Patent Publication Number: US-2020282787-A1

Title: Top suspension mount comprising a removable insert, assembly comprising such a mount, and manufacturing process for such a mount

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a National Stage Patent Application of International Patent Application No. PCT/EP2017/068469, filed Jul. 21, 2017, which claims the benefit of French Application Serial No. 1657533, filed Aug. 3, 2016, the contents of each are incorporated by reference in their entireties. 
    
    
     TECHNICAL FIELD 
     The invention relates to the field of anti-vibratory devices for vehicles, and more particularly a top suspension mount, an assembly comprising such a mount and a shock absorber, as well as a process for manufacturing such a top suspension mount. 
     BACKGROUND 
     The known vehicle top suspension mounts generally comprise three distinct elements, an anti-vibratory block, a metal casing receiving the anti-vibratory block and a cover fastened to the casing so as to limit the deflection of at least a part of the anti-vibratory block. In other words, the cover cooperates, as a stop, with the anti-vibratory block in a predetermined direction. The anti-vibratory block is first assembled to the casing, while the cover is fixed to the casing in a second step, generally by crimping or punching. Such assembly is long and costly. There is therefore a need in this direction. 
     SUMMARY 
     The present disclosure relates to a vehicle top suspension mount. 
     One embodiment relates to a vehicle top suspension mount comprising an anti-vibratory block housed in a casing, and a removable insert, the anti-vibratory block comprising an elastomeric body having a first contact surface while the removable insert has a second contact surface, the second contact surface being distant from the first contact surface, in which the elastomeric body is deformable so that the first contact surface cooperates at least partially, as a support, with the second contact surface. 
     It is understood that the removable insert is a distinct part of the anti-vibratory block and of the casing, and which is inserted in the assembly formed by the anti-vibratory block and the casing while being able to be withdrawn from it. For example, the insert is force-fitted. 
     It is likewise understood that when the insert is assembled with the assembly formed by the casing and the anti-vibratory block, a space is arranged between the first contact surface and the second contact surface so that under at least one regime of the deformation of the elastomeric body, the first contact surface and the second contact surface cooperates wholly or partially with each other. In other words, the elastomeric body has at least one deformation where the first contact surface cooperates wholly or partially with the second contact surface. Of course, no element extends into the space between the first contact surface and the second contact surface. 
     It is likewise understood that the first contact surface is formed integrally by a single wall (i.e. so the first surface is continuous) or has several parts formed by distinct walls (i.e. so the first surface is discontinuous). Likewise, the second contact surface is formed integrally by a single wall (i.e. so the second surface is continuous) or has several parts formed by distinct walls (i.e. so the second surface is discontinuous). For example, the first contact surface has as many parts as the second contact surface, but not necessarily. 
     Such a top suspension mount structure is simple while its assembly is particularly easy thanks to the insert. It is sufficient to merely insert the insert into the assembly formed by the casing and the anti-vibratory block to complete the assembly of the vehicle top suspension mount. Thus, the irksome step of crimping or punching the cover of the top suspension mount known is avoided. 
     Moreover, the deflection of the anti-vibratory block during the deformations of the elastomeric body remains controlled by the cooperation of the first contact surface with the second contact surface. Indeed, during the at least one regime of deformation of the elastomeric body, the first contact surface makes contact with the second contact surface, as a result of which the deformation of the elastomeric body is limited which limits the stroke of the anti-vibratory block. This makes it possible to obtain a damping behaviour with two regimes of the top suspension mount, namely a first regime where the elastomeric body is free to deform and hence shows a certain rigidity, and a second regime where the elastomeric body cooperates with the second contact surface so that the rigidity of the top suspension mount is higher in relation to its rigidity in the first regime. 
     In certain embodiments, the first contact surface is arranged opposite the second contact surface. 
     For example, the space between the first and second surfaces is substantially constant, but not necessarily. Such a configuration is simple to implement, and makes it possible to obtain a structure simple to assemble. 
     In certain embodiments, the anti-vibratory block comprises a ring configured to be joined to a shock absorber rod, said ring extending in an axial direction, the removable insert comprising fingers extending in an axial direction, the second contact surface extending onto the fingers. 
     It is thus understood that the second contact surface is discontinuous and extends onto all the fingers (i.e. onto at least one wall of each of the fingers). Of course, the shape of the fingers is not limited. It is likewise understood that the second contact surface extends in the axial direction. For example, the first contact surface likewise extends in the axial direction, but not necessarily. 
