Powertrain Roll Restrictor Using Compression Rubber Elements

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Solution Overview

Problem

Conventional powertrain roll restrictors face durability issues due to shear loading of rubber elements, requiring thicker sections and compromising performance, while also needing adhesive bonding to metal brackets, which increases manufacturing complexity and cost.

Innovation Solution

A modular powertrain torque roll restrictor design featuring separate drive and reverse main rubber elements held in compression between metal brackets, eliminating the need for adhesive bonding and allowing for tailored characteristics across various platforms, reducing material usage and manufacturing time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If rubber elements are used in shear loading to limit powertrain roll motion, then the roll restrictor can control powertrain roll during transient dynamic events, but the durability of the rubber is compromised and thicker rubber sections are required

Engineering Contradiction:

Improverubber durabilityVSAvoidrubber section thickness

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent inverts the conventional loading approach by using compression loading instead of shear loading for the rubber elements. The roll restrictor is designed so that rubber elements are compressed between the powertrain and the vehicle body, rather than being sheared. This inversion of the loading mechanism improves rubber durability while allowing for thinner rubber sections.

Inventive Principle:

Principle #13The other way round (Inversion)

2Strength

If rubber is bonded to metal brackets using adhesive molding to ensure adequate bond strength, then the roll restrictor can be assembled, but the manufacturing complexity and cost increase

Engineering Contradiction:

Improvebond strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the adhesive bonding process from the manufacturing sequence. Instead of molding rubber directly onto metal brackets with adhesive, the design uses separate rubber elements that are compressed into position, removing the need for adhesive application and curing steps.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the chemical bonding mechanism (adhesive) with a mechanical bonding mechanism (compression fitting). The rubber elements are held in place through compressive force between the powertrain and vehicle body, substituting chemical adhesion with mechanical constraint.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If thicker rubber sections are used to compensate for durability issues in shear type roll restrictors, then the roll restrictor can meet durability requirements, but the weight and material usage increase

Engineering Contradiction:

Improvedurability requirementVSAvoidrubber material volume

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent inverts the loading approach from shear to compression, which fundamentally changes the stress distribution in the rubber elements. Compression loading allows for more efficient stress distribution and better durability performance with less material, directly reducing the quantity of rubber needed while meeting durability requirements.

Inventive Principle:

Principle #13The other way round (Inversion)

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 enhances durability and reduces weight and cost by utilizing compressive loading instead of shear, allowing for interchangeable components and tailored performance without compromising on stiffness or durability.

Implementation Method 1

a first rubber element positioned between the first bracket and the second bracket, the first rubber element having a drive compressed state between the first bracket and the second bracket upon travel in a drive direction

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

the first rubber element having a drive compressed state between the first bracket and the second bracket upon travel in a drive direction

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS11685256B2Powertrain mount roll restrictor with rubber elements in compression

Publication Date: 2023.06.27 FORD GLOBAL TECH LLC

AI summary

A powertrain torque roll restrictor includes a first bracket having an elongated body defining a first bracket opening at a distal end and a central axis, a second bracket coaxial with and adjacent to the first bracket, and a third bracket coaxial with and adjacent to the second bracket opposite from the first bracket, with the third bracket defining a third bracket opening cooperable with the first bracket opening. The second bracket defines a second bracket opening receiving the elongated body such that the second bracket is positioned about the elongated body. The powertrain torque roll restrictor further includes a first rubber element positioned between the first bracket and the second bracket, and a second rubber element positioned between the second bracket and the third bracket, with the brackets being configured to hold the respective rubber element in compression.