Driveshaft Insert Adhesive Bonding for Axial Movement Control

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Solution Overview

Problem

Existing driveshaft technologies face challenges in effectively interfacing with components to transmit power without axial movement limitations and without the use of welding, particularly in heavy vehicles where torsion and shear forces are prevalent.

Innovation Solution

A non-metallic driveshaft mechanism incorporating a metallic driveshaft insert with a splined interior surface and an exterior surface, adhered to the driveshaft using adhesive, allowing for rotation and axial movement restriction through a radially outwardly extending wall portion, and a yoke with a splined shaft that engages the driveshaft insert for uniform torque application.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If a driveshaft is interfaced with components to transmit power, then power transmission efficiency is improved, but axial movement control and rotational coupling are compromised

Engineering Contradiction:

Improvepower transmission efficiencyVSAvoidaxial movement control

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The driveshaft interface is divided into multiple functional segments: a splined portion for torque transmission, an intermediate portion for adhesive bonding, and a radially outwardly extending wall portion for axial positioning. This segmentation allows each portion to perform its specific function optimally, resolving the contradiction between power transmission and axial movement control.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The driveshaft insert is nested within the hollow driveshaft, with the insert's exterior surface received within the driveshaft's interior cavity. This nested configuration allows the insert to provide structural functionality while being contained within the driveshaft, enabling both power transmission and axial movement control simultaneously.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If welding is used to interface driveshaft with components, then structural strength is improved, but manufacturing complexity and weight increase

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent replaces welding (a thermal/mechanical joining process) with adhesive bonding (a chemical joining process). The adhesive is applied to the intermediate portion of the driveshaft insert, bonding it to either the driveshaft interior surface or a retaining member. This substitution eliminates the complexity of welding operations while maintaining structural integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The driveshaft insert is made of metal while the driveshaft is made of non-metallic material, creating a composite structure. The adhesive bonding interface joins these dissimilar materials, providing a versatile joining method that is simpler than welding and suitable for composite construction.

Inventive Principle:

Principle #40Composite materials

3Power

If a metallic insert is used in a non-metallic driveshaft, then torque transmission is improved, but weight increases

Engineering Contradiction:

Improvetorque transmission capabilityVSAvoiddriveshaft weight

Core Design Contradiction:

PowerVSWeight of moving object

Solution Approach 1:

Instead of making the entire driveshaft metallic to improve torque transmission, the patent applies a metallic insert only at the specific location where torque transmission is needed. The insert is contained within the hollow driveshaft, providing local reinforcement without requiring the entire structure to be heavy metal.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The metallic insert is nested within the hollow driveshaft structure, allowing the lightweight non-metallic driveshaft to maintain its overall low weight while the inserted metallic portion provides the necessary torque transmission capability at the interface location.

Inventive Principle:

Principle #7Nested doll (Nesting)

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

Enables efficient power transmission between the driveshaft and yoke without welding, allowing for axial movement while maintaining rotational coupling, thus addressing the limitations of existing technologies in heavy vehicle applications.

Implementation Method 1

A portion of the exterior surface of the driveshaft insert is adhered to the interior surface of the non-metallic driveshaft fixing the driveshaft insert relative to the non-metallic driveshaft

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

The splined portion is configured to engage with the splined shaft of the yoke such that rotation of the driveshaft is transmitted to the yoke

Methodology Applied

Scientific EffectMechanical engagement through splines: Gear

Implementation Method 3

The first radially outwardly extending wall portion is configured to limit the axial movement of the driveshaft toward the second open end of the sidewall

Methodology Applied

Scientific EffectMechanical constraint through geometric feature: Mechanical Fastener

Data Source

PatentUS8597131B2Driveshaft insert and driveshaft mechanism

Publication Date: 2013.12.03 MACHINE SERVICE

AI summary

A driveshaft mechanism tiding a driveshaft insert and a driveshaft are provided. The driveshaft insert is coupled to the driveshaft. The driveshaft insert is configured to couple with a component such that the driveshaft and the component rotate together.