Variable Thickness Damper Inlay for Commercial Vehicles
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Solution Overview
Problem
Conventional damper inlays for vehicles require an outer sleeve for mounting, increasing complexity and cost due to additional parts and larger dimensions, which complicates manufacturing and installation.
Innovation Solution
A damper inlay design featuring a core element and radial damper with variable radial thickness, eliminating the need for an outer sleeve by ensuring a tight fit and adjustable stiffness through alternating sections of higher and lower radial thickness, along with convex and concave contours for easy installation and improved deformation capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an outer sleeve is added to the damper inlay for mounting purposes, then the mounting characteristics are improved, but the overall dimensions increase and manufacturing complexity increases
Solution Approach 1:
The patent merges the mounting function directly into the radial damper structure by creating an integration zone where the radial damper and mounting zone form a unified component. This eliminates the need for a separate outer sleeve while maintaining the mounting capability, as the radial damper itself provides the interface for press-fitting into the housing.
Solution Approach 2:
The radial damper serves multiple functions simultaneously: it provides radial damping, defines the outer contour for mounting, and creates the integration zone for press-fitting into the housing. This multi-functionality eliminates the need for dedicated mounting sleeves or additional components.
2Ease of operation
If an outer sleeve is added to the damper inlay, then mounting characteristics are improved, but production costs increase due to additional manufacturing steps
Solution Approach 1:
The mounting function is merged into the radial damper manufacturing process. The radial damper is produced with an integrated integration zone that includes the mounting interface, allowing the entire component to be manufactured in a single process without additional assembly steps for mounting sleeves.
Solution Approach 2:
The mounting function is extracted from being a separate component feature and integrated directly into the radial damper's structural design. The integration zone with its specific contour and wall thickness is built into the radial damper itself, eliminating the need for separate mounting parts.
3Ease of manufacture
If constant radial thickness is used in the radial damper, then manufacturing is simpler, but the damper cannot achieve tight fit or optimized deformation capacity
Solution Approach 1:
The radial damper features variable radial thickness with a thinner integration zone specifically at the mounting interface and a thicker damping zone in the radial damping area. This local variation in thickness provides both tight fit during mounting and optimized deformation capacity during operation, with each zone tailored to its specific functional requirements.
Solution Approach 2:
The radial damper design incorporates dynamic thickness variation that allows different sections to deform differently under load. The integration zone has controlled thickness for precise mounting, while the damping zone has greater thickness and deformation capacity to handle radial loads effectively.
4Device complexity
If variable radial thickness is implemented in the radial damper, then outer sleeve is eliminated and tight fit is achieved, but manufacturing complexity increases
Solution Approach 1:
The variable thickness is implemented as a localized feature in the integration zone rather than throughout the entire radial damper. The integration zone has reduced wall thickness compared to the damping zone, creating the necessary variation for tight fit while maintaining manufacturing feasibility through targeted design in specific areas.
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 design simplifies manufacturing, reduces production costs, and facilitates convenient housing installation while maintaining a secure fit and enhanced deformation capabilities under load, improving the damper's performance and installation properties.
Implementation Method 1
a radial damper (10) for damping radial loads perpendicular to a longitudinal axis (12) of the damper inlay (6)
Implementation Method 2
The sections of higher radial thickness can flexibly deform radially and axially when large loads are applied to the damper inlay
Data Source
Figure 1
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Figure 3
AI summary
The invention relates to a damper inlay (6, 106), in particular a hybrid top mount inlay (6, 106) for a vehicle, in particular a commercial vehicle, said damper inlay (6, 106) comprising a core element (8, 108), a radial damper (10, 110) for damping radial loads perpendicular to a longitudinal axis (12, 112) of the damper inlay (6, 106), said radial damper (10, 110) radially surrounding the core element (8, 108), wherein the core element (8, 108) and the radial damper (10, 110) comprise a centrally arranged through hole (14, 114), the through hole extending along the longitudinal axis (12, 112) of the damper inlay (6, 106). According to the invention at least one of the core element (8, 108) or the radial damper (10, 110) comprise a variable radial thickness (16, 116) in a circumferential direction (18, 118) around the longitudinal axis (12, 112).