Sintered Friction Lining on Conical Synchronizer Ring
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Solution Overview
Problem
The production of conical external synchronizer rings with a friction lining is complex due to the need for a two-part structure and a subsequent adhesive-coating process, which is inefficient and lacks the strength of a metallic connection.
Innovation Solution
A flat blank is pre-punched, coated with a sintered friction lining, and then formed into a conical shape, allowing the metallic friction lining to be integrated before final production, eliminating the need for a complex adhesive-coating process and enhancing the strength of the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a two-part structure with separate base body and friction lining is used, then the friction lining can be attached to the carrier surface, but the production process becomes complex and the connection strength is reduced due to adhesive-coating requirements
Solution Approach 1:
The patent merges the base body and friction lining into a single integrated component by forming the friction lining directly from the blank material through selective sintering. This eliminates the separate attachment process and adhesive-coating steps, resolving the contradiction by achieving both strong metallic connection and simplified production.
Solution Approach 