Sub-frame Mounting Device with Foam Filler for NVH
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Solution Overview
Problem
Conventional mounting devices for sub-frames face issues such as material property changes and potential cracking due to high-temperature welding, as well as strength deterioration in the heat-affected zone, leading to reduced assembly hardness and impact absorption performance.
Innovation Solution
A mounting device for a sub-frame that incorporates a foam filler within the mounting bracket, combined with a reinforced panel and a mounting bolt featuring a flange and grooves, where the foam filler is hardened by heat treatment and contains epoxy resin, enhancing the contact area and binding forces between components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to fix the mounting bolt, then assembly hardness is improved, but material property changes and cracking occur due to high temperature
Solution Approach 1:
The patent introduces foam filler as an intermediary substance between the mounting bracket and the mounting bolt. The foam filler expands to fill the internal cavity, providing mechanical support and fixation without requiring high-temperature welding, thereby preventing material property changes and cracking while still achieving the desired assembly hardness.
Solution Approach 2:
The patent replaces the thermal welding process with a mechanical expansion system. The foam filler is injected in a liquid or low-viscosity state and then expands mechanically to fill the cavity and secure the mounting bolt, substituting the high-temperature thermal field with a mechanical expansion process that does not damage the surrounding materials.
2Reliability
If foam filler is filled in the mounting bracket, then impact absorption is improved, but assembly complexity increases
Solution Approach 1:
The foam filler serves multiple functions simultaneously: it provides mechanical support, absorbs impact, dampens vibrations, and secures the mounting bolt in place. This multi-functionality reduces the need for additional separate components, thereby offsetting the apparent increase in complexity with actual functional consolidation.
Solution Approach 2:
The foam filler is a porous material that provides excellent impact absorption and vibration damping properties. Its cellular structure allows it to deform under impact while maintaining structural integrity, providing superior energy absorption compared to solid materials of the same weight, thereby improving reliability without requiring additional complex damping 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
The solution improves assembly hardness, impact absorption, and durability, minimizing welding faults and enhancing Noise, Vibration, Harshness (NVH) performance by distributing load effectively and increasing the contact area with the foam filler.
Implementation Method 1
a foam filler foamed by a heat treatment and filled in a space formed by the front side inside member, the mounting bracket, the reinforce panel, and a front side outside member
Data Source
AI summary
A mounting device for a sub-frame may include a mounting bracket positioned to correspond with a one side penetration opening formed at a front side inside member of the front side member, a reinforce panel provided to an upper surface of the front side inside member, a mounting bolt separated with a bolt part and a head by a flange which is positioned at a center thereof, joined to a circumference of a bolt opening of the mounting bracket through the flange on a state that the bolt part is inserted into the bolt opening of the mounting bracket, and joined on a state that the head is wedged through the penetration opening of the front side inside member to the welding opening of the reinforce panel, and a foam filler foamed by a heat treatment and filled in a space formed by the front side inside member, the mounting bracket, the reinforce panel, and a front side outside member.