Split Ring Bushing Assembly for Stabilizer Bar Zero Clearance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current stabilizer bar mounting systems face challenges in achieving zero clearance and maintaining torsional freedom while accommodating frame build variations and limited packaging space, especially with larger stabilizer bars, as existing solutions like slipper bushings and gripper bars often exceed the strain capacity of rubber materials.
Innovation Solution
A bushing assembly comprising a split ring with axial retention flanges and an elastomer bushing with a reduced coefficient of friction, secured by a strap clamp and split clamp, which creates a zero clearance condition and allows for high axial rate, enabling minimal cross-car deflection and torsional freedom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If slipper bushings are used to allow torsional and axial movement, then the stabilizer bar achieves freedom of movement, but large clearances are required which exceed available packaging space
Solution Approach 1:
The elastomer bushing changes the friction parameter between the stabilizer bar and mounting structure, providing low-friction movement that enables torsional and axial freedom without requiring large clearances. The material properties of the elastomer allow movement while maintaining compact dimensions.
Solution Approach 2:
The bushing assembly uses composite construction combining the elastomer bushing with the split ring and metallic components. This composite structure provides both the movement freedom of elastomeric materials and the structural integrity of metal components, achieving compact design with full range of motion.
2Area of stationary object
If a collar is attached to limit movement, then clearance requirements are reduced, but frame build variations still require some clearance
Solution Approach 1:
The elastomer bushing uses material property changes (low friction coefficient) to provide movement control that accommodates frame build variations without requiring precise clearance tolerances. The elastomeric material compensates for variations while maintaining reliable movement control.
3Reliability
If a gripper or bonded stabilizer bar with rubber component is used to limit motion, then motion control is improved, but the rubber material exceeds its strain capacity with larger stabilizer bars
Solution Approach 1:
The elastomer bushing acts as an intermediary between the stabilizer bar and the split ring, providing motion control through its low-friction surface rather than through strain in the rubber material itself. This mediator approach allows motion control without subjecting the elastomer to excessive strains that would occur in bonded configurations.
Solution Approach 2:
The invention replaces the bonded rubber-to-bar mechanical connection with a low-friction elastomeric surface that allows controlled movement. This substitution eliminates the strain concentration at the rubber-to-bar interface while maintaining motion control through the elastomer's friction characteristics.
4Ease of operation
If the inner diameter of the elastomer bushing has a reduced coefficient of friction, then torsional freedom is improved, but the elastomeric material requires modification
Solution Approach 1:
The elastomer bushing incorporates PTFE liner or lubricant pockets as composite features within the elastomeric material. This composite construction provides the low-friction surface needed for torsional freedom while maintaining the elastomeric material's other beneficial properties. The PTFE or lubricant acts as a friction-reducing layer within the bushing structure.
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 bushing assembly achieves a high axial rate, minimizing cross-car deflection and allowing the stabilizer bar to fit in tight spaces while maintaining torsional freedom, and absorbs frame build variations through mechanical interlocks and adhesive layers.
Implementation Method 1
The inner diameter of the elastomer bushing has a reduced coefficient of friction when compared to an elastomeric material the elastomer bushing is constructed of
Implementation Method 2
an elastomer bushing defining an inner diameter, an outer diameter, a first bushing end, a second bushing end
Data Source
AI summary
A bushing assembly for a stabilizer bar in a vehicle includes a split ring defining a passageway engaging with an outer surface of the stabilizer bar, an outer diameter surface, a first split ring end, a second split ring end, and at least one axial retention flange disposed at either the first split ring end or the second split ring end. The bushing assembly includes an elastomer bushing defining an inner diameter, an outer diameter, a first bushing end, a second bushing end, a first axial flange disposed at the first bushing end, and a second axial flange at the second bushing end. At least one of the first axial flange and the second axial flange abut against the at least one axial retention flange of the split ring to create a zero clearance condition. The bushing assembly also includes a strap clamp securing the bushing assembly to the vehicle.