Upper Support Cup Piece Pre-Compression Manufacturing
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Solution Overview
Problem
Conventional methods for pre-compressing rubber elastic bodies in upper supports for shock absorbers often result in roll-back deformation and increased risk of cracks, particularly when using cup pieces, which complicates the manufacturing process and reduces durability.
Innovation Solution
A manufacturing method where a cup piece with a tubular portion having a large diameter portion, a small diameter portion, and a stepped portion is integrally vulcanized with a rubber elastic body, with only the small diameter portion being diameter widened to impart pre-compression, preventing roll-back deformation and reducing the risk of cracks by maintaining the large diameter portion's dimensions and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the tubular portion of the cup piece is diameter widened to impart pre-compression to the rubber elastic body, then pre-compression is effectively applied, but roll-back deformation occurs and the risk of cracks increases
Solution Approach 1:
The tubular portion is divided into three distinct sections: a large diameter portion (first section) that maintains original dimensions, a small diameter portion (second section) that is diameter widened, and a stepped portion (third section) connecting them. This segmentation allows pre-compression to be applied only where needed while preserving the structural integrity of the flanged portion.
Solution Approach 2:
Different sections of the tubular portion are given different properties: the large diameter portion maintains the original shape and size to prevent deformation, while the small diameter portion is specifically designed to be diameter widened for pre-compression. This local differentiation ensures that pre-compression is applied precisely where required without causing roll-back deformation.
2Manufacturing precision
If a separate cylindrical inner piece is used to impart pre-compression, then pre-compression can be effectively applied, but the device complexity and manufacturing cost increase
Solution Approach 1:
The cup piece is designed to integrate multiple functions: it serves as both the rebound stopper piece and the pre-compression structure. The tubular portion of the cup piece itself is modified with the large diameter portion, small diameter portion, and stepped portion, eliminating the need for a separate cylindrical inner piece while maintaining the pre-compression function.
Solution Approach 2:
The cup piece is designed to perform multiple functions: it acts as a rebound stopper, provides structural support, and imparts pre-compression to the rubber elastic body through its modified tubular portion. This multi-functionality reduces the total number of components needed in the upper support assembly.
3Manufacturing precision
If the entire tubular portion is diameter widened, then pre-compression is applied uniformly, but the flanged portion deforms due to tensile force
Solution Approach 1:
The tubular portion is segmented into a large diameter portion that maintains the original dimensions and a small diameter portion that is diameter widened. This segmentation prevents tensile force from propagating to the flanged portion, thereby preventing roll-back deformation while still achieving uniform pre-compression in the small diameter portion.
Solution Approach 2:
The diameter widening is applied locally only to the small diameter portion rather than the entire tubular portion. This localized modification ensures that pre-compression is applied uniformly where needed while the large diameter portion and flanged portion maintain their original shape and structural integrity.
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 method allows for the omission of a separate cylindrical inner piece, reduces weight and costs, prevents roll-back deformation, and enhances the durability of the rubber elastic body by ensuring pre-compression is effectively applied without causing deformation or cracking, thus improving the overall performance and longevity of the upper support.
Implementation Method 1
an upper support elastically connecting a piston rod for a shock absorber in a suspension of a vehicle to a vehicle body, and acting to prevent vibration therebetween
Implementation Method 2
a rubber elastic body which is integrally vulcanize adhered to the inner piece and the outer piece
Data Source
AI summary
When manufacturing an upper support which includes a cup piece as an inner piece, an outer piece, and a rubber elastic body integrally vulcanize adhered thereto, the shape of a tubular portion of a cup piece before integral vulcanized adhesion with the rubber elastic body is a shape having a large diameter portion at a top portion continuous with a flanged portion, a small diameter portion at a bottom portion, and a stepped portion therebetween. Following integral vulcanized adhesion with the rubber elastic body, only the small diameter portion is diameter widened by press-fitting a diameter widening jig to impart pre-compression to the rubber elastic body. No roll-back deformation of a flanged portion occurs when integrally vulcanize adhering the cup piece to the rubber elastic body, and also when imparting pre-compression to the rubber elastic body by diameter widening a tubular portion of the cup piece.