Hybrid Steel-Plastic Module Bracket for Suspension
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Solution Overview
Problem
Existing module bracket devices for suspension systems require bolting and press-fit processes, increasing manufacturing costs and time, and are heavy due to the use of steel and aluminum materials.
Innovation Solution
A module bracket device integrating steel and engineering plastic components through injection molding and structural coupling, eliminating the need for bolting or press-fit processes, with an insulator bush formed integrally to reduce weight while maintaining strength and rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If steel and aluminum materials are used for module bracket components, then strength and rigidity are maintained, but weight increases
Solution Approach 1:
The patent applies composite materials by integrating steel bracket components with engineering plastic components (polymer materials) to form a hybrid structure. The steel portions provide necessary strength and rigidity, while the plastic portions reduce overall weight. This composite approach allows optimization of each material's properties in different functional areas of the module bracket assembly.
2Ease of manufacture
If bolting and press-fit processes are used to couple steel and plastic components, then structural integrity is achieved, but manufacturing cost and time increase
Solution Approach 1:
The patent merges the steel bracket component and plastic insulator bush components into a single integrated structure through injection molding. The plastic material is injected directly onto the steel components, creating a monolithic assembly that eliminates the need for separate bolting or press-fit operations. This combining of components and processes reduces manufacturing steps, cost, and time while maintaining structural integrity through the molded joint.
3Productivity
If multiple separate components are assembled through bolting and press-fit, then structural integrity is achieved, but manufacturing time increases
Solution Approach 1:
The invention combines multiple assembly operations (bolting, press-fit) and multiple components (steel bracket, insulator bush, mounting bracket) into a single injection molding process. The plastic insulator bush is molded directly onto the steel bracket components, creating an integrated assembly that requires no subsequent fastening operations. This dramatically simplifies the device structure and eliminates complex multi-step assembly procedures.
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 reduces component weight and manufacturing costs while maintaining structural integrity, enhancing the coupling force between steel and plastic components, and ensuring the existing strength and rigidity of the suspension system.
Implementation Method 1
a module bracket injection molded at a lower portion of the steel bracket while surrounding the bush cup
Implementation Method 2
injection molded... while surrounding the bush cup
Data Source
AI summary
A module bracket device for a suspension system, which is used to mount a shock absorber at a vehicle body side may include a bush cup having an insulator bush mounted therein, a steel bracket disposed at an upper portion of the bush cup with a gap therebetween, and a module bracket injection molded at a lower portion of the steel bracket while surrounding the bush cup.