Clutch Release Bearing Stop Disk Radial Locking
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Solution Overview
Problem
The production of clutch release bearings with plastic thrust washers attached to metal flanges is complex due to the need for precise insertion and encapsulation, leading to high tool costs and potential flange weakening.
Innovation Solution
The introduction of radial deviations on the flange's through opening, which form a non-rotatable positive connection with the thrust washer's second leg, securing it axially and against rotation, using form-fitting elements like projections and undercuts, allowing for a secure and easy assembly without additional axial installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thrust washer is attached to the flange by injection molding encapsulation, then the connection is secure, but the production process becomes complex and tool costs increase
Solution Approach 1:
The connection is divided into two independent elements: axial securing through the L-shaped thrust washer geometry and circumferential securing through radial deviations (projections/depressions). This segmentation eliminates the need for complex injection molding encapsulation while maintaining secure connection.
Solution Approach 2:
The radial deviations (projections or depressions) are pre-formed on the flange and thrust washer before assembly. During assembly, these pre-formed features automatically engage to prevent relative rotation, eliminating the need for post-assembly encapsulation processes.
2Reliability
If the thrust washer is attached by injection molding, then the connection is secure, but the flange may be weakened
Solution Approach 1:
The connection mechanism is segmented into axial support (first leg on flange outer circumference) and circumferential locking (radial deviations engaging rotation stops). This avoids concentrated encapsulation forces that could weaken the flange while distributing loads through geometric interlocking.
Solution Approach 2:
The injection molding encapsulation process is completely extracted and replaced by a mechanical interlocking system using radial deviations and rotation stops. This eliminates the harmful effects of encapsulation on flange strength while maintaining connection security.
3Reliability
If radial deviations are added to the flange and thrust washer, then anti-rotation locking is achieved, but the manufacturing precision requirements increase
Solution Approach 1:
The radial deviations (projections or depressions) are localized features with limited circumferential extent, not requiring high precision over the entire circumference. The rotation stops provide localized engagement points that are easier to manufacture with standard tolerances.
Solution Approach 2:
The radial deviations are designed as asymmetric features (protruding noses, cams, ribs) that provide directional guidance and locking. This asymmetric geometry ensures proper orientation during assembly while allowing for broader manufacturing tolerances compared to symmetric precision features.
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a clutch release bearing (3, 41) comprises a non-rotating outer ring (4, 47) and a rotating inner ring (5, 46), the outer ring (4, 47) and the inner ring (5, 46) having races (6, 7) for rolling bodies (8). The clutch release bearing (3, 41) further comprises a stop disk (1, 32, 33, 34, 50) for clutch spring ends (9) to abut against, said disk having an L-shaped longitudinal section. The stop disk (1, 32, 33, 34, 50), in the longitudinal section, has a first limb (10) which is axially supported on a flange (2, 49). The stop disk (1, 32, 33, 34, 50) has a second limb (11, 36) which, when seen in the longitudinal section, extends away from the first limb (10) at an angle and which axially dips into a center through opening (12) of the flange (2, 49) while radially resting on the inner circumference of the through opening (12).