Polymer Composite Strut Insulator Weight Reduction
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Solution Overview
Problem
Conventional vehicle suspension system insulators are heavy due to the need for steel brackets, which hinders fuel efficiency improvements and increases weight, while also requiring multiple components, complicating assembly and increasing NVH issues.
Innovation Solution
A polymer composite strut insulator with a fiber-reinforced bracket, integrated rubber injection passages, and a bearing assembly that reduces weight and components by using a polymer composite bracket with a mounting fastening portion and a bearing assembling portion, along with an elastic mass and a bearing ball rail inserter, to improve NVH performance and simplify assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If steel brackets are used to support the suspension system, then stability and strength are improved, but weight increases
Solution Approach 1:
The patent applies composite materials by replacing traditional steel brackets with polymer composite brackets that incorporate metal inserts. The composite structure combines the high strength of metal inserts with the weight advantages of polymer materials, achieving both structural integrity and weight reduction. The metal inserts are embedded within the polymer composite matrix to provide localized strength where needed while maintaining overall lightweight construction.
2Reliability
If multiple components (brackets, rubber dampers, bolts) are used to form the insulator, then reliability and damping performance are improved, but device complexity increases
Solution Approach 1:
The patent merges multiple separate components into an integrated assembly. The polymer composite bracket incorporates metal inserts directly embedded within it, eliminating the need for separate mounting brackets and fasteners. The rubber damper is integrated with the bracket assembly, creating a unified insulator structure that maintains all necessary functions (support, damping, vibration isolation) while reducing component count and simplifying assembly.
3Reliability
If traditional insulator design with multiple parts is used, then functional performance is maintained, but manufacturing productivity decreases
Solution Approach 1:
The patent applies preliminary action by pre-embedding metal inserts into the polymer composite bracket during the molding process. This preliminary integration of fastening elements eliminates the need for separate drilling, tapping, or fastener installation steps during assembly. The rubber damper is also pre-integrated with the bracket assembly, allowing the entire insulator to be manufactured as a near-net-shape component that requires minimal post-processing or assembly operations.
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 polymer composite strut insulator significantly reduces vehicle weight and component count, enhances NVH performance by effectively absorbing road impacts and vibrations, and simplifies assembly, thereby improving ride comfort and fuel efficiency.
Implementation Method 1
an elastic mass cross-linked to the polymer composite bracket in order for the cup hole surrounding the central hole formed at the central portion of the polymer composite bracket to be divided into an upper cup hole and a lower cup hole
Data Source
AI summary
A polymer composite strut insulator may include a polymer composite bracket made of polymer composite, divided into a mounting fastening portion having an inserter into which mounting bolts are press-inserted to penetrate and a bearing assembling portion, and provided with a central hole at a central portion, an elastic mass cross-linked to the polymer composite bracket in order for the cup hole surrounding the central hole formed at the central portion of the polymer composite bracket to be divided into an upper cup hole and a lower cup hole, the upper cup hole being coupled to an upper cup and the lower cup hole being coupled to a lower cup, and a bearing disposed at the bearing assembling portion.