Dual-Material CV Joint Deflector Ring for Boot-Safe Debris Shielding
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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.
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 extends radially outwardly from the inner ring portion, providing protection against water and debris while preventing damage to adjacent components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the deflector ring is made entirely of metal material, then it 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 in different regions: the inner portion near the CV joint housing is made of rigid metal to effectively deflect water and debris, while the outer peripheral edge is made of flexible rubber material to prevent damage to sealing boots and other components during handling and storage. This local differentiation of material properties resolves the contradiction between deflection effectiveness and harm prevention.
Solution Approach 2:
The deflector ring combines two different materials (metal and rubber) into a single composite structure. The metal portion provides the necessary rigidity for water and debris deflection, while the rubber portion provides flexibility to prevent damage during handling. This composite material approach allows the deflector ring to simultaneously achieve both functions.
2Strength
If the deflector ring is made entirely of metal material, then it provides structural strength, but the rigid edge can become plastically deformed and lose functionality
Solution Approach 1:
The deflector ring uses rigid metal material for the inner portion that requires structural strength to deflect water and debris, while the outer peripheral edge uses flexible rubber material that is resistant to plastic deformation during handling and storage. This local differentiation ensures both structural strength and functional integrity are maintained in their respective regions.
Solution Approach 2:
The composite structure combines metal and rubber materials, where the metal provides structural strength for the deflection function and the rubber provides deformation resistance for the protective edge. This material combination resolves the contradiction between strength and functional integrity.
3Device complexity
If the deflector ring is made entirely of metal material, then it is simple in design, but it causes damage to adjacent components during shipping and handling
Solution Approach 1:
The deflector ring applies different material properties to different regions: the inner metal portion maintains the simple monolithic design for effective deflection, while the outer peripheral edge is covered with flexible rubber material to prevent damage to adjacent components. This localized approach minimizes complexity increase while eliminating harmful effects.
Solution Approach 2:
The composite construction of metal and rubber materials allows the deflector ring to maintain structural simplicity for the deflection function while adding the protective rubber edge to prevent damage during shipping and handling, thus resolving the contradiction between design simplicity and harm prevention.
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 dual-material deflector ring effectively prevents damage to the sealing boots and other components by eliminating sharp edges and reducing the risk of deformation, ensuring the wheel bearing remains protected from water and debris.
Implementation Method 1
a flexible, resilient outer ring portion made of non-metallic material
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.