Composite Tolerance Ring for Controlled Slip Torque in Assemblies

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Solution Overview

Problem

Existing tolerance rings do not effectively provide desired slip performance while maintaining appropriate tolerance compensation and durability in assemblies, particularly in automotive applications.

Innovation Solution

A composite tolerance ring composed of a substrate and a low friction layer, optionally with an adhesive and corrosion protection layers, is formed to enhance slip performance and durability by incorporating materials like stainless steel and polyether ether ketone (PEEK) with specific thicknesses and configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a traditional tolerance ring is used to constrain movement between components, then movement constraint is achieved, but desired slip performance cannot be provided

Engineering Contradiction:

Improveslip performanceVSAvoidslip control capability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The tolerance ring is constructed as a composite structure with a substrate and a low friction layer. The substrate provides structural integrity and tolerance compensation, while the low friction layer (such as PTFE or PEEK) enables controlled slip performance. This composite material approach allows the single component to simultaneously provide both movement constraint and desired slip characteristics.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The low friction layer is applied selectively to specific surfaces of the tolerance ring where slip is desired. This localized application of different material properties allows the tolerance ring to maintain high friction for tolerance compensation in some areas while providing low friction for controlled slip in other areas, achieving both functions within a single component.

Inventive Principle:

Principle #3Local quality

2Reliability

If a tolerance ring provides tolerance compensation between components, then assembly tolerance is compensated, but durability is reduced

Engineering Contradiction:

Improveassembly tolerance compensationVSAvoidassembly lifetime

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The composite structure combines a durable substrate material (such as metal) with a low friction layer. The substrate provides long-term structural stability and tolerance compensation, while the low friction layer reduces wear during operation. This combination maintains the durability needed for long service life while enabling the tolerance compensation function.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The low friction layer fundamentally changes the friction parameter at the contact surfaces, reducing the coefficient of friction to enable controlled slip. This parameter change allows the tolerance ring to accommodate tolerance variations without generating excessive heat or wear, thereby extending the assembly lifetime while maintaining tolerance compensation.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If a tolerance ring is designed for rapid assembly, then assembly time is reduced, but control over slip surfaces is lost

Engineering Contradiction:

Improveassembly speedVSAvoidslip surface control

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The tolerance ring with integrated low friction layer serves multiple functions simultaneously: it provides tolerance compensation, enables controlled slip, and facilitates rapid assembly. The low friction property inherent in materials like PTFE or PEEK naturally reduces assembly resistance, allowing quick installation while maintaining precise control over which surfaces will slip during operation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 composite tolerance ring provides improved slip performance and extended assembly lifetime by compensating for tolerances and coefficient of expansion, ensuring reliable operation in automotive components.

Implementation Method 1

A composite tolerance ring composed of a substrate and a low friction layer

Methodology Applied

Scientific EffectLow friction: Lubrication

Implementation Method 2

optionally with an adhesive and corrosion protection layers

Methodology Applied

Scientific EffectAdhesive: Adhesive

Implementation Method 3

an adhesive and corrosion protection layers

Methodology Applied

Scientific EffectCorrosion protection:

Data Source

PatentEP4073397B1Assembly comprising a tolerance ring between two components with desired slipping torque at the surfaces of contact

Publication Date: 2026.03.25 SAINT GOBAIN PERFORMANCE PLASTICS RENCOL LIMITED

Figure 1~2D
Figure 3A~3B
Figure 3C~4

AI summary

An assembly including an inner component, an outer component and a tolerance ring (100) located between the inner and outer components to provide an interference fit therebetween. The tolerance ring includes a sidewall (102) including a plurality of radially extending projections (108) on a first radial surface and an unformed region (114) on a second radial surface opposite the first radial surface. The tolerance ring (100) provides a first break-away torque, τ1, defined as the breakaway torque between the tolerance ring projections (108) and an inner component or an outer component and the tolerance ring (100) provides a second break-away torque, τ2, defined as the breakaway torque between the unformed region (114) and the other of the inner component or the outer component, wherein 1.1 τ1 ≤ τ2.