Integrated Top Mount Assembly to Block Bearing-Insulator Contamination
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Solution Overview
Problem
The existing top mount assembly in vehicle suspension systems is prone to foreign substances entering between the strut bearing and insulator, leading to separation and damage, due to their non-integral design.
Innovation Solution
The top mount assembly is redesigned with an upper housing of the strut bearing formed integrally with the insulator using insert injection molding, ensuring a stable and rigid structure by coupling the insulator and strut bearing firmly, and incorporating a recess part with reinforcing ribs to prevent dimensional instability and rigidity degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the strut bearing and insulator are designed as separate fitted components, then the manufacturing and assembly process is simpler, but foreign substances can flow between them causing separation and damage
Solution Approach 1:
The patent merges the strut bearing and insulator into a single integral component formed by injection molding. The insulator is molded directly onto the strut bearing in one manufacturing process, eliminating the gap between components and preventing foreign substance intrusion while maintaining manufacturing efficiency.
2Strength
If the upper plate protrudes outward beyond the lower plate, then the insulator structure is more robust, but it increases the risk of foreign substance accumulation and damage
Solution Approach 1:
The patent applies local quality by providing different plate configurations based on specific needs. The upper plate may protrude in areas requiring structural robustness while being contained by the housing in areas where foreign substance accumulation is a concern, optimizing both strength and protection.
3Ease of repair
If the insulator and strut bearing are fitted separately, then component replacement is easier, but the assembly becomes loose and damaged over time
Solution Approach 1:
The patent combines the insulator and strut bearing into an integral assembly that maintains stable composition and prevents loosening. The unified structure eliminates the separation issue while the molded design allows for complete assembly replacement as a single unit, maintaining ease of repair.
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 configuration effectively prevents foreign matter intrusion, enhances the structural stability and rigidity of the top mount assembly, and ensures the insulator and strut bearing remain firmly coupled, preventing damage and maintaining assembly integrity.
Implementation Method 1
an upper housing of the strut bearing is formed to be coupled integrally with the insulator
Data Source
AI summary
A top mount assembly includes an insulator comprising an upper plate, a lower plate, and a rubber bushing accommodated in an accommodation space defined between the upper plate and the lower plate; and a strut bearing comprising an upper housing, a lower housing, and a bearing interposed between the upper housing and the lower housing and configured to rotate the lower housing relative to the upper housing. The upper housing of the strut bearing may comprise an insulator mounting part formed on an upper portion of the upper housing and on which the insulator is mounted, the insulator mounting part may comprise a lower plate mounting part on which the lower plate of the insulator is mounted and an upper plate supporting part formed outside the lower plate mounting part, and the upper plate support part may be configured to support a lower surface of the upper plate.