Suspension Strut Upper Stop Assembly With Preloaded Filter Block
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Solution Overview
Problem
Existing motor vehicle suspension strut assemblies require multiple parts, complex assembly processes, and are not suitable for steering suspensions, with issues including corrosion, lack of pre-stressing of filter blocks, and inadequate integration of bearings.
Innovation Solution
A pre-stressed upper stop assembly for a motor vehicle suspension leg comprising a plain or rolling bearing and a filtering sub-assembly, where the filter block is preloaded between a lower support and a cover, and secured using fastening means that allow independent attachment to the vehicle body, with fastening flaps or crimping processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the filter block is pre-stressed between lower support and cover before mounting on the vehicle, then the impact resistance is enhanced and assembly is simplified, but the complexity of the fixing mechanism increases
Solution Approach 1:
The filter block is pre-stressed between the lower support and cover before the assembly is mounted on the vehicle. This preliminary action of pre-stressing the filter block enhances impact resistance by ensuring the filter is properly compressed and secured in advance, rather than attempting to stress it after installation.
Solution Approach 2:
The fixing mechanism is divided into two independent parts: (1) fixing means that ensures the cover is fixed to the lower support, and (2) fixing openings in the cover that allow the assembly to be fixed to the vehicle body. This segmentation allows the pre-stressing function to be separated from the mounting function, resolving the contradiction between enhanced strength and reduced complexity.
2Productivity
If the fixing openings are arranged radially outside the bearing, then the assembly process is streamlined and production rate is maintained, but the structural design becomes more complex
Solution Approach 1:
The fixing openings are positioned at a specific location - radially outside the bearing - rather than being distributed throughout the cover. This localized positioning optimizes the assembly process by allowing straightforward access for fastening operations while maintaining high production rates, while the structural complexity is managed by concentrating the design feature in one specific area.
3Ease of manufacture
If the cover is fixed independently of the vehicle body, then the assembly process is simplified, but the number of fixing components increases
Solution Approach 1:
The fixing system is segmented into two distinct functions: (1) fixing means (such as clips or lugs) that independently secure the cover to the lower support, and (2) fixing openings that receive fastening elements for attaching the assembly to the vehicle body. This segmentation simplifies the assembly process by allowing the cover-cover support connection to be established separately and independently from the vehicle body attachment.
Solution Approach 2:
The cover serves multiple functions: it houses the pre-stressed filter block, provides fixing means to attach to the lower support, and contains fixing openings for vehicle body attachment. This multi-functionality reduces the need for separate components, offsetting the increase in fixing components with the consolidation of functions into the cover itself.
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 solution provides a simplified assembly process, reduces corrosion risk, and ensures secure attachment of the filter block to the vehicle body, while accommodating the bearing and allowing for pre-stressing, enhancing the durability and efficiency of the suspension system.
Implementation Method 1
a filter block made of elastomeric material, the filter block extending along a reference axis and having an interface for securing one end of a rod of a shock absorber of the suspension strut
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to an upper strut stop assembly (100), the assembly comprising: a bearing (2) and a filter sub-assembly (10) bearing against the bearing (2), which includes: a filter block (20); a lower support (30) having a central portion (31) bearing against a lower face (22) of the filter block (20) and a peripheral portion (32); a cover (40) having a central portion (41) bearing against an upper face (23) of the filter block (20) and a peripheral portion (42) bearing against the annular peripheral portion (32) of the lower support (30). The peripheral portion (42) of the cover (40) is provided with mounting openings (44) arranged radially outside the bearing (2) for attaching the filter sub-assembly (10) to a body element (103) of the vehicle.Fastening means ensure the attachment of the cover (40) with the lower support (30) with a preload of the filter block (20), independently of the fixing openings (44).