Vehicle Suspension Connecting Structure With Integrated Rigid Joint
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Solution Overview
Problem
Existing vehicle suspension structures face challenges in enhancing the rigidity of connecting portions without increasing component weight or manufacturing costs, as conventional methods often require additional components like struts for reinforcement.
Innovation Solution
A suspension structure for vehicles is designed using press-formed first and second plates with integrated flange portions, where the connecting portions are formed by overlapping and weld-bonding these plates to enhance rigidity without additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cross-sectional shape of the connecting portion is increased to enhance rigidity, then the rigidity is improved, but the component weight increases
Solution Approach 1:
The invention transitions from increasing cross-sectional dimensions to creating a three-dimensional structured connecting portion with multiple wall portions forming a cage-like structure. This dimensional transformation allows rigidity enhancement through geometric configuration rather than simply increasing material thickness, thereby avoiding weight increase.
Solution Approach 2:
The connecting portion is divided into multiple wall portions (first, second, third, and fourth wall portions) that form a segmented, cage-like structure. This segmentation creates multiple load-bearing surfaces and structural pathways that enhance rigidity without requiring a solid, heavy cross-section, thus improving strength-to-weight ratio.
2Strength
If the thicknesses of the wall portions are increased to enhance rigidity, then the rigidity is improved, but the manufacturing costs increase
Solution Approach 1:
Instead of increasing wall thickness in a single dimension, the invention creates a multi-dimensional wall structure with four distinct wall portions extending in different directions. This dimensional approach enhances rigidity through structural geometry rather than material quantity, reducing manufacturing complexity and cost.
Solution Approach 2:
The invention merges the body portion and connecting portion into a single integrated press-formed component. This consolidation eliminates the need for separate manufacturing and assembly processes for reinforcement elements, simplifying production and reducing manufacturing costs while achieving the required rigidity.
3Strength
If additional components like struts are added to enhance rigidity, then the rigidity is improved, but the device complexity increases
Solution Approach 1:
The invention integrates the connecting portion directly into the body portion as an integral part of the press-formed component. This merging eliminates the need for separate strut components and their associated assembly operations, reducing device complexity while maintaining structural rigidity through the multi-wall configuration.
Solution Approach 2:
The body portion serves multiple functions: it provides the main structural support, contains the connecting portion with enhanced rigidity, and integrates mounting surfaces for suspension components. This multi-functionality eliminates the need for dedicated reinforcement components like struts, simplifying the overall device structure.
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 approach improves the rigidity of connecting portions while maintaining cost-effectiveness and ease of assembly, without the need for separate components like struts, thus optimizing manufacturing efficiency and reducing costs.
Implementation Method 1
a first flat plate portion which is continuous with a principal surface of the first body portion and is bent and extends with respect to the principal surface
Implementation Method 2
The flange portion of the first plate is overlaid on and bonded to the second body portion of the second plate
Data Source
AI summary
A suspension structure for vehicle includes a first plate, a second plate, and a first connecting portion. The first plate includes a flange portion which is bent with respect to a first flat plate portion. The flange portion of the first plate is overlaid on and bonded to a second body portion of the second plate. A portion facing the first flat plate portion in the first plate is open, and a first mounting surface is formable by press working in a single state with the bent first flat plate portion. A portion facing a second flat plate portion in the second plate is also open. The connecting portion is constructed by bringing the first flat plate portion and the second flat plate portion face-to-face with each other with a space between the first and second flat plate portions and spacing the first mounting surface and a second mounting surface.