Strut Bearing Top Mount Plate Integration
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Solution Overview
Problem
Existing strut bearing assemblies for MacPherson strut systems require multiple assembly steps and separate components, including a cap, guide ring, and thrust bearing, which can increase manufacturing complexity and costs.
Innovation Solution
A suspension strut bearing design where the top mount plate, made of metal, integrates an upper raceway and overmolded seals, reducing the number of components and assembly steps by incorporating the upper raceway directly into the top mount plate and eliminating the need for a separate cap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cap, guide ring, and thrust bearing are used as separate components, then the bearing assembly provides reliable support and damping, but the manufacturing complexity and assembly steps increase
Solution Approach 1:
The patent combines the cap, guide ring, and thrust bearing into a single integrated top mount component. The top mount includes an integrated thrust bearing with rolling elements positioned between a upper raceway (formed directly in the top mount plate) and a lower raceway (formed on the guidance ring). This merging eliminates the need for separate cap and guide ring components while maintaining the bearing's support and damping functions.
Solution Approach 2:
The top mount plate serves multiple functions: it provides structural mounting to the vehicle frame, forms the upper raceway for the thrust bearing, integrates the sealing system, and supports the guidance ring. This multi-functional design consolidates what were previously separate components into a single universal part.
2Reliability
If multiple separate components are used, then the bearing can be assembled with proper fit and function, but the assembly process requires more steps and time
Solution Approach 1:
By integrating the thrust bearing, upper raceway, seals, and guidance ring features into a single top mount component, the assembly process is simplified. Fewer parts need to be handled, positioned, and secured during assembly, directly increasing productivity while maintaining proper fit and function through precision integration of all features into one molded part.
3Ease of manufacture
If separate components are used, then each component can be manufactured independently, but the overall manufacturing cost increases
Solution Approach 1:
The integration of multiple features into a single top mount plate reduces the total number of parts that need to be manufactured, stored, and assembled. While the top mount itself requires precision manufacturing, eliminating separate cap and guide ring components reduces overall material consumption, manufacturing steps, and associated costs.
Solution Approach 2:
The top mount is manufactured as a composite structure combining the rigid plate material with the integrated thrust bearing elements and sealing materials. This composite approach allows for optimized material selection and reduced total material usage compared to assembling multiple separate metal and polymer components.
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
This design simplifies the assembly process, reduces manufacturing costs, and allows for preassembly of the bearing components before final installation on the vehicle frame without compromising performance or vibration damping capabilities.
Implementation Method 1
The internal seal and the external seal are overmolded to the top mount
Implementation Method 2
A plurality of rolling elements contact the upper raceway and the lower raceway to enable relative oscillation between the top mount and the guidance ring about the axis
Implementation Method 3
A guidance ring is configured to oscillate relative to the top mount about the axis
Data Source
AI summary
A suspension strut bearing includes a top mount. The top mount is coupled to a guidance ring, wherein relative rotation or oscillation between the guidance ring and the top mount is enabled via rolling elements between an upper raceway and a lower raceway. The top mount has a top mount plate with an internal seal and an external seal. Both seals are overmolded to the top mounted plate and inhibit debris or the like from interfering with the operation of the rolling elements in the raceways. By overmolding the seals, a separate cap is no longer needed to be part of the suspension strut bearing. Further, the upper raceway can be integrated into the top mount plate itself. For example, the top mount plate can be shaped or formed to take the shape of the upper raceway, rather than having a separate element attached to the top mount plate.