Composite Friction Coupling for Even Pressure Distribution
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Solution Overview
Problem
Existing friction couplings face issues with uneven pressure distribution leading to warped couplings and undesired wear, lack of desired rigidity or strength-weight ratio, and weakness in joining composite materials, particularly due to the use of heavy materials like steel.
Innovation Solution
A friction connecting means utilizing carbon fiber composite material with a pressure pocket that expands radially to create a friction coupling, featuring a braided structure and a second composite layer to direct force, allowing engagement without altering element features or adding weight, and using a hydraulic fluid or solidifying plastic as a pressure medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional friction couplings use pressure medium in separate pockets, then the coupling can be activated, but the pressure distribution becomes uneven causing warping and undesired wear
Solution Approach 1:
The patent uses a flexible membrane to separate the pressure medium from the friction surfaces. This membrane distributes the pressure evenly across the friction surfaces while allowing the pressure medium to act on multiple pockets simultaneously, eliminating warping and ensuring uniform pressure distribution during operation
Solution Approach 2:
The membrane acts as an intermediary element between the pressure medium and the friction surfaces. It transfers the pressure force uniformly to multiple friction pockets, ensuring even pressure distribution without direct contact between the pressure medium and the friction elements
2Strength
If gluing and clenching techniques are used to join friction coupling elements, then the elements can be connected, but the desired rigidity and strength-weight ratio are not achieved
Solution Approach 1:
The friction coupling is divided into separate modular elements that can be assembled and disassembled without permanent joining. The segments are held together by friction force, eliminating the need for gluing or clenching while maintaining the desired rigidity and strength-weight ratio
Solution Approach 2:
The friction coupling elements are designed to self-lock through friction force when pressed together by the membrane. The system uses its own operational force (pressure differential) to maintain the connection, eliminating the need for additional joining mechanisms
3Strength
If heavy materials like steel are used for friction coupling, then the joining strength increases, but the overall weight increases and causes the joining to break
Solution Approach 1:
The patent employs composite material construction for the friction coupling elements, combining materials with high strength-to-weight ratios. This allows the coupling to maintain the necessary joining strength while significantly reducing the overall weight compared to traditional steel constructions
Solution Approach 2:
The invention changes the material parameters by selecting materials with optimized strength-to-weight characteristics. The friction surfaces and structural elements use materials that provide sufficient friction force and mechanical strength without the excessive weight of traditional metals
4Ease of manufacture
If clench elements are used to join friction coupling, then the connection can be formed, but the element must have a recess which changes and deteriorates the material properties
Solution Approach 1:
The invention extracts the clenching function entirely from the system by using friction-based connection instead. This eliminates the need for recesses or holes in the friction coupling elements, preserving the complete material structure and properties of all components
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
Enables even pressure distribution, maintains rigidity and durability, and provides a strong, lightweight friction coupling that effectively connects composite and non-composite materials without warping or deteriorating material properties.
Implementation Method 1
the pressure pocket in an idle state has a circular or oval cross section expanding radially when the pressure is increased forcing the carbon fiber composite material layer to expand radially
Implementation Method 2
creating a friction coupling
Implementation Method 3
the pressure medium is a plastic material in liquid form which is solidified at a predetermined pressure, creating a permanent state
Data Source
Figure 1~2
Figure 1A~3A
Figure 3~4
AI summary
A friction connecting means (10) includes a receiving element (11) and engagement elements (12, 12'). The receiving element (11) has a pressure pocket provided with a carbon fiber composite material layer.