Ball Bearing with Folded Outer Ring for Clutch Thrust Devices
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Solution Overview
Problem
Existing rear drive modules in all-wheel drive driveline systems for motor vehicles face challenges in reducing friction torque within clutch thrust devices, which affects fuel efficiency and operational stability.
Innovation Solution
A ball bearing with a fixed inner ring and a rotatable outer ring, featuring a toroidal and radial portion design with a folded portion for axial contact, is used to transmit axial forces and reduce friction torque, integrated with a clutch thrust bearing device that includes an axially movable piston and a resilient biasing member for efficient connection and disconnection of wheels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a clutch bearing with a plurality of needles is used, then the axial force transmission is achieved, but the friction torque is high which increases fuel consumption
Solution Approach 1:
The patent replaces the needle bearing mechanical system with a ball bearing system. The ball bearing uses spherical rolling elements instead of needle rollers, which reduces contact area and friction torque while maintaining axial force transmission capability through the raceway geometry and ball arrangement.
Solution Approach 2:
The patent changes the bearing type parameter from needle bearing to ball bearing, and modifies the raceway geometry parameters (curved surfaces) to optimize the contact mechanics. This parameter change transitions the friction regime from sliding to rolling, significantly reducing friction torque and energy loss.
2Ease of manufacture
If a ball bearing with folded portion is designed, then the manufacturing cost is reduced and ease of manufacture is improved, but the structural complexity increases
Solution Approach 1:
The patent merges the axial location function and the axial force transmission function into a single integrated ball bearing component. The folded portion of the outer ring combines the bearing outer race with an axial stop feature, eliminating the need for separate location components and simplifying the overall assembly.
Solution Approach 2:
The ball bearing is designed with multi-functionality: the folded portion of the outer ring simultaneously serves as the bearing outer race, an axial location element for the piston, and a force transmission element. This universal design reduces the number of separate components needed in the clutch thrust bearing device.
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 ball bearing design significantly reduces friction torque, enhancing fuel efficiency and operational stability by allowing for easy and cost-effective manufacturing, while enabling efficient connection and disconnection of wheels in the driveline system.
Implementation Method 1
a ball bearing comprising a fixed inner ring, a rotatable outer ring, and one series of balls located in a raceway chamber defined between the rings
Implementation Method 2
a resilient biasing member exerting an axial preload onto the ball bearing
Implementation Method 3
the piston cavity being connected to a source of hydraulic fluid which may variably provide pressurized fluid in the cavity to axially move the piston
Data Source
AI summary
A ball bearing includes a fixed inner ring able to bear against an axially movable piston, a rotatable outer ring, and one series of balls between the fixed inner ring and the rotatable outer ring. The rotatable outer ring also includes a folded portion able to bear against a resilient biasing member. The ball bearing can be integrated into a clutch thrust bearing device. The clutch thrust bearing device can be integrated into a driveline system. The driveline system can be included in an all-wheel drive driveline system of a motor vehicle.