TPE Anti-Vibration Bushing Structure for Lighter Motor Brackets
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Solution Overview
Problem
Existing anti-vibration brackets for electric motors in vehicles are heavy, complex to manufacture, and inadequate for reliably damping or absorbing vibrations generated by electric motors.
Innovation Solution
A bushing for anti-vibration brackets made from a thermoplastic elastomer (TPE) with an outer structure and inner sleeve, featuring a connecting structure with helical blades that allows for lighter weight, easier manufacturing, and improved vibration damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional anti-vibration brackets are used, then vibration damping is provided, but the brackets are heavy and complicated to manufacture
Solution Approach 1:
The patent changes the material parameter from traditional rubber or thermoset elastomers to thermoplastic elastomers (TPE), which fundamentally alters the manufacturing process. TPE allows injection molding without vulcanization, transforming the manufacturing method from multi-step (molding + vulcanization + bonding) to single-step injection molding, thereby reducing manufacturing complexity while maintaining vibration damping effectiveness
Solution Approach 2:
The patent employs composite material strategy by using TPE that combines thermoplastic processability with elastomeric vibration damping properties. This composite material approach enables the bushing to be manufactured like thermoplastics (easy injection molding) while retaining the elastic deformation and energy absorption characteristics of elastomers, thus resolving the contradiction between ease of manufacture and vibration damping reliability
2Ease of manufacture
If thermoset elastomers are used for bushings, then vibration absorption is achieved, but manufacturing requires vulcanization cores and bonding agents increasing complexity
Solution Approach 1:
The patent extracts and eliminates the vulcanization core and bonding agent components from the manufacturing process by switching to TPE material. TPE's thermoplastic nature allows direct injection molding and self-bonding to metal inserts, removing the need for separate vulcanization and bonding steps, thus reducing device complexity in the manufacturing process
Solution Approach 2:
The TPE material provides self-service functionality by automatically bonding to metal inserts and other TPE components through its thermoplastic properties during injection molding. The material self-adheres without requiring external bonding agents or complex assembly processes, simplifying the manufacturing process and reducing the number of process steps
3Reliability
If traditional rubber materials are used, then elastomeric properties are maintained, but manufacturing cost and complexity increase
Solution Approach 1:
The patent changes the material parameter from thermoset rubber to thermoplastic elastomer, which fundamentally alters both manufacturing cost and elastomeric property delivery. TPE maintains elastomeric properties through physical entanglement and reversible phase separation rather than chemical crosslinking, enabling lower-cost injection molding without vulcanization while preserving the required elastomeric behavior for vibration absorption
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 TPE bushing is lighter, easier to manufacture, and effectively absorbs vibrations across a broad frequency range, improving NVH properties and reducing manufacturing costs.
Implementation Method 1
Elastomeric material(s) allow for a reversible displacement and reversible stretching of structural components of the bushing. A displacement of a structural part causes a dampened force in the opposite direction of the displacement, thereby effectively absorbing vibrational energy caused by a vibration exerting component held by the bushing.
Implementation Method 2
A displacement of a structural part causes a dampened force in the opposite direction of the displacement, thereby effectively absorbing vibrational energy caused by a vibration exerting component held by the bushing.
Implementation Method 3
An additional benefit of using thermoplastic elastomers is the ability to stretch to moderate elongations and return to its near original shape creating a longer life and better physical range than other materials.
Data Source
AI summary
A bushing for an anti-vibration bracket is disclosed. The bushing comprises an outer structure and an inner sleeve. In embodiments, the outer structure comprises a connecting structure connected to the inner sleeve and the outer structure that is adapted to connect to an opening of an anti-vibration bracket. In embodiments, the inner sleeve comprises a through hole adapted to connect to an at least partially tube-shaped member, and the connecting structure may be comprised of a thermoplastic elastomer (TPE).