     The anti-vibratory block comprises the elastomeric body and the ring. Thus, it is understood that when a shock absorber is fastened to the ring, the ring is subjected to different forces during the use of the vehicle. Those forces move the ring and deform the elastomeric body, especially in a direction perpendicular to the axial direction (i.e. in a radial direction). The second contact surface hence contacts the first contact surface when the elastomeric body deforms radially. 
     Such a structure is simple and permits easy joining of the insert to the assembly formed by the anti-vibratory block and the casing. 
     In certain embodiments, the insert is configured to be inserted in the axial direction into the assembly formed by the casing and the anti-vibratory block. 
     Such a configuration permits particularly easy and reliable assembly, the forces to which the second contact surface is subjected being perpendicular to the axial direction. Thus, the deformations of the elastomeric body do not run the risk of withdrawing the insert from the assembly formed by the anti-vibratory block and the casing. 
     In certain embodiments, the anti-vibratory block comprises a ring configured to be joined to a shock absorber rod, said ring extending in an axial direction, the elastomeric body being deformable so that the first contact surface cooperates at least partially as a support with the second contact surface when the ring is moved in an axial direction. 
     It is therefore understood that when the ring is moved axially, that is to say, when an axial force is applied to the ring by a shock absorber, the elastomeric body deforms so that the first contact surface cooperates as a support with the second contact surface. For example, when the first and second contact surfaces extend axially, the elastomeric body is deformed in the radial direction when the ring is moved in the axial direction so that the first contact surface wholly or partially becomes a support against the second contact surface. 
     The present disclosure likewise relates to an assembly comprising a vehicle top suspension mount and a shock absorber. 
     One embodiment relates to an assembly comprising a vehicle top suspension mount, such as described in the present disclosure, joined to a shock absorber. 
     The present disclosure relates also to a manufacturing process of a vehicle top suspension mount. 
     One embodiment relates to a manufacturing process for a vehicle top suspension mount such as described in the present disclosure, comprising the steps of supplying an anti-vibratory block comprising an elastomeric body having a first contact surface, over-moulding a casing around the anti-vibratory block by providing at least one space opposite the first contact surface, furnishing a removable insert having a second contact surface, the removable insert being able to be joined to the element formed by the casing and the anti-vibratory block so that the first contact surface is distant from the second contact surface and can cooperate at least partially with the second contact surface during at least one deformation of the elastomeric body. 
     The structure of the vehicle top suspension mount, the subject matter of the present disclosure, makes it possible to manufacture the assembly formed by the anti-vibratory block and the casing in a single piece. This is particularly advantageous and reduces the number of steps necessary for the assembly of said top suspension mount. The assembly of the upper suspension support thus does not comprise more than the step of the insertion of the removable insert into the assembly comprising the casing and the anti-vibratory block. 
     Thus, it is possible to manufacture the casing of polymeric material and to over-mould it on the anti-vibratory block, and especially on the elastomeric body. A polymeric material is a mixture containing a base material (generally a polymer) which may be moulded, shaped, generally hot and/or under pressure, in order to produce one piece. For example, the polymeric material is a synthetic organic polymeric material. For example, the polymeric material is a thermoplastic. 
     In certain embodiments, the removable insert can be assembled so that the second contact surface is arranged opposite the first contact surface. 
     In certain embodiments, the elastomeric body is over-moulded around the ring. 
     Thus, the elastomeric body is over-moulded around the ring while the casing is over-moulded around the elastomeric body. Such a process is particularly well suited to manufacturing such a vehicle top suspension mount on an industrial scale and in an optimum manner. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention and its advantages will be better understood after the reading of the detailed description provided below of different embodiments of the invention given as non-limiting examples. This description refers to the pages of annexed figures, on which: 
         FIG. 1  shows a perspective view of a vehicle top suspension mount, the removable insert approaching the assembly comprising the casing and the anti-vibratory block, 
         FIG. 2  shows the vehicle top suspension mount seen according to sectional drawing II of  FIG. 1 , 
         FIGS. 3A to 3C  show three phases in the course of assembly of the vehicle top mount fitted to a shock absorber, with a vehicle body, and 
         FIG. 4  shows the deformations of the elastomeric body during the axial movement of the ring. 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1 and 2  show a vehicle top suspension mount  10  seen in perspective and in section respectively, where removable insert  24  is not inserted into assembly  20  formed by casing  18  and anti-vibratory block  16   
     Anti-vibratory block  16  comprises elastomeric body  16 A having a first contact surface  40  and a ring  16 B configured to be joined to a shock absorber rod, this ring  16 B showing a rotationally symmetrical shape extending along axis X. More generally, the anti-vibratory block  16  extends in the axial direction X. The first contact surface  40  likewise extends in the axial direction X. Of course, the elastomeric body  16 A is more flexible than ring  16 B so as to be able to deform elastically and to damp the vibrations sustained by ring  16 B so that those vibrations are not transmitted, wholly or partially, to casing  18 . For example, ring  16 B is made of metal or of polymeric material. For the manufacturing of anti-vibratory block  16 , the elastomeric body  16 A is over-moulded around ring  16 B. 
