Adhesive-Free Cushion Ring Sprocket for Chain Meshing Noise
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Solution Overview
Problem
Existing sprocket designs for chain drive devices face challenges in reducing impact and hitting noise caused by chain meshing, and the production process for cushion rings made of thermosetting resins is cumbersome and time-consuming, with issues related to adhesive application and material waste.
Innovation Solution
A sprocket design that secures a cushion ring to the sprocket body without an adhesive layer, using a thermoplastic resin for the cushion ring, which is molded and secured through a thermoplastic resin injection molding process, simplifying the process and reducing material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If thermosetting resin cushion rings are used to reduce impact and noise, then noise reduction is improved, but the production process becomes cumbersome and time-consuming
Solution Approach 1:
The invention changes the material parameter from thermosetting resin to thermoplastic resin, which fundamentally alters the bonding mechanism. Thermoplastic resin allows the cushion ring to be bonded to the sprocket body through cooling and solidification rather than chemical curing, eliminating the need for adhesives and complex vulcanization processes while maintaining noise reduction effectiveness
Solution Approach 2:
The invention extracts and removes the adhesive layer from the bonding process. By using thermoplastic resin that can be directly molded onto the sprocket body and secured through cooling, the complex adhesive application and vulcanization steps are completely eliminated, streamlining the production process
2Object-affected harmful factors
If thermosetting resin cushion rings are used, then noise reduction is improved, but the process complexity increases due to adhesive application and vulcanization
Solution Approach 1:
The invention changes the material parameter from thermosetting resin to thermoplastic resin, which fundamentally alters the bonding mechanism. Thermoplastic resin allows the cushion ring to be bonded to the sprocket body through cooling and solidification rather than chemical curing, eliminating the need for adhesives and complex vulcanization processes while maintaining noise reduction effectiveness
Solution Approach 2:
The invention merges the cushion ring material and bonding agent into a single thermoplastic resin component. The thermoplastic resin serves both as the cushioning material and as the bonding medium that secures the ring to the sprocket body, eliminating the need for separate adhesive layers and simplifying the overall structure
3Object-affected harmful factors
If thermosetting resin is used for cushion rings, then noise reduction is achieved, but material waste increases due to non-reusability
Solution Approach 1:
The invention changes the material parameter from thermosetting resin to thermoplastic resin. This parameter change enables the material to be melted and reused, transforming it from a disposable material to a recyclable one, thereby reducing material waste while maintaining the noise reduction function
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 reduces impact and hitting noise caused by chain meshing while simplifying the production process, enhancing resource efficiency, and minimizing material waste by eliminating the need for adhesive application and allowing for easier recycling of thermoplastic resin materials.
Implementation Method 1
a cushion ring made of a thermoplastic resin
Implementation Method 2
the thermoplastic resin is injected into a mold under pressure, the thermoplastic resin is cooled under the mold
Implementation Method 3
the thermoplastic resin is injected into a mold under pressure
Data Source
AI summary
To provide a sprocket that not only reduces impact and hitting noise caused by contact and seating of a chain when it meshes with the sprocket, but also simplifies a setting of process conditions for securing a cushion ring on a side face of a sprocket body. The sprocket includes the sprocket body formed with a plurality of teeth on a circumferential surface thereof, and the cushion ring provided to at least one side face of the sprocket body and having an outer circumferential surface that makes contact with link plates of a chain. The cushion ring is secured to the sprocket body without an adhesive layer.