Composite Friction Insert for Secure Press-Fit Connections
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Solution Overview
Problem
Existing non-positive connections, such as those used in machine components, often face challenges in achieving a high coefficient of friction, especially between steel surfaces, which can lead to insecure connections due to low friction coefficients, and existing methods to increase friction, like coatings, are cumbersome and costly, especially for large or complex geometries.
Innovation Solution
A friction-increasing insert comprising a composite carrier with glass, ceramic, and plastic, combined with hard cores of at least 8 μm diameter, bonded using an adhesion promoter, which is pressed between joining partners to create an interference fit, enhancing the coefficient of friction without the need for extensive surface treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a coating is applied to increase the coefficient of friction, then the friction increases, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The patent uses a disposable friction-increasing insert that is placed between the joining partners instead of permanently coating them. This insert can be a simple layer of friction material or a composite structure with hard cores embedded in a matrix, designed to be consumed or replaced rather than permanently installed. This approach avoids the complex, expensive coating processes while achieving the desired friction increase.
Solution Approach 2:
The patent employs composite materials for the friction-increasing insert, combining friction-generating materials with binding agents or structural supports. The insert may consist of friction material particles embedded in a matrix material, creating a composite structure that provides both high friction and mechanical stability without requiring complex coating processes on the joining partners themselves.
2Force
If the joining partners are pressed together to create interference fit, then the friction increases, but the risk of damage to the joining partners increases
Solution Approach 1:
The patent introduces a friction-increasing insert as an intermediary element between the joining partners. This insert absorbs the compressive forces during assembly and distributes them evenly, preventing direct high-stress contact between the joining partners. The insert acts as a buffer that generates friction to secure the connection while protecting the joining partners from damage.
Solution Approach 2:
The friction-increasing insert may utilize porous or compressible materials that can deform under compression to accommodate the joining partners. This porosity allows the insert to compress and distribute loads evenly, reducing stress concentrations that could damage the joining partners while still maintaining sufficient friction for a secure connection.
3Reliability
If the coefficient of friction is increased for steel surfaces, then the connection security improves, but the manufacturing cost and effort increase
Solution Approach 1:
The patent extracts the friction-increasing function from the joining partners themselves and places it in a separate, dedicated insert. Instead of modifying the joining partners with complex coatings or surface treatments, the friction-generating material is contained within a separate component that is simply inserted between the joining partners. This separation makes the system easier to manufacture while maintaining connection security.
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 allows for a simple, flexible, and cost-effective increase in frictional forces and moments transmitted, enabling secure non-positive connections with improved mechanical stability and reduced risk of corrosion, suitable for various complex geometries and applications.
Implementation Method 1
Each of the hard cores is bonded to the composite carrier by means of an adhesion promoter
Implementation Method 2
The friction between two partners in contact is the reaction of the present tribological system to a load directed towards the component surfaces
Data Source
Figure 1A~3C
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Figure 7~8
AI summary
The present invention relates to a friction-enhancing insert comprising a composite carrier (1) and a plurality of hard cores (21), wherein the composite carrier comprises glass and/or ceramic (12) as well as plastic (11), and each of the hard cores (21) has a volume-equivalent sphere diameter (D21) of at least 8 µm and is bonded to the composite carrier (1) by means of an adhesion promoter (22), and wherein the uncompressed composite carrier (1) has a thickness (d1) in the range of 10 µm to 100 µm and/or the friction-enhancing insert (3) has a thickness (d3) of less than or equal to 420 µm when the composite carrier (1) is uncompressed. The invention further relates to a method for producing a friction-enhancing insert and a method for producing a press fit between two joining partners.