     Casing  18  is made of polymeric material and over-moulded around anti-vibratory block  16 . Thus, assembly  20  formed by anti-vibratory block  16  and by casing  18  forms one single piece. A space E is provided opposite the first contact surface  40 . Casing  18  has an annular shape of axis X. In particular, the casing shows internal portion  18 A which encloses both sides of the anti-vibratory block in axial direction X. In other words, anti-vibratory block  16  is sandwiched in axial direction X by internal portion  18 A of casing  18 . 
     Of course, and this broadly speaking, a radial direction R is a direction perpendicular to axis X. The azimuthal or circumferential direction C corresponds to the direction describing a ring around axial direction X. The three directions—axial X, radial R and azimuthal C correspond to the directions defined by elevation, radius and angle respectively within a cylindrical coordinate system. Finally, unless otherwise stated, the adjectives “internal” and “external” are used with reference to a radial direction R so that the interior part (i.e. radially interior) of an element is closer to axis X than the external part (i.e. radially external) of the same element. 
     Casing  18  has an external portion  18 B showing a peripheral wall  19 , tongues  22  configured to cooperate with a vehicle body and each forming a securing element being arranged in the peripheral wall  19 . In this embodiment, casing  18  comprises four tongues  22 . Each tongue  22  extends substantially in axial direction X in assembly position (that is to say, forming an angle lower than 30° to the axial direction). Each tongue  22  is movable between an assembly position, a position shown in  FIGS. 1, 2, 3A and 3B , and a securing position, a position shown in  FIGS. 3C and 4 . It is noted that in the assembly position the tongues  22  project radially towards the exterior of the peripheral wall  19  while in the securing position tongues  22  “project even more” towards the outside of the peripheral wall  19 , that is to say, that they project radially towards the outside beyond the assembly position. Moreover, in this example, by their elasticity, the natural position of the tongues  22  (i.e. at rest or when they are not subject to any constraint) correspond to the assembly position. Tongues  22  are configured to block, in the securing position, top suspension mount  10  in relation to a vehicle body when vehicle top mount is joined to a vehicle body (see  FIG. 3C ). 
     Casing  18  likewise has a shoulder  23  configured to cooperate with a vehicle body. This shoulder  23  is annular and extends circumferentially along the whole periphery of the external portion  18 B of casing  18 . In this example, shoulder  23  comprises O-ring  25 . 
     Thus, shoulder  23  is configured to cooperate as a support with a vehicle body in a first axial direction X 1  while tongues  22  are configured to cooperate as a support with the vehicle body in a second axial direction X 2  opposite to the first axial direction X 1 . 
     The removable insert  24  has an annular shape of axis X, and has as many fingers  26  as casing  18  has tongues  22 , namely in this embodiment four fingers  26 . Fingers  26  extend in axial direction X from an annular base  29 . The insert is configured to be inserted in axial direction X into assembly  20  formed by anti-vibratory block  16  and casing  18 . It is noted that surface  29 A of base  29  opposite the fingers  26  forms a centring fillet configured to cooperate in a form-locking manner with a jounce bumper  32  (see  FIG. 4 ). 
     The internal faces of the fingers  26  form a second contact surface  42  extending in axial direction X opposite to and at a distance from first contact surface  40 . Thus, the first and second contact surfaces  40  and  42  are discontinuous. Of course, according to one variant, the first contact surface could be continuous while the second contact surface is discontinuous, or inversely. When insert  24  is inserted into assembly  20  formed by anti-vibratory block  16  and casing  18 , first contact surface  40  and second contact surface  42  are radially distant from each other by a distance D (see  FIG. 4 ). 
     The distal end portion  26 A of fingers  26  has an inclined external surface  27  so that the distance between surface  27  and axis X decreases in axial direction X going towards the distal end of the fingers (i.e. in axial direction X 1 ). This inclined surface  27  is configured to cooperate as a support with tongues  22  so as to bring, during the insertion of insert  24  into assembly  20 , tongues  22  from the assembly position to the securing position, and to keep tongues  22  in the securing position. Thus, insert  24  is configured to bring tongues  22  from the assembly position towards the securing position and to lock tongues  22  into the securing position. 
