Co-Moulded Bearing Holder Support for Simpler Drum Assembly
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Solution Overview
Problem
Existing bearing-holder supports for rotating elements, such as washing machine drums, are complex and costly to produce due to multiple components and assembly phases, with previous solutions involving metal or plastic materials that require intricate manufacturing and additional molding steps.
Innovation Solution
A bearing-holder support comprising a tubular plastic tube made of modular semi-tubes co-moulded with rolling contact bearings, where each semi-tube forms an annular housing for the bearing, allowing axial blocking without external elements and simplifying assembly by integrating the bearings directly into the plastic structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal tube with separate annular housings and spacer are used, then bearing support is structurally sound, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent combines the tube, annular housings, and spacer into a single integrated plastic component. The tube is made up of two semi-tubes that are co-moulded with the annular housings and spacer, eliminating the need for separate manufacturing and assembly of these parts. This merging reduces manufacturing complexity while maintaining structural integrity through the unified design.
Solution Approach 2:
The patent uses plastic material instead of metal for the tube and housing structure. The plastic material provides sufficient structural strength while enabling more efficient manufacturing processes. The co-moulding technique creates a composite structure where the plastic tube integrates multiple functional elements (housing, spacer, mounting features) into a single piece.
2Ease of manufacture
If separate annular housings are produced by chip removal working, then bearings can be mounted, but production time and cost increase
Solution Approach 1:
The annular housings are pre-formed as integral parts of the tube during the co-moulding process, before bearing installation. The mould cavities are designed to create the housing geometry and bearing retention features in a single manufacturing step, eliminating the need for subsequent chip removal working and bearing forcing operations.
Solution Approach 2:
The tube manufacturing process is merged with the housing formation process through co-moulding. Both the tube body and annular housings are created simultaneously in one moulding cycle, dramatically reducing production time compared to sequential manufacturing of separate components.
3Ease of operation
If plastic tube with co-moulded bearings is used, then assembly is simplified, but manufacturing complexity increases due to multiple moulds
Solution Approach 1:
The tube is divided into two semi-tubes that are co-moulded with the respective annular housings. This segmentation allows the mould to be opened and bearings to be positioned in the correct orientation during co-moulding, while still achieving integration of all components. The semi-tubes are later joined to form the complete tube assembly.
Solution Approach 2:
The mould itself acts as an intermediary tool that simultaneously positions the bearings, forms the semi-tubes, and creates the annular housings in a coordinated manner. The mould cavities are designed to hold bearings in place during the co-moulding process, ensuring correct positioning without requiring additional blocking operations.
4Reliability
If bearings are forced inside housings after tube installation, then bearing support is functional, but assembly complexity and cost increase
Solution Approach 1:
The bearings are pre-positioned within the mould cavities before the co-moulding process begins. The co-moulding operation then forms the plastic tube and housing around the pre-positioned bearings, permanently securing them in their correct locations. This eliminates the need for subsequent bearing installation operations after tube assembly.
Solution Approach 2:
The bearing positioning operation is merged with the tube manufacturing operation through co-moulding. Both actions occur simultaneously in one process step, creating an integrated assembly where bearings are permanently embedded in the housing structure without requiring separate installation steps.
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 solution reduces production complexity and cost by integrating bearings into a single plastic piece, ensuring stable axial blocking and coaxial alignment, thus simplifying the assembly process and enhancing anchoring robustness.
Implementation Method 1
a tubular plastic tube (22) made of two modular semi-tubes (22a, 22b), each of which presents a respective annular housing (25a, 25b) obtained by co-moulding of the modular portion itself with a respective bearing (23a, 23b)
Data Source
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AI summary
Bearing-holder support (21) for rotating elements, the bearing-holder support (21) being suitable forbeing engaged by a shaft (11), and being provided with two rolling contact bearings (23a) (23b), and atubular plastic tube (22) which extends along a longitudinal axis A of the motor shaft and presents two inner annular housings (25a)(25b) for housing the two bearings (23a) (23b); the plastic tube (22) being made up of two modular semitubes (22a) (22b), each of which presents a relative annular housing (25a) (25b) which is obtained by co-moulding of the modular portion itself with a relative bearing (23a) (23b) in order to axially block the bearing (23a) (23b) itself inside the annular housing (25a) (25b) itself.