Polygonal Tolerance Ring Spanning Large Radial Gaps
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Solution Overview
Problem
Traditional tolerance rings are not well-suited for applications with large radial gaps between inner and outer components, as their projections typically extend less than 1.5 mm, limiting their effectiveness in gaps greater than 2 mm.
Innovation Solution
The development of a tolerance ring with a body comprising a plurality of sidewall segments, each forming specific contact points with components and meeting at angles greater than 60°, forming a regular equilateral polygon to accommodate larger radial gaps by bending and deflecting under load, and optionally incorporating stiffeners to adjust stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If traditional tolerance rings use stamped projections to transmit forces, then force transmission is achieved, but the projection length is limited to less than 1.5 mm which prevents effective use in large radial gaps greater than 2 mm
Solution Approach 1:
The tolerance ring body is divided into multiple sidewall segments (typically 3-12 segments) that form a polygonal structure. Each sidewall segment acts as an independent force transmission element, allowing the overall structure to achieve greater effective projection length while maintaining the mechanical properties needed for force transmission across large radial gaps
Solution Approach 2:
The invention transitions from a traditional annular band shape to a polygonal cross-section with multiple sidewall segments. This dimensional change in the cross-sectional geometry enables the structure to span larger radial gaps by distributing forces across multiple segments rather than relying on single stamped projections
2Adaptability or versatility
If the band of resilient material is formed from a thin strip to accommodate slip conditions, then slip characteristics are improved, but the stamped projections extend less than 1.5 mm limiting applicability to large radial gaps
Solution Approach 1:
The thin strip material is segmented into multiple sidewall segments forming a polygon. This segmentation allows each segment to maintain the flexibility and slip characteristics of thin material while the collective polygonal structure achieves the effective length needed for large radial gaps
Solution Approach 2:
The tolerance ring utilizes a thin strip of resilient material formed into a polygonal cross-section with sidewall segments. This flexible thin-film structure maintains slip characteristics while the polygonal geometry enables spanning of large radial gaps that would be impossible with traditional stamped projections
3Ease of manufacture
If tolerance rings are designed for small radial gaps with traditional annular shape, then manufacturing is simple, but they cannot accommodate variations in diameter or large radial gaps
Solution Approach 1:
The annular band is segmented into polygonal sidewall segments that can deflect and adapt to diameter variations. This segmentation maintains relative manufacturing simplicity while dramatically improving adaptability to different radial gaps and diameter tolerances
Solution Approach 2:
The polygonal sidewall segments are designed to deflect dynamically under load, allowing the tolerance ring to adapt to variations in inner and outer component diameters. This dynamic deflection capability enables accommodation of large radial gaps and diameter variations while maintaining force transmission
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 the tolerance ring to span larger radial gaps without compromising radial strength or slip characteristics, allowing effective force transmission between components.
Implementation Method 1
each sidewall segment is adapted to form one point of contact with an inner component and two points of contact with an outer component... the tolerance ring comprises a regular equilateral polygon... bending and deflecting under load
Data Source
Figure 1
Figure 2~3
Figure 4A~4B
AI summary
A tolerance ring (2) comprising a body including a plurality of sidewall segments (6), each sidewall segment having a thickness and a height, wherein the body has an aspect ratio, as measured by a ratio of the height of the sidewall segment to the thickness of the sidewall segment, of no less than 2:1. An assembly comprising an outer component defining a bore (30); an inner component disposed within the bore of the outer component; and a tolerance ring disposed between the inner and outer components, the tolerance ring comprising a body including a plurality of sidewall segments (6), each sidewall segment having a thickness and a height, wherein each sidewall segment contacts the inner component.