Suspension Thrust Assembly Bonding via Curved Overmolded Interface
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Solution Overview
Problem
In existing suspension thrust assemblies, the damping component deforms under the force of a suspension spring, leading to radial displacement and increased risk of partial detachment from the rigid component due to a flat contact bonding surface.
Innovation Solution
The damping component is overmolded and formed to the rigid component, with a ring-shaped protrusion on the damping component fitting into a ring-shaped groove on the rigid component, and additional features like groove bosses, blind holes, stepped bosses, and ribs are used to increase the contact bonding area and prevent displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flat contact bonding surface is used between the damping component and rigid component, then the manufacturing process is simple, but the damping component deforms under spring force causing radial displacement and increased detachment risk
Solution Approach 1:
The patent replaces the flat contact bonding surface with a curved surface design. The damping component features a curved bonding surface that conforms to the curved surface of the rigid component, allowing the damping material to deform radially under spring force while maintaining continuous contact. This curvature enables the damping component to expand radially without creating detachment risks, resolving the contradiction between manufacturing simplicity and bonding reliability.
2Reliability
If the damping component is allowed to expand radially under spring force, then the damping function is improved, but the risk of partial detachment from the rigid component increases
Solution Approach 1:
The curved bonding surfaces enable radial expansion of the damping component while maintaining contact. The curvature allows the damping material to deform outward under spring force without creating gaps or detachment, as the curved geometry naturally accommodates the radial displacement while preserving the bonding interface.
3Strength
If the contact bonding area between damping component and rigid component is increased, then the bonding strength is improved, but the complexity of the component structure increases
Solution Approach 1:
The curved bonding surfaces inherently increase the contact bonding area compared to a flat surface, as the curvature allows for greater surface engagement between the damping and rigid components. This increased area enhances bonding strength while the curvature itself is a simple geometric feature that does not significantly increase manufacturing complexity.
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 enhances the contact bonding area and prevents axial and radial displacement of the damping component relative to the rigid component, reducing the risk of detachment and ensuring stability under the force exerted by the suspension spring.
Implementation Method 1
due to a force exerted by a suspension spring on the damping component, the damping component will be deformed, thereby causing the damping component to generate radial displacement relative to the rigid component
Data Source
AI summary
A suspension thrust assembly, the suspension thrust assembly including a damping component and a rigid component, the damping component being overmolded and formed to the rigid component; the damping component including a damping radial portion; the rigid component including a rigid radial portion; where a ring-shaped damping component protrusion is provided on the damping radial portion, a ring-shaped rigid component groove is provided on the rigid radial portion, and the damping component protrusion is fitted in the rigid component groove.