Elastomeric Prestressed Bearing Manufacturing Method
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Solution Overview
Problem
Existing rolling bearings for steering columns are costly due to expensive manufacturing processes and materials, such as stamped sheet metal and molded rubber washers, and high-cost spring metal washers, which also face challenges with misalignment and torque variability.
Innovation Solution
A method involving extruding an elastic tube, cutting it to form a rectangular section, mounting it in the casing, assembling the inner ring and rolling elements, and crimping the casing to create a prestressed bearing using a flexible elastomeric prestressing washer for permanent elasticity, which maintains zero clearance and low torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stamped sheet metal and molded rubber washers are used, then the bearing can be assembled, but the manufacturing cost increases due to expensive processes
Solution Approach 1:
The patent changes the material parameters by using extruded elastomeric material instead of molded rubber, and uses crimping deformation instead of heat treatment. This transforms the manufacturing process from high-cost stamping and molding to lower-cost extrusion and mechanical deformation, while maintaining the functional requirements for elastic preload and bearing performance
Solution Approach 2:
The patent replaces expensive stamped metal tracks and molded rubber washers with simpler extruded elastomeric elements that can be manufactured more economically. The extruded elements achieve the same functional purpose at lower material and processing cost, effectively substituting high-cost components with lower-cost alternatives that meet performance requirements
2Reliability
If conical Belleville type prestressing washer is used, then the bearing operates without play, but the manufacturing cost increases due to expensive spring metal washer
Solution Approach 1:
The patent replaces the expensive conical Belleville spring metal washer with a simpler extruded elastomeric element. The elastomeric material provides the necessary elastic prestressing function at lower cost, eliminating the need for precision-conformed metal spring washers while maintaining zero clearance operation through the elastic deformation of the extruded element
Solution Approach 2:
The patent uses composite construction by combining the extruded elastomeric element with the crimped metal casing. The elastomeric material provides elastic prestressing while the crimped metal structure provides rigid containment, creating a composite system that achieves zero clearance and eliminates play without requiring expensive precision metal spring components
3Ease of manufacture
If extruded elastomeric element with crimping is used, then manufacturing cost decreases, but assembly complexity must be managed
Solution Approach 1:
The patent performs preliminary actions by pre-extruding the elastomeric elements to precise dimensions and pre-crimping the casing sections before final assembly. The extruded elements are prepared in advance with correct geometry, and the casing is pre-formed with crimped sections, which simplifies the final assembly process by eliminating the need for complex in-situ forming operations
Solution Approach 2:
The patent divides the casing into multiple sections that are crimped separately and then assembled together with the extruded elastomeric elements inserted between them. This segmentation allows for simpler, more manageable assembly steps where each section can be prepared and assembled independently, reducing overall assembly complexity despite the novel manufacturing approach
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
This method results in an economical and reliable rolling bearing suitable for low-speed steering columns with high misalignment tolerance, ensuring zero clearance and constant torque while reducing material costs and assembly complexity.
Implementation Method 1
The elastic deformation of the rectangular section element which forms a prestressing element maintains the prestress permanently
Implementation Method 2
crimping one end of the axial part of the casing to form the second radial portion of said casing and prestress the bearing thus formed
Data Source
Figure 1~5
Figure 2~4
Figure 6~7
AI summary
The device i.e. antifriction bearing (4), has a prestressed annular element i.e. prestressed washer (13), arranged in an envelope (10) for being axially prestressed between one of radial portions of the envelope and a lateral surface of one of annular rods (11, 12). The envelope has an axial portion directed towards the interior and is connected on the radial portion for forming an annular chamber with U-shaped cross section in which the annular element is partly arranged. The annular element is formed of an elastic material and has a rectangular section at a free end.