering Contradiction:

Improvebonding durabilityVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies spheroidality by replacing sharp edges with rounded or curved edges at the bonding portion of the case bracket. This curvature eliminates stress concentration points that would otherwise lead to separation and cracks. The rounded edge design maintains structural integrity and bonding durability without adding significant complexity, as it involves a simple geometric modification rather than additional components.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Reliability

If bonding surface area is insufficient, then bonding force is reduced and durability decreases, but increasing surface area may require larger components

Engineering Contradiction:

Improvebonding forceVSAvoidcomponent size

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent applies local quality by concentrating bonding efforts at specific critical locations rather than attempting to bond across the entire surface. The rounded edge design creates an optimized bonding zone with improved stress distribution, and selective reinforcement or coating is applied only at these critical bonding portions. This approach achieves sufficient bonding force without requiring a uniformly large bonding surface area across the entire component.

Inventive Principle:

Principle #3Local quality

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 enhances durability by 39% and improves bonding force by 310%, effectively preventing rust and maintaining quality by ensuring a stable bonding surface and sealing the engine mount.

Implementation Method 1

improve durability with improvement of stress concentration at edges

Methodology Applied

Scientific EffectStress concentration reduction:

Implementation Method 2

a fluid filled type mount having two fluid-filled liquid chambers formed inside an insulator made of synthetic resin, and a nozzle plate disposed between the liquid chambers for flow of the fluid, thereby reducing both high- and low-frequency vibrations

Methodology Applied

Scientific EffectElastic effect of fluid:

Implementation Method 3

an engine mount is generally of a lever type using the elastic force of the material itself

Methodology Applied

Scientific EffectElastic force: Elasticity

Data Source

PatentUS9242541B2Integrated type engine mount for vehicle

Publication Date: 2016.01.26 HYUNDAI MOTOR CO LTD

AI summary

An integrated engine mount for a vehicle may include a housing bracket and a base bracket vertically coupled, a car body bracket to be connected with a car body, and an insulator and a case bracket fitted inside the housing bracket and the base bracket. An edge of an upper end of the case bracket may be bent to form a folded portion and the folded portion is covered with a rubber member.