Threaded Upper Strut Mount Cap for Higher Suspension Loads
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Solution Overview
Problem
Existing vehicle suspension components, particularly those used in battery electric vehicles, struggle to withstand the increased loading due to the weight of these vehicles, leading to reduced load capacity and potential damage from localized force distribution.
Innovation Solution
A threaded cap is used to operably couple the upper strut mount to the mounting bracket, distributing load forces evenly through threads, enhancing the load capacity and reducing stress points.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional mounting interface is used to couple the upper strut mount to the body, then the device complexity is low and ease of manufacture is high, but the load capacity is insufficient to withstand increased loading from battery electric vehicle weight
Solution Approach 1:
The mounting interface is segmented into multiple functional components: a mounting bracket with aperture, a threaded cap with internal threads, and a bushing. This segmentation allows each component to be optimized for its specific function while collectively providing enhanced load capacity through distributed force transmission across multiple contact surfaces and threads.
Solution Approach 2:
The threaded cap is inserted into the mounting bracket aperture, and the bushing is positioned within the aperture as well. This nested arrangement allows the components to work together in a compact configuration, with the threaded cap providing external attachment to the body while the bushing provides internal coupling to the damper, creating a multi-layered load path.
2Reliability
If a threaded cap with first and second threads is used to operably couple the upper strut mount to the mounting bracket, then the load capacity and durability are improved through even force distribution, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The threaded cap serves multiple functions simultaneously: it provides structural support for mounting, creates threaded engagement surfaces for both the mounting bracket (first threads) and the upper strut mount (second threads), and distributes loads across its threaded surfaces. This multi-functionality consolidates what would otherwise require multiple separate components into a single manufacturable part.
Solution Approach 2:
The threaded cap utilizes thread parameters (pitch, diameter, thread form) to transform the nature of force transmission. By converting direct axial loads into distributed shear forces across multiple thread engagements, the design achieves higher reliability without requiring proportionally higher material strength or larger component dimensions.
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 threaded cap design improves the load capacity and longevity of the upper strut mount by evenly distributing forces, reducing stress on the mounting bracket and enhancing the suspension system's durability.
Implementation Method 1
The threaded cap may include a first thread which may operably couple to the mounting bracket at a second thread which may be disposed at the aperture of the mounting bracket
Data Source
AI summary
A strut assembly for a vehicle may therefore be provided. The strut assembly may include a damper which may absorb loading along a longitudinal axis of the damper to reduce ride harshness, a lower strut mount which may operably couple the strut assembly to a control arm of the vehicle, and an upper strut mount which may operably couple the strut assembly to a body of the vehicle. The upper strut mount may include a mounting bracket which may operably couple the upper strut mount to the body, a threaded cap which may be operably coupled to the mounting bracket, and a bushing which may be disposed within the mounting bracket to operably couple the damper to the mounting bracket. The threaded cap may include a first thread which may operably couple to the mounting bracket at a second thread disposed at the aperture of the mounting bracket.