Connecting Rod Tang Mounting Assembly for Galvanic Isolation
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Solution Overview
Problem
Existing mounting assemblies for connecting rods and tangs suffer from galvanic corrosion at the interface between carbon-fiber-reinforced plastic connecting portions and metal tangs, leading to premature wear and increased weight and cost due to the use of glass-fiber-reinforced plastic layers, which also hinder recycling of carbon fibers.
Innovation Solution
A mounting assembly configuration featuring contact rings with radial flanges positioned between the connecting rod and tang, forming axial spaces to prevent direct contact and eliminate galvanic corrosion, using carbon-fiber-reinforced thermoplastic or thermosetting matrix for the connecting rod and metal for the tang, with contact rings made of fiber-reinforced plastics or metals like stainless steel or titanium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a layer of glass-fiber-reinforced plastic material is provided on the surface of the connecting portions to prevent galvanic corrosion, then galvanic corrosion is reduced or prevented, but the weight of the mounting assembly increases and the manufacturing cost increases
Solution Approach 1:
A contact ring made of plastic material is introduced as an intermediary element between the metal tang and the carbon-fiber-reinforced plastic connecting portions. This contact ring serves as a mediator that prevents direct contact between dissimilar metals, thereby eliminating galvanic corrosion without requiring additional protective layers on the connecting portions themselves.
Solution Approach 2:
The protective function is extracted from the connecting portions themselves and transferred to a separate, dedicated contact ring component. This allows the connecting portions to maintain their original lightweight carbon-fiber construction while the contact ring provides the corrosion prevention function.
2Reliability
If a layer of glass-fiber-reinforced plastic material is provided on the surface of the connecting portions to prevent galvanic corrosion, then galvanic corrosion is reduced or prevented, but the manufacturing cost increases
Solution Approach 1:
A contact ring made of plastic material is introduced as an intermediary element between the metal tang and the carbon-fiber-reinforced plastic connecting portions. This contact ring serves as a mediator that prevents direct contact between dissimilar metals, thereby eliminating galvanic corrosion without requiring additional protective layers on the connecting portions themselves.
Solution Approach 2:
The protective function is extracted from the connecting portions themselves and transferred to a separate, dedicated contact ring component. This allows the connecting portions to maintain their original lightweight carbon-fiber construction while the contact ring provides the corrosion prevention function.
3Reliability
If glass fibers are present in the protective layer on the connecting portions, then galvanic corrosion is prevented, but the recycling of carbon fibers becomes difficult or impossible
Solution Approach 1:
A contact ring made of plastic material is introduced as an intermediary element between the metal tang and the carbon-fiber-reinforced plastic connecting portions. This contact ring serves as a mediator that prevents direct contact between dissimilar metals, thereby eliminating galvanic corrosion without requiring additional protective layers on the connecting portions themselves.
Solution Approach 2:
The contact ring is made of homogeneous plastic material without glass fibers, which prevents contamination of the carbon fibers in the connecting portions. This allows the carbon fibers to be recycled separately without being mixed with glass fibers, maintaining their recyclability.
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 solution effectively prevents galvanic corrosion, reduces assembly weight and cost, and allows for recycling of carbon fibers, while maintaining mechanical integrity and ease of manufacturing.
Implementation Method 1
The proximity and contact that result from the mounting of the connecting rod 2 and of the tang 5 lead to the occurrence of galvanic corrosion at the interface between the connecting portions 3 and 4 and the tang 5
Data Source
AI summary
A method for connecting a tang between a first arm and a second arm of a connecting rod includes inserting a cylindrical portion of a contact ring into a bore of the first arm until a bearing surface of the first flange contacts a first side of the first arm, deforming the second end of the cylindrical portion of the contact ring to form a second flange and to cause a bearing surface of the second flange to contact the second side of the first arm, inserting the tang axially between the first arm and the second arm, and inserting a mounting shaft through the bore of the first arm and a bore of the tang and a bore of the second arm so that a gap exists between the first arm and the tang.