Laminated Rubber Vibration Damper Bonding
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Solution Overview
Problem
Current methods for bonding rubber to rigid parts, such as crankshaft dampers, face challenges in maintaining high states of compression over the life of the composite part without sacrificing adhesion or tuning of rubber properties, and often require conventional adhesives with demanding surface preparation processes.
Innovation Solution
A process involving a press-fit, vulcanized rubber member with a core layer sandwiched between self-bonding rubber layers, where the self-bonding layers include an adhesion promoter not present in the core layer, allowing for high compression states without conventional adhesives and optimizing rubber properties, using a laminate structure with the core and adhesive layers having compatible elastomers and cure systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional adhesives are used to bond rubber to rigid parts, then adhesion is improved, but surface preparation requirements and process complexity increase
Solution Approach 1:
The rubber composition itself provides adhesion through self-bonding capability, eliminating the need for separate adhesive materials. The rubber formulation includes specific components that enable it to bond directly to metal surfaces without requiring external adhesives or complex surface treatments
Solution Approach 2:
The adhesive function is extracted from the system by incorporating adhesion-promoting components directly into the rubber composition, removing the need for separate adhesive materials and simplifying the overall bonding system
2Reliability
If rubber is bonded to metal surfaces with high compression, then durability is improved, but rubber may go into tension upon cooling resulting in premature failures
Solution Approach 1:
The rubber formulation is specifically designed with adjusted compositional parameters including polymer selection, filler content, and curing system to maintain optimal mechanical properties across a wide temperature range, preventing the rubber from transitioning to a tensile state during cooling
Solution Approach 2:
The rubber composition is formulated as a composite material incorporating specific polymers, fillers, and curing agents that work together to maintain structural integrity and prevent tensile failure under thermal cycling conditions
3Device complexity
If self-bonding rubber formulations are used to eliminate adhesives, then process complexity is reduced, but it has proven difficult to retain sufficient compression to achieve desired durability targets
Solution Approach 1:
The rubber formulation parameters are specifically optimized to balance bonding strength and compression retention, including polymer selection, filler content, and curing system composition, allowing the rubber to maintain sufficient compression while achieving adequate adhesion to metal surfaces
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 approach achieves excellent bonding and maintains rubber compression, reducing process costs and eliminating the need for special surface treatments, while ensuring durability and flexibility in the bonded part.
Implementation Method 1
a press-fit, vulcanized rubber member residing in compression between two rigid members and bonded thereto
Implementation Method 2
achieve higher states of compression over the life of the composite part without sacrificing adhesion
Data Source
AI summary
A method of forming a bonded part with a press-fit, vulcanized rubber member residing in compression between two rigid members and bonded thereto. The rubber member is a laminate with a core layer between two self-bonding rubber layers. The bonded part may be, for example, a vibration damper, isolator or absorber. The core layer and the self-bonding layers may have the same primary elastomer and cure system type, and the self-bonding layers have an adhesion promoter not present in the core layer. The adhesive layers may be from 0.05 to 1 mm thick or from 5% to 10% of the laminate thickness.The method includes forming a rubber core layer, curing it, applying a rubber adhesive layer on each side to form a laminate, inserting the laminate between two rigid members under compression, and post-curing to form a bonded part. The adhesive layers may be partially cured before inserting.