     It is noted that insert  24  is inserted into assembly  20  so that fingers  26  extend into space E, extending axially and arranged radially between external portion  18 B of casing  18 , on the one hand, and the anti-vibratory block  16  of internal portion  18 A of casing, on the other. Moreover, casing  18  and insert  24  are configured so that insert  24  is force-fitted into assembly  20 . Space E opening being on both sides of assembly  20  in axial direction X, to withdraw insert  24  from assembly  20  it is for example possible to press the distal end of fingers  26  in direction X 2 . 
     We will now describe the joining of the top suspension mount  10  to a vehicle body with reference to  FIGS. 3A  à  3 C. In this example, top suspension mount  10  is part of an assembly  50  comprising, furthermore, shock absorber  28  and jounce bumper  32 . Top suspension mount  10  is fastened to shock absorber  28 , and more particularly to rod  28 B of shock absorber  28  in a manner known elsewhere. Moreover, jounce bumper  32  is fitted to rod  28 B and arranged axially between body  28 A of the shock absorber  28  and removable insert  24 . 
     In  FIG. 3A , insert  24  is only partly inserted into assembly  20  formed by anti-vibratory block  16  and casing  18 , so that it does not cooperate with tongues  22 . Tongues  22  are thus in the assembly position. 
     In  FIG. 3A , assembly  50  is shown opposite vehicle body  100 , and upper suspension support  10  is introduced into housing  102  of body  100  provided for this purpose. Considered in axial direction X (i.e. in the vertical direction in  FIGS. 3A, 3B and 3C ), assembly  20  formed by anti-vibratory block  16  and by casing  18  forms the upper part of top suspension mount  10  which is introduced first into housing  102 , from the bottom. In other words, casing  18  is inserted into housing  102 . Insert  24  forms the lower part of the upper suspension support  10 . 
     Top suspension mount  10  is introduced into housing  102  in axial direction X 1  until shoulder  23  cooperates as a support (directly and/or via O-ring  25 ) with body  100 . Tongues  22  being in the assembly position, they do not hamper the introduction of top suspension mount  10  into housing  102  and do not cooperate with rim  104  of housing  102 . 
     In  FIG. 3B , shoulder  23  cooperates as a support with body  100  while tongues  22  are always in the assembly position. Shock absorber  28  continues to be pushed upwards in axial direction X 1  so that rod  28 B sinks into body  28 A and body  28 A presses jounce bumper  32 . Thus, insert  24  is fitted into assembly  20  with shock absorber  28  by means of jounce bumper  32  in axial direction X in insertion direction X 1 . 
     In  FIG. 3C , the insertion of insert  24  into assembly  20  has been completed so that insert  24  brought tongues  22  from the assembly position to the securing position, as symbolised by the thick-line arrows. Tongues  22  hence project more towards the outside of casing  18  than in assembly position so that their distal end cooperates with body  100 , and more particularly in this embodiment with the shoulder formed by rim  104 , and block top mount  10  in axial direction X in the direction of withdrawal from the top suspension mount  10  in relation to vehicle body  100  (i.e. in direction X 2 ). Of course, when the pressure exerted on shock absorber  28  is released, shock absorber  28  and jounce bumper  32  return to the initial position while insert  24 , force-fitted into assembly  20  remains in position inside assembly  20  and locks tongues  22  in the securing position. 
       FIG. 4  shows in more detail the top suspension mount  10  joined to vehicle body  100 . In this configuration, tongues  22  are in the securing position while first contact surface  40  and second contact face  42  are opposite each other and distant from each other by a distance D. When an axial force F is applied by shock absorber  28  to ring  16 B so that ring  16 B moves in axial direction X, the elastomeric body  16 A deforms so that first contact surface  40  cooperates at least partially as a support with second contact surface  42  in accordance with at least one regime of deformation of the elastomeric body  16 A (i.e. according to at least one deformation of the elastomeric body  16 A). Such a regime of deformation is shown as a dashed line in  FIG. 4 . Thus, it is considered that elastomeric body  16 A is deformable so that first contact surface  40  cooperates at least partially as a support with second contact surface  42 . Thanks to this cooperation as a support for the contact surfaces  40  and  42 , the amplitude of the deflection of ring  16 B in axial direction X is limited. 
     Although the present invention has been described with reference to specific embodiments, it is obvious that modifications and changes can be made to these examples without departing from the general scope of the invention such as defined by the claims. In particular, individual characteristics of the different embodiments illustrated/mentioned can be combined in additional embodiments. Consequently, the description and the drawings must be considered in an illustrative rather than restrictive sense. 
     It is likewise obvious that all the characteristics described with reference to a process are transposable, alone or in combination, to a device, and inversely, all the characteristics described with reference to a device are transposable, alone or in combination, to a process.