Hybrid Suspension Arm Injection-Molded Insert
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Solution Overview
Problem
Existing hybrid suspension arms require additional machining processes, such as edge folding or drilling, to enhance the coupling between the metal and plastic components, increasing production costs and complexity, while also making it difficult to predict the mechanical behavior of the arm.
Innovation Solution
A hybrid suspension arm design featuring a metal main body with an insert made of plastic, where the insert includes filiform connecting portions that act as braces to securely attach to both the inner and outer sides of the main body, creating a three-dimensional lattice structure that enhances the coupling force without additional machining, and includes a head protruding through passages to increase mechanical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If edge folding or drilling processes are used to enhance coupling between metal and plastic components, then the coupling force is improved, but the processing time and production cost increase
Solution Approach 1:
The invention incorporates protrusions directly into the plastic insert during the injection molding process, before the actual assembly with the metal component. This preliminary formation of coupling features eliminates the need for subsequent edge folding or drilling operations, thereby reducing processing time while maintaining strong coupling force between the metal and plastic components
Solution Approach 2:
The plastic insert is designed with self-locking protrusions that automatically engage with corresponding features on the metal component during assembly. The protrusions are shaped to provide mechanical interlocking without requiring additional fastening operations, allowing the components to self-assemble and secure themselves, thus eliminating time-consuming secondary processing steps
2Strength
If edge folding or drilling processes are used to enhance coupling between metal and plastic components, then the coupling force is improved, but the production cost increases
Solution Approach 1:
The coupling features (protrusions) are integrated into the plastic insert design and formed during the injection molding process. This eliminates the need for separate edge folding or drilling operations that would require additional machinery, setup time, and labor, thereby reducing overall production cost while maintaining effective coupling force
Solution Approach 2:
The invention combines the formation of the plastic insert and the coupling features into a single injection molding operation. By merging the creation of the insert body and the protrusions into one process step, the invention eliminates multiple manufacturing operations, reducing both direct and indirect production costs associated with separate edge folding or drilling processes
3Device complexity
If traditional coupling methods are used, then the processing steps are simple, but the mechanical behavior of the arm becomes difficult to predict
Solution Approach 1:
The invention modifies the geometric parameters of the coupling interface by designing specific protrusion shapes, sizes, and distributions on the plastic insert. These parameter changes create a more uniform and predictable stress distribution during assembly and operation, enabling better finite element analysis and more accurate prediction of the arm's mechanical behavior, while the processing steps remain relatively simple injection molding operations
4Strength
If additional machining processes are used to enhance coupling, then the coupling force is improved, but the device complexity increases
Solution Approach 1:
The coupling features are pre-formed as protrusions on the plastic insert during injection molding, before assembly with the metal component. This preliminary formation eliminates the need for subsequent edge folding or drilling operations, achieving strong coupling force without adding complexity to the overall device or process sequence
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 provides a more efficient and cost-effective coupling between the metal and plastic components, reducing processing time and costs, while improving the mechanical resistance and fastening force, allowing for better prediction of the arm's mechanical behavior.
Implementation Method 1
an insert (3) made of a second material, generally plastic, coupled by injection molding to the main body (2)
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
Supporting hybrid suspension arm (1) comprising a main body (2) made of a first material and equipped with a first end region (2a) and a second end region (2b), said main body having an inner side (2c), an outer side (2d), a first edge section (2e) and a second edge section (2f) which are arranged between said first end region (2a) and said second end region (2b), opposite each other, said hybrid arm further comprising at least one insert (3) made of a second material and being coupled by injection molding to said main body (2), said insert (3) comprising a first portion (31) combined with said inner side (2c) of said main body (2), characterized in that said insert further comprises at least one second filiform connecting portion (32) combined with said outer side (2d) of said main body to connect two regions (31a, 31b) of said first portion (31) to each other respectively arranged at said first edge section (2e) and said second edge portion (2f).