Sandwich Push Chain Structure for Narrow Stable Chain Drives
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Solution Overview
Problem
Existing push chains used in chain drives for applications like window and door operation are bulky, costly to produce, and require complex guidance to prevent bending, while also lacking in stability and efficient power transmission.
Innovation Solution
A push chain design featuring toothed segment disks and chain tension anchors arranged in a sandwich-like configuration with bolts that are flush or recessed, providing a narrow profile, high stability, and secure axial fixation through press fits or laser welding, allowing for efficient power transmission and deflection with minimal force loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bolts protrude beyond the chain tie rods to ensure secure connection, then connection reliability is improved, but the push chain width increases and it may get caught on surrounding components
Solution Approach 1:
The harmful protruding parts (bolt heads) are removed from the chain link structure. Instead of having bolts protrude beyond the chain tie rods, the bolts are designed to be flush or recessed, extracting the problematic protrusion while maintaining the connection function through alternative means (press fit, deformation, or countersunk holes).
Solution Approach 2:
The bolt heads are nested within the chain tie rod structure. The bolts are inserted into countersunk holes or deformed to fit within the chain tie rod thickness, creating a nested configuration where the connection element (bolt) is contained within the structural element (chain tie rod), eliminating external protrusions.
2Reliability
If additional clamping or fixing means are used to secure bolts axially, then connection stability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The bolts secure themselves to the chain tension anchors without requiring additional clamping or fixing means. Through press fit (frictional connection), deformation of the bolt end, or countersunk hole configuration, the bolts achieve self-fixation, eliminating the need for separate securing components and reducing overall device complexity.
Solution Approach 2:
The functions of connection and axial fixation are merged into a single bolt design. Instead of using separate bolts and additional clamping mechanisms, the bolt itself is designed to provide both connection and self-fixation through integrated features like press fit surfaces, deformable ends, or countersunk configurations.
3Reliability
If cams protrude from pulley plane to serve as end stops, then overextension prevention is improved, but manufacturing effort and device complexity increase
Solution Approach 1:
The separate cam components protruding from the pulley plane are removed. The end stop function is extracted and integrated directly into the toothed segment disc structure through laterally projecting elements that form end stops when discs are arranged next to each other, eliminating the need for separate cam components and reducing manufacturing complexity.
4Stability of the object's composition
If chain links are designed with wide configuration for stability, then stability is improved, but the push chain cannot achieve narrow design and may snag on components
Solution Approach 1:
The chain link components are arranged in a nested or sandwich configuration where toothed segment discs are positioned between chain tension anchors in alternating layers. This nested arrangement allows the components to support each other structurally for stability while maintaining a compact overall width, as each component is contained within the structure rather than extending outward.
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 design achieves a compact, cost-effective, and stable push chain with improved power transmission and reduced risk of snagging, enabling efficient operation with minimal force loss during deflection and enhanced resistance to overstretching.
Implementation Method 1
the bolts are advantageously pressed immovably into the bolt receiving holes of the chain tension anchors with a press fit (frictional or force-locking connection)
Implementation Method 2
The bolt head is preferably compressed by machining or external pressure in such a way that it secures or locks the assembly against displacement in the axial direction
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The invention relates to a rigid push chain (2) that can be operated by a chain drive. The chain links of the push chain (2) are designed such that, while achieving the highest possible stability and good power transmission, as well as good deflection and smooth running characteristics, the narrowest possible design can be realized. Furthermore, it is an objective to further simplify the manufacturing process.The push chain (2) comprises an inner part (54) composed of toothed segment discs (4), an intermediate part (56) also composed of toothed segment discs (4), and an outer part composed of chain tension anchors (40). The intermediate part (56) surrounds the inner part (54) in a sandwich-like manner, and the outer part surrounds the intermediate part (56) in a sandwich-like manner. The toothed segment discs (4) and the chain tension anchors (40) have aligned bolt receiving holes (16, 18, 42, 44) and are connected to each other by means of bolts (20, 22) inserted through the bolt receiving holes (16, 18, 42, 44). The bolts (20, 22) are dimensioned such that they do not protrude beyond the outer surfaces of the chain tension anchors (40).