Intermediate Shaft Bearing Support With Frictional Elastomer Decoupling
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Solution Overview
Problem
The high cost of manufacturing intermediate shaft bearings due to the use of chemical bonding and adhesion promoters, which complicates the process and increases costs, while also causing issues with torsional twisting in vehicle drivetrain systems.
Innovation Solution
A device comprising a bearing part, a carrier part, and a molded part that decouples the two through a frictional connection, eliminating the need for special surfaces for adhesion promoters and reducing the complexity and cost of manufacturing, with the molded part being made of elastomer to dampen vibrations and absorb impacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chemical bonding and adhesion promoters are used to connect the elastomer track to the bearing carrier, then the bonding strength and reliability are improved, but the manufacturing cost and process complexity increase significantly
Solution Approach 1:
The patent replaces the chemical bonding system (adhesion promoters and vulcanization process) with a mechanical connection system. The elastomer track is connected to the bearing carrier through a mechanical interlocking structure where the track extends into a recess of the carrier, eliminating the need for chemical adhesives and complex bonding processes while maintaining connection reliability
Solution Approach 2:
The patent extracts and removes the adhesion promoter and chemical bonding process from the manufacturing system. By designing a mechanical interlocking structure, the complex chemical bonding steps are completely taken out of the manufacturing process, reducing both cost and complexity while maintaining the functional requirement of secure connection
2Reliability
If special surfaces are designed on the molded part, bearing part and carrier part for adhesion promoters, then the chemical bonding is established successfully and sustainably, but the manufacturing cost and surface treatment requirements increase
Solution Approach 1:
The patent replaces the surface chemistry approach (adhesion promoters and special surface treatments) with a mechanical interlocking approach. The elastomer track simply extends into a recess of the bearing carrier, creating a mechanical key-way connection that does not require specially treated surfaces or chemical adhesives, thereby simplifying manufacturing while ensuring sustainable connection
3Ease of manufacture
If the molded part is frictionally connected to the inner surface and outer surface, then the frictional connection can be produced by simple insertion without adhesion promoters, but the connection strength may be reduced compared to chemical bonding
Solution Approach 1:
The patent employs curved or arcuate surfaces in the mechanical interlocking structure, where the elastomer track has a curved cross-section that fits into a corresponding curved recess in the bearing carrier. This curvature design increases the contact area and frictional engagement between the track and carrier, compensating for the absence of chemical bonding while maintaining simple insertion assembly
Solution Approach 2:
The patent optimizes the frictional connection by adjusting geometric parameters such as the curvature radius, contact surface area, and interference fit dimensions of the mechanical interlocking structure. By carefully selecting these parameters, the connection strength achieved through friction and mechanical engagement matches or exceeds that of chemical bonding, while maintaining assembly simplicity
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 reduces the transmission of vibrations, compensates for manufacturing tolerances, and lowers production costs by eliminating the need for adhesion promoters, while maintaining effective support for intermediate shafts in gearbox systems.
Implementation Method 1
the molded part being made of elastomer to dampen vibrations and absorb impacts
Implementation Method 2
the molded part being made of elastomer to dampen vibrations and absorb impacts
Implementation Method 3
the molded part being frictionally connected to the inner surface and the outer surface
Data Source
AI summary
The invention relates to an apparatus for supporting an intermediate shaft, such as an intermediate shaft of a gearbox. In an embodiment, the apparatus comprises at least one bearing part for supporting an intermediate shaft and having an outer surface with at least a section that is circumferential; at least one carrier part having an inner surface extending about the outer surface at a first distance from the bearing part; and at least one molded part for decoupling the carrier part from the bearing part, the molded part disposed between the inner surface and the outer surface, and the molded part being frictionally engaged with the inner surface and the outer surface. The invention provides a device that, among other things, can be manufactured cost-effectively.