Compressed Overlapping Friction Joints for Clutch Durability
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Solution Overview
Problem
Wet-type friction clutches with segmented friction materials experience premature material failure due to fluid ingress at uncompressed edges, leading to reduced durability and oil leakage during engagement.
Innovation Solution
The friction material segments are overlapped and compressed to form a joint with increased density, preventing fluid flow and maintaining uniform thickness, thereby enhancing durability and reducing oil leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire segment at the joint is highly compressed to improve durability, then the joint strength and material density are improved, but the reduced thickness causes fluid flow between the inner diameter and outer diameter leading to oil leakage
Solution Approach 1:
The patent applies different compression levels to different regions of the friction material segment. The joint region is highly compressed to improve durability and prevent fluid ingress, while the intermediate portions maintain their original thickness to prevent oil leakage. This creates a gradient structure where each region has optimized properties for its specific function.
Solution Approach 2:
Instead of compressing the entire segment uniformly, the patent applies compression only to the joint region where it is most needed for durability. This partial action approach achieves the durability improvement at the joint without the excessive compression that would cause oil leakage, thereby resolving the contradiction.
2Ease of manufacture
If the friction material ring is stamped out in segments to reduce manufacturing waste, then material utilization is improved, but the edges between segments cause premature material failure
Solution Approach 1:
The patent applies preliminary compression to the joint regions before the segments are fully assembled into the friction material ring. This pre-compression creates a dense, durable joint that resists fluid ingress and premature failure, addressing the reliability issue while maintaining the manufacturing efficiency of segmented construction.
Solution Approach 2:
The patent changes the physical parameter of the joint region by applying high compression, which alters the density and structural properties of the material at the joints. This parameter change transforms the vulnerable joint edges into durable connections that resist material failure.
3Length of stationary object
If uncompressed edges are left at the segment joints to maintain thickness, then fluid ingress is prevented, but the joint strength is reduced leading to premature failure
Solution Approach 1:
The patent creates a local quality distinction where the joint region is highly compressed to increase strength, while the intermediate portions maintain their original thickness. This localized approach allows the joint to have high strength without requiring the entire segment to be thick, resolving the contradiction between thickness and joint strength.
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 highly compressed joints improve the durability and reduce oil leakage by creating a uniform thickness that prevents fluid flow between the inner and outer diameters of the friction material ring, enhancing the overall performance of the friction clutch.
Implementation Method 1
an end of the first segment overlapping an end of the second segment to form a joint that is compressed more than intermediate portions of the first and second segments
Data Source
AI summary
A friction material part is provided. The friction material part includes a first segment and a second segment, an end of the first segment overlapping an end of the second segment to form a joint that is compressed more than intermediate portions of the first and second segments. A method for manufacturing a friction material part is also provided. The method includes overlapping an end of a first friction material segment and an end of a second friction material segment; and compressing the overlapped ends to form a compressed joint.