Overmolded Suspension Strut with Ring-Section Joint
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Solution Overview
Problem
The existing chassis components for wheel suspension require a high assembly effort due to the complex introduction of movably connected joint parts, particularly in the production process where the joint housing is pressed into place.
Innovation Solution
A chassis component design featuring a ring-segment-shaped fastening element that positions the spherical joint body between opposing hinge receiving openings, allowing for overmoulding to create the second joint part, simplifying assembly and ensuring a form-fitting connection while preventing axial distance reduction due to plastic shrinkage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the joint body is pressed into the joint housing using traditional assembly methods, then the joint parts are securely connected, but the assembly effort and complexity increase significantly
Solution Approach 1:
The joint housing and joint mounting holes are integrated into a single overmolded component, combining what were previously separate parts into one unified structure. This eliminates the need for separate assembly steps of inserting and securing the joint housing, directly reducing assembly complexity while maintaining secure connection through the integrated positive-locking design
2Ease of manufacture
If the joint housing is produced by traditional molding methods, then manufacturing is straightforward, but additional assembly steps are required to insert and secure the joint housing
Solution Approach 1:
The joint mounting holes are pre-formed as integral features of the overmolded joint housing, and the joint body is pre-positioned between these holes during the molding process. This preliminary integration of positioning features eliminates subsequent assembly steps, directly improving productivity without compromising manufacturing ease
3Ease of manufacture
If the joint housing is made from plastic material, then weight is reduced and manufacturing is simplified, but shrinkage during cooling can alter the axial distance between joint mounting holes
Solution Approach 1:
The fastening element is pre-installed on the joint body before overmolding, creating a preliminary structural framework that counteracts the shrinkage forces during plastic cooling. This element applies compensating forces in advance to prevent dimensional changes, maintaining manufacturing precision while allowing the use of plastic materials for ease of manufacture
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 significantly reduces assembly complexity by integrating the joint receiving openings and joint body, creating a secure form-fitting connection and maintaining the axial distance between openings, thus enhancing the production efficiency and reliability of the chassis component.
Implementation Method 1
The joint body is positioned and held between the joint mounting holes by means of the fastening element arranged in a ring segment shape on the joint body
Implementation Method 2
the joint mounting holes and the joint body positioned between them are integrated into the joint housing produced by overmolding
Implementation Method 3
the fastening element prevents shrinkage of the plastic joint housing from altering, and in particular reducing, the axial distance between the joint mounting holes
Data Source
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AI summary
The invention relates to a chassis component (1) for a wheel suspension, comprising a strut arrangement having at least one strut (2), which is embodied as a profiled part having an open cross-sectional shape, wherein the at least one strut (2) comprises a profiled base (3) and two wall sections (4) extending therefrom, wherein an articulation point (5) is provided on at least one end of the strut (2), for receiving two movably interconnected articulation parts (13, 30), a first articulation part (13) comprising a spherical articulation body (14) and a second articulation part (30) rotatably and/or pivotably receiving the articulation body (14), wherein the wall sections (4) comprise, in the region of the at least one articulation point (5), a first articulation receiving opening (6) and a second articulation receiving opening (7) which are arranged opposite each other, wherein the articulation body (14) is positioned between the first and the second articulation receiving openings (6, 7) by means of a fastening element (24) in the shape of a ring segment, which is arranged on the articulation body (14), and wherein the articulation receiving openings (6, 7) and the articulation body (14) positioned thereinbetween are integrated into an articulation housing (31) which is produced by overmoulding and forms the second articulation part (30).