Vehicle Roll Rod Extrusion Molding Vibration Insulation
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Solution Overview
Problem
Conventional roll rods for vehicles have poor insulation performance, high manufacturing costs due to complex assembly and material loss, and reduced durability due to the squeeze method used in their production.
Innovation Solution
A roll rod design utilizing extrusion molding for the rod and case brackets, with a simplified structure, and incorporating a rear insulator and stopping rubber to enhance vibration insulation and durability, along with a manufacturing method that forms the components through extrusion molding to reduce costs and improve durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the squeeze method is used to manufacture rod brackets and case brackets to secure rigidity, then the rigidity of brackets is improved, but manufacturing costs are increased and durability is deteriorated due to large material loss and pores in molded products
Solution Approach 1:
The patent changes the manufacturing method from squeeze casting to extrusion molding, fundamentally altering the production parameters. This process change eliminates material waste and pore formation while maintaining bracket rigidity, directly resolving the contradiction between manufacturing cost/durability and structural strength
Solution Approach 2:
The patent replaces the squeeze casting mechanical process with extrusion molding. This substitution eliminates the harmful effects of squeeze casting (material loss, pores) while achieving the desired rigidity through a different mechanical approach that aligns material flow with structural requirements
2Device complexity
If the rear insulator is assembled between the end plate and rod bracket in a pre-compressed state to simplify assembly, then assembly complexity is reduced, but insulation performance deteriorates due to poor vibration isolation
Solution Approach 1:
The rear insulator is pre-formed with protrusions that will engage with recesses in the brackets, but the actual assembly is performed without pre-compression. This allows the insulator to be prepared in advance (reducing assembly complexity) while maintaining its vibration isolation properties during installation
Solution Approach 2:
The protrusions and recesses act as intermediary features that facilitate assembly without requiring pre-compression. These mechanical features guide the insulator into place and secure it after assembly, resolving the contradiction between simplified assembly and insulation performance
3Reliability
If a conventional roll rod structure with multiple separate components is used to ensure structural integrity, then durability is improved, but manufacturing costs increase and weight increases due to complex assembly
Solution Approach 1:
The patent merges multiple separate components (rod bracket, case bracket, rear insulator, stopping rubber) into an integrated assembly where components are combined through extrusion molding and secure fitting. This reduces the number of separate parts and assembly steps while maintaining structural integrity and durability
Solution Approach 2:
The patent uses composite construction by combining different materials (metal brackets with rubber insulators and stopping elements) in a unified design. This allows the assembly to achieve the durability of metal components while incorporating the vibration isolation properties of rubber, reducing the need for separate protective components
Data Source
AI summary
A roll rod for a vehicle includes: a front insulator connected to a powertrain; a rod bracket to mount the front insulator on a front end portion of the rod bracket; a case bracket disposed outside the rod bracket and fastened to a vehicle body; a stopping rubber formed at a rear end portion of the rod bracket and disposed in an inner space defined by the case bracket; and a rear insulator formed between the rod bracket and the case bracket, where the rear insulator is secured to an outer side surface of the rod bracket and an inner side surface of the case bracket. The roll rod enhances an insulation rate against vibration of a powertrain and improves durability while reducing manufacturing costs through the simple structure and application of an extrusion molding method.