Integrated Bracket Nut Structure for Rigid Weld-Free Coupling
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Solution Overview
Problem
Mechanical coupling methods, such as bolts and nuts, often lack sufficient rigidity at high-load or impact-bearing points, particularly in vehicle suspension systems, where weld nuts can be prone to durability issues and corrosion, making them unsuitable for components requiring high rigidity.
Innovation Solution
A nut integrated with a bracket is formed through a multi-step process involving drawing, piercing, forging, and cam upsetting, creating an increased thickness portion at the nut's tip, which is then integrated with the bracket to enhance rigidity, eliminating the need for welding and ensuring joint rigidity by forming a protruding end that fits with another bracket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If weld nuts are used for mechanical coupling, then ease of manufacture is improved, but reliability deteriorates due to durability issues and corrosion
Solution Approach 1:
The patent merges the bracket and nut into a single integrated component formed from one piece of plate material through stamping and forging processes. This eliminates the separate weld nut assembly, removing the welding step while maintaining ease of manufacture through integrated forming operations, and simultaneously improving reliability by eliminating weld joints prone to corrosion and durability issues.
2Ease of operation
If traditional bolts and nuts are used for coupling, then ease of operation is improved, but strength deteriorates at high-load or impact-bearing points
Solution Approach 1:
The integrated bracket-nut structure combines the support function of the bracket with the fastening function of the nut into a single monolithic component. This eliminates weak interfaces between separate parts, providing superior strength at coupling points while maintaining ease of operation through standard bolt insertion into the integrated nut structure.
3Strength
If the nut tip is thickened to increase rigidity, then strength is improved, but manufacturing precision deteriorates due to complex forming processes
Solution Approach 1:
The patent performs preliminary forming operations during the stamping and forging processes to pre-establish the increased thickness portion at the nut tip. By incorporating the thickness enhancement into the primary forming steps rather than adding it as a separate post-processing operation, the patent maintains manufacturing precision while achieving the desired strength improvement.
Solution Approach 2:
The patent utilizes parameter changes in the forming process, specifically controlling the forging and stamping parameters to create the increased thickness portion at the nut tip. By optimizing the forming pressure, temperature, and tooling geometry, the patent achieves precise control over the thickness distribution, maintaining manufacturing precision while enhancing strength where needed.
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 integrated nut and bracket configuration increases rigidity at input points, particularly in vehicle suspension systems, by providing a robust coupling that avoids the durability issues associated with weld nuts, ensuring reliable joint integrity without welding defects or corrosion.
Implementation Method 1
forming a beading portion by performing a drawing process, through multiple steps, on a plate material supplied between a punch and a die, and then forming the nut, which has an increased thickness portion at a tip thereof, integrally with the bracket through piercing, forging, and cam upsetting processes
Data Source
AI summary
A method of manufacturing a nut integrated with a bracket forms the nut formed integrally with the bracket or a slab base nut by using a plate material supplied between a punch and a die. The slab base nut includes a base plate and a boss extending from the base plate and including female-threads. The base plate and the boss are integrated into a single piece without welding trace.