Modular Plain Bearing Snap-Fit Interlocking Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional polymer bearings, especially double flanged ones, face manufacturing complexity and stress concentration issues due to the need for complex tooling and flange formation, which complicates both production and installation, and existing methods like bending collar elements are inefficient and prone to defects.
Innovation Solution
An un-flanged modular plain bearing design featuring snap-fit interconnected end portions and extenders with chamfered fingers, allowing for assembly in a modular fashion using conventional injection molding techniques, eliminating the need for flanges and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flanges are added to double flanged bearings to aid location and provide thrust washer surfaces, then the bearing can be securely located in housing, but the manufacturing complexity and device complexity increase significantly
Solution Approach 1:
The bearing is divided into multiple modular segments that can be assembled together to form the complete bearing assembly. Each segment can be manufactured separately using simple tooling, avoiding the need for complex multi-part tooling required for single-piece double flanged bearings. The modular segments are connected through interlocking features that provide secure location without requiring complex flange structures.
2Force
If flanges are added to double flanged bearings to provide thrust washer surfaces, then thrust loading capability is improved, but the ease of manufacture deteriorates due to complex tooling requirements
Solution Approach 1:
The thrust loading function is distributed across multiple bearing segments rather than requiring a complex single-piece flanged structure. Each segment can be manufactured using simple injection molding tooling, and the collective assembly provides the necessary thrust washer surfaces and load-bearing capability.
Solution Approach 2:
The bearing segments are combined into a unified assembly that collectively provides thrust loading capability. The interlocking features merge the segments into a structurally integrated unit that functions as a complete bearing assembly with adequate thrust support.
3Ease of manufacture
If collar elements are bent from flat to flange position to form double flanged bearing, then the bearing can be formed from simpler components, but stress concentration and potential fracture points are created
Solution Approach 1:
The bearing is segmented into multiple pieces that are assembled together without requiring bending operations. This eliminates the stress concentrations and fracture risks associated with bending collar elements, while still achieving the double flanged bearing functionality through the modular assembly.
4Productivity
If long polymeric cylindrical bearings are made with multiple injection gates, then the mold filling is improved, but cold welding occurs at joint points reducing bearing strength
Solution Approach 1:
The bearing is designed as an assembly of multiple segments that are manufactured separately and then mechanically interconnected. This approach replaces the problematic cold welding joints of multi-gate injection molding with robust mechanical interlocking features, eliminating the strength weakness while still enabling efficient production of long bearings.
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 design simplifies the production and assembly of polymer bearings, reduces stress concentrations, and enables the creation of longer bearings with improved interlocking strength, making them easier to manufacture and install while maintaining structural integrity.
Implementation Method 1
The plurality of fingers are shaped to cooperatively engage in a snap fit connection
Data Source
Figure 1A~1B
Figure 2
Figure 3~4
AI summary
A modular plain bearing is provided. The modular plain bearing includes a first end portion (102) having a terminal edge with a plurality of first fingers (128) and a second end portion (102) having a terminal edge with a plurality of second fingers (128). The plurality of fingers cooperatively engage to provide a snap fit connection between the parts. For longer plain bearings, a bearing extender (200) is provided. The bearing extender includes at least a first connector (208) having a plurality of first connector fingers (210). The bearing extender may include either a second connector opposite the first connector having a plurality of second connector fingers.