Composite CV Joint Deflector Ring for Boot-Safe Bearing Protection
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Solution Overview
Problem
Current deflector rings in constant velocity joints are made entirely of metal, leading to sharp edges that can damage rubber sealing boots and other components during handling, storage, or shipping, and are prone to deformation, compromising their functionality and the protection of wheel bearings.
Innovation Solution
A deflector ring design featuring a rigid inner ring portion made of metal and a flexible, resilient outer ring portion made of non-metallic material, such as polymeric material, which is designed to prevent damage to adjacent components and maintain functionality even when flexed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the deflector ring is made entirely of metal material, then the deflector ring can effectively deflect water and debris, but the sharp rigid edge can damage rubber sealing boots and other components during handling and storage
Solution Approach 1:
The deflector ring is designed with different material properties at different locations: the inner portion near the CV joint housing is made of rigid metal to maintain structural integrity and deflection function, while the outer peripheral edge is made of flexible material to prevent damage to sealing boots and other components during handling and storage
Solution Approach 2:
The deflector ring combines two different materials - a rigid metal material for the inner portion and a flexible material for the outer peripheral edge - to create a composite structure that simultaneously provides structural strength and protective flexibility, eliminating the need for entirely metal construction while maintaining deflector functionality
2Strength
If the deflector ring edge is made rigid to maintain structural integrity, then the deflector ring can protect wheel bearings, but the rigid edge can become plastically deformed and lose functionality
Solution Approach 1:
The deflector ring is designed with different material properties at different locations: the inner portion near the CV joint housing is made of rigid metal to maintain structural integrity and deflection function, while the outer peripheral edge is made of flexible material to prevent damage to sealing boots and other components during handling and storage
Solution Approach 2:
The deflector ring combines two different materials - a rigid metal material for the inner portion and a flexible material for the outer peripheral edge - to create a composite structure that simultaneously provides structural strength and protective flexibility, eliminating the need for entirely metal construction while maintaining deflector 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 combination of materials prevents damage to the deflector ring and adjacent components, ensuring the protection of wheel bearings from water and debris while maintaining the deflector ring's functionality throughout handling and storage.
Implementation Method 1
a flexible, resilient outer ring portion
Data Source
AI summary
A constant velocity joint assembly includes a housing body having an outer surface and an inner surface extending between a first housing end and a second housing end along a central axis. The inner surface of the housing body defines a raceway. A plurality of rollers are disposed in the raceway. A flexible boot is operably fixed to the housing body, with the flexible boot extending along the central axis. A deflector ring is fixed to the outer surface of the housing body. The deflector ring has a metal inner ring portion and a non-metal outer ring portion.