Polymer Body Mount Assembly Without an Outer Metal Sleeve
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Solution Overview
Problem
Body-on-frame vehicle body mount assemblies with outer metal sleeves face issues of corrosion, weight addition, and increased manufacturing complexity due to exposure to dirt, dust, and road salt, necessitating a lighter and corrosion-resistant solution.
Innovation Solution
The use of a vehicle body mount assembly design that replaces the outer metal sleeve with a polymer mounting bracket and thermoplastic outer sleeve, incorporating an elastomeric damper and fastening elements, eliminating the need for an outer metal sleeve while maintaining structural integrity and attachment security.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an outer metal sleeve is used to protect the elastomeric damper, then corrosion resistance is improved, but weight increases
Solution Approach 1:
The patent removes the outer metal sleeve from the body mount assembly, extracting the problematic component that caused both corrosion issues and weight increase. The elastomeric damper is exposed directly, eliminating the need for corrosion-resistant coating while reducing overall assembly weight.
Solution Approach 2:
The patent uses composite material construction by bonding the elastomeric damper directly to metal sleeves without an outer metal sleeve. This composite approach leverages the corrosion-resistant properties of the elastomeric material itself, eliminating the need for additional protective metal layers.
2Reliability
If an outer metal sleeve with corrosion resistant coating is used, then protection against dirt, dust, and road salt is improved, but manufacturing complexity increases
Solution Approach 1:
The patent eliminates the outer metal sleeve and its associated corrosion-resistant coating process, simplifying the manufacturing workflow. The assembly process is reduced by removing the coating step and reducing the number of components that need to be handled and assembled.
Solution Approach 2:
The patent changes the material parameter from metal to elastomeric compound, which inherently provides corrosion and environmental protection without requiring additional protective coatings or complex surface treatment processes.
3Strength
If an outer metal sleeve is used, then structural integrity is maintained, but weight is added
Solution Approach 1:
The patent creates a composite structure where the elastomeric damper is bonded directly to the metal inner sleeve, forming an integrated load-bearing assembly. This composite construction maintains structural integrity through the bond interface while eliminating the weight of the outer metal sleeve.
Solution Approach 2:
The patent offsets the weight of metal components by using lightweight elastomeric material to perform protective and structural functions. The elastomeric damper provides both cushioning and structural support, replacing the need for heavy outer metal protection.
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 lightweight, corrosion-resistant, and cost-effective body mount assembly that securely attaches the vehicle body to the frame without an outer metal sleeve, reducing weight and manufacturing complexity while maintaining attachment security.
Implementation Method 1
an elastomeric (e.g., rubber) damper bonded to and between an inner metal sleeve and an outer metal sleeve
Implementation Method 2
the polymer mounting bracket and/or the polymer outer sleeve are formed from a thermoplastic material selected from the group consisting of nylon, polybenzimidazole (PBI), polycarbonate (PC), polyether sulfone (PES), polyoxymethylene (POM), polyether ether ketone (PEEK), polyetherimide (PEI), polyethylene (PE), polyphenylene oxide (PPO), polyphenylene sulfide (PPS), polypropylene (PP), polyvinyl chloride (PVC), polyvinylidene fluoride, PVDF, and combinations thereof
Data Source
AI summary
A vehicle body mount assembly includes an inner metal sleeve, a polymer mounting bracket with a damper opening oriented coaxially with the inner metal sleeve, an elastomeric damper disposed within the damper opening between the inner metal sleeve and the polymer mounting bracket, at least one fastening element embedded in and extending from the polymer mounting bracket, and a ferrule disposed at least partially within the inner metal sleeve. A polymer outer sleeve can be included and disposed between elastomeric damper and the polymer mounting bracket. Also, the at least one fastening element can be a stud bolt with a head embedded in the polymer mounting bracket, a nut embedded in the polymer mounting bracket, or a metal sleeve configured for a bolt to extend therethrough embedded in the polymer mounting bracket.