Synthetic Insert Suspension Thrust Bearing
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Solution Overview
Problem
Existing suspension thrust bearing devices for motor vehicles are costly to manufacture, complex to produce, and heavy due to the use of metal reinforcing inserts, which also require costly anti-corrosion treatments and increase pollution.
Innovation Solution
The use of synthetic material inserts molded into synthetic material caps, allowing for lightweight, flexible, and easily recyclable designs that simplify production and reduce costs by eliminating the need for metal inserts and anti-corrosion treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal reinforcing insert is used in the lower supporting cap, then the mechanical strength against suspension spring forces is improved, but the weight of the cap and overall device increases
Solution Approach 1:
The patent changes the material parameter from metal to synthetic polymer for the reinforcing insert, maintaining structural strength while significantly reducing weight. The synthetic material insert provides the necessary mechanical reinforcement against suspension spring forces without the density penalty of metal materials.
Solution Approach 2:
The patent employs composite construction by integrating a synthetic material insert within the lower supporting cap structure. This composite approach combines the strength properties of the insert material with the formability and damping characteristics of the cap material, achieving both mechanical strength and weight reduction.
2Strength
If a metal reinforcing insert is used in the lower supporting cap, then the mechanical strength is improved, but the manufacturing complexity and cost increase due to additional processes
Solution Approach 1:
The patent merges the reinforcing insert and the lower supporting cap into a single integrated component manufactured in one molding process. The insert is molded directly into the cap structure, eliminating separate manufacturing steps for forming the insert, assembling it into the cap, and applying anti-corrosion treatments, thereby simplifying the overall manufacturing process.
Solution Approach 2:
The patent adopts synthetic material inserts that can be manufactured more economically than metal inserts. These synthetic inserts eliminate the need for costly anti-corrosion surface treatments and complex assembly processes, reducing both manufacturing cost and complexity while providing sufficient service life for the suspension application.
3Reliability
If anti-corrosion surface treatments are applied to metal inserts, then the corrosion resistance is improved, but the manufacturing cost and environmental pollution increase
Solution Approach 1:
The patent extracts the metal insert from the design and replaces it entirely with a synthetic material insert. This elimination of metal removes the need for anti-corrosion surface treatments such as electrophoresis, thereby reducing manufacturing cost and eliminating the associated environmental pollution from these treatment processes.
Solution Approach 2:
The patent uses synthetic material inserts that inherently resist corrosion without requiring additional protective surface treatments. This approach eliminates costly and environmentally harmful anti-corrosion processes while providing sufficient durability for the suspension application lifecycle.
4Strength
If a metal reinforcing insert is used in the lower supporting cap, then the mechanical strength is improved, but the production time increases due to multiple manufacturing steps
Solution Approach 1:
The patent combines the manufacturing of the reinforcing insert and the lower supporting cap into a single integrated molding operation. The synthetic material insert is molded directly into the cap structure in one continuous process, eliminating the sequential steps of forming the insert separately, assembling it into the cap, and applying surface treatments, thereby significantly reducing production time.
Data Source
AI summary
The suspension thrust bearing device for a motor vehicle comprises a rolling bearing (22) forming a thrust and provided with an upper ring, a lower ring, and at least one row of rolling elements placed between the rings, a bearing cap (18) in contact with the upper ring, and a supporting cap (20) in contact with the lower ring and forming a bearing means for a suspension spring (12). At least one of the said caps comprises a body formed of at least a first synthetic material and an insert (34) at least partly covered by the said body. The said insert is formed of at least a second synthetic material different from the first synthetic material.