Stabilizer Link Weight Reduction and Housing Position Adjustment
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Solution Overview
Problem
Existing methods for manufacturing stabilizer links require new molds for different circumferential positions and distances between housings, limiting flexibility and increasing production costs.
Innovation Solution
A method involving a solid or hollow support bar made of light metal or fiber-reinforced plastic, where end portions are inserted into molds as cores, and housings are formed by injection molding, allowing for adjustable positions and distances without changing molds, using resin that shrinks to rigidly fix housings to the support bar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional integral molding method is used to manufacture housing and support bar, then structural stability is ensured, but weight reduction cannot be achieved and flexibility for adjusting circumferential position and distance is lost
Solution Approach 1:
The stabilizer link is divided into separate components: the support bar (made of light metal) and the housing (made of resin). These components are manufactured separately and then assembled together, allowing weight reduction through material selection and flexibility in adjusting the circumferential position and distance between housings without being constrained by a fixed integral mold structure.
Solution Approach 2:
The invention uses composite material construction by combining light metal (such as aluminum alloy) for the support bar and resin for the housing. This composite approach achieves weight reduction while maintaining structural integrity and providing design flexibility for adjusting geometric parameters without requiring new molds.
2Manufacturing precision
If new molds are prepared for different circumferential positions and distances, then manufacturing precision is maintained, but device complexity and production costs increase
Solution Approach 1:
The invention introduces adjustability into the system by allowing the housing to be positioned at different circumferential locations and distances along the support bar. This dynamic configuration capability is achieved through the separate component design and assembly process, eliminating the need for multiple fixed molds while maintaining manufacturing precision through controlled assembly procedures.
Solution Approach 2:
A single mold design can produce housings that are subsequently assembled in various positions and configurations on the support bar. This universal approach allows one mold to serve multiple purposes for different stabilizer link configurations, reducing the total number of molds needed while maintaining manufacturing precision through standardized housing production and flexible assembly.
3Ease of manufacture
If resin injection molding is used to fix housing to support bar, then ease of manufacture is improved, but potential for rotation or separation must be prevented
Solution Approach 1:
The invention replaces traditional mechanical fastening methods (such as bolts or clips) with resin injection molding to bond the housing to the support bar. This substitution simplifies the manufacturing process by creating an integral-like bond through material injection, improving ease of manufacture while the resin's adhesive and structural properties prevent rotation and separation, ensuring reliability.
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
Enables weight reduction and adjustable positions and distances between housings, reducing the need for multiple molds and facilitating flexible manufacturing without compromising stability or rotation prevention.
Implementation Method 1
the injected resin is mold-shrunk, whereby the housings are rigidly fixed to both end portions of the support bar
Data Source
Figure 1~2
Figure 3A~4B
Figure 5A~7
AI summary
A stabilizer link in which weight reduction can be achieved and the circumferential position and the distance between both housings can be adjusted, and a method for manufacturing same, are provided. A solid bar made of a light weight metal or a fiber reinforced plastic is used for a support bar 60. An end portion 61 of the support bar is inserted into a mold as a core, and a housing 50 is formed at the end portion 61 of the support bar 60 by injection molding. In this case, the resin is mold-shrunk, whereby a boss portion 52 of the housing 50 covers and adheres to the whole circumference of the end portion 61 of the support bar 60 thereof. Therefore, the boss portion 52 is rigidly fixed to the end portion 61.