Restrictive-Bending Flex Coupling With Tunable Shaft Stiffness
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Solution Overview
Problem
Existing flex couplers in automotive shaft assemblies compromise noise and vibration dampening to meet increased bending stiffness requirements, failing to effectively isolate unwanted noise and vibrations from reaching the driver.
Innovation Solution
A flex coupling assembly that decouples axial and torsional stiffness from bending stiffness, allowing for adjustable performance without affecting noise and vibration dampening, featuring a resilient flex coupling with a metal core overmolded with an elastomeric body and bushings to regulate bending stiffness and facilitate relative movement between shafts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a dampening coupler is used to reduce noise and vibration, then noise and vibration isolation is improved, but bending stiffness is reduced
Solution Approach 1:
The dampening coupler is segmented into distinct functional zones: a dampening section with radial slots for noise and vibration isolation, and a bending stiffness section with circumferential ribs for structural support. This segmentation allows each zone to independently perform its specific function without compromising the other.
Solution Approach 2:
Different regions of the coupler are given different local properties: the dampening section has a compliant, slot-filled structure optimized for vibration isolation, while the bending stiffness section has a rigid, rib-reinforced structure optimized for structural support. Each local region is tailored to its specific functional requirement.
2Strength
If bending stiffness requirements are increased to meet manufacturer demands, then structural rigidity is improved, but noise and vibration dampening effectiveness is compromised
Solution Approach 1:
The coupler is divided into functional segments where circumferential ribs provide bending stiffness in one direction while radial slots with dampening material provide vibration isolation in perpendicular directions. This segmentation resolves the contradiction by assigning different structural characteristics to different spatial zones.
Solution Approach 2:
The coupler employs composite construction combining rigid plastic material for structural integrity with viscoelastic dampening material filled into radial slots. This composite approach enables simultaneous achievement of high bending stiffness and effective noise/vibration dampening.
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
The solution provides enhanced bending stiffness while maintaining torsional and axial stiffness and dampening performance, allowing for adjustable design parameters to optimize noise and vibration isolation.
Implementation Method 1
A resilient flex coupling is sandwiched between the end face of the lower housing and the flange. The resilient flex coupling is fixed to the upper flange and to the retention member by the plurality of retention fastener members.
Implementation Method 2
The resilient flex coupling has a metal core overmolded with an elastomeric body
Implementation Method 3
wherein the at least one bushing can be provided having a radial thickness, as desired, to regulate the bending stiffness across the flex coupling assembly between the first and second shafts
Data Source
AI summary
A flex coupling assembly for coupling a first shaft to a second shaft of a shaft assembly. The flex coupling assembly includes a lower housing having a housing wall bounding a cavity between a first end having an end face and an open second end. A first shaft is fixed to the end face and extends along an axis. An upper flange, spaced from the lower housing, has a second shaft fixed thereto extending along the axis. A retention member, disposed in the cavity, is operably fixed to the upper flange. A resilient flex coupling, disposed between the end face and the flange, is operably fixed to the upper flange and the retention member and to the lower housing. The lower housing and the flange are moveable axially toward and away from one another and rotatably about the axis via flexing of the resilient flex coupling which dampens noise and vibrations between the first and second shafts.