Segmented Suspension Thrust Bearing Cap for Lower Material Use
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Solution Overview
Problem
The manufacturing costs of suspension thrust bearing assemblies for motor vehicle suspension struts are high due to the material and weight requirements of existing designs.
Innovation Solution
A suspension thrust bearing assembly with an upper bearing cap featuring a discontinuous annular surface with axially projecting protuberances, reducing material usage and allowing for cost-effective production by either forming the protuberances as part of the cap or attaching them separately, thereby minimizing material costs and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the upper bearing cap uses a continuous annular surface design, then the structural strength and load-bearing capacity are sufficient, but the material usage and manufacturing cost increase
Solution Approach 1:
The continuous annular bearing surface is segmented into multiple discrete protuberances distributed around the upper bearing cap. This segmentation reduces the total material volume while maintaining load distribution capability, as the protuberances are spaced to contact the upper bearing seat at multiple points rather than forming a continuous surface.
Solution Approach 2:
Instead of providing uniform material distribution across the entire annular surface, the design concentrates material only where needed - at the protuberance locations that contact the upper bearing seat. This local quality approach ensures sufficient contact area for load transmission while eliminating unnecessary material in non-contact regions.
2Weight of moving object
If the upper bearing cap uses a continuous annular surface design, then the load-bearing capacity is sufficient, but the weight of the assembly increases
Solution Approach 1:
The bearing surface is divided into discrete protuberances rather than a continuous surface, reducing the overall material mass. The segmented structure maintains load-bearing capacity through distributed contact points that collectively support the axial and radial loads transmitted through the suspension thrust bearing assembly.
3Ease of manufacture
If the protuberances are formed as integral part of the upper bearing cap, then the manufacturing process is simplified, but the molding complexity increases
Solution Approach 1:
The protuberances are integrated into the upper bearing cap as an integral feature, combining what could be separate components into a single molded part. This merging eliminates assembly steps for attaching bearing surfaces to the cap, simplifying the overall manufacturing process despite requiring more complex mold design to form the protuberance geometry.
Data Source
AI summary
A suspension thrust bearing assembly includes a lower support cap, an upper bearing cap having an annular upper surface facing axially away from the lower support cap, and at least one bearing disposed between the caps. The annular upper surface includes a plurality of axially projecting protuberances spaced apart in the circumferential direction.