Steering Knuckle Mount Braces for Off-Road Impact Protection

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Solution Overview

Problem

Factory-supplied mounting structures for vehicle steering knuckles are prone to damage from rocks and other obstacles during off-road activities, leading to steering malfunctions and alignment issues due to their lack of strength and protection.

Innovation Solution

The development of reinforcing braces with sturdy metal flanges and base plates that attach to the factory-supplied chassis mounts, providing additional strength and a deflecting shield to protect the mounting hardware from impacts, allowing the use of after-market camber plates and tabs for enhanced reinforcement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If factory-supplied mounting structures are used, then the vehicle can be assembled quickly and easily, but the mounting structures are prone to damage from rocks and obstacles during off-road activities

Engineering Contradiction:

Improveease of assemblyVSAvoiddamage resistance

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The mounting structure is divided into two separate components: the factory-supplied mounting structure and the aftermarket reinforcement brace. The brace is a separate piece that attaches to the existing mounting structure, allowing the original easy-to-assemble design to be retained while adding protective functionality through an additional component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reinforcement brace is designed to attach to and surround the factory-supplied mounting structure, creating a nested configuration where the brace envelops the original mounting points. This nested arrangement provides enhanced protection while maintaining the underlying factory structure.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If after-market heavy-duty steering knuckles and control arms are installed, then the steering assembly can withstand added forces from rock crawling, but the factory mounts for attaching the lower control arm to the chassis remain vulnerable

Engineering Contradiction:

Improveforce withstanding capacityVSAvoidmounting structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Instead of replacing the entire mounting system with heavy-duty components, the reinforcement is applied locally only at the vulnerable mounting points where the lower control arm attaches to the chassis. The reinforcement braces are positioned specifically at the front and rear mounting locations, providing targeted strength enhancement without requiring complex modifications throughout the entire steering assembly.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The solution applies partial reinforcement by installing braces only at the critical mounting points rather than upgrading the entire steering system. This partial action approach provides sufficient protection for the vulnerable factory mounts while avoiding the complexity and cost of complete system replacement.

Inventive Principle:

Principle #16Partial or excessive action

3Adaptability or versatility

If camber plates with oval-shaped openings are used, then camber adjustment is possible, but jolts and forces cause hardware to move in the openings leading to tab deformation

Engineering Contradiction:

Improvecamber adjustment capabilityVSAvoidhardware stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The reinforcement braces are installed beforehand to provide a stable, reinforced background structure that prevents hardware movement. By strengthening the mounting structure in advance, the braces create a stable foundation that accommodates the camber adjustment hardware while preventing the deformation issues that occur with standard mounting structures under load.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Data Source

PatentUS11794814B2Reinforcement and protection braces for mounting structures of vehicle steering knuckle lower control arms

Publication Date: 2023.10.24 MARLIN CRAWLER INC

AI summary

The present invention provides reinforcing braces for attachment to factory-supplied chassis mounts for the lower control arms of steering knuckles of vehicles to reinforce and shield the mounts from objects below the vehicle encountered when traveling through rugged terrain. Each brace includes a pair of parallel sturdy metal flanges that are attached to a sturdy metal lower base plate. Each flange is designed to be attached to one of the flanges of the factory-supplied chassis mounts, and has an opening therein for receiving mounting hardware, and an open section for engagement with camber adjustment structures. The sturdy base plates provide a lower shield to protect the chassis and mounting hardware from damage from contact with large objects encountered below the vehicle. The front base plate may also include an elongated front shield for deflecting large objects as the vehicle moves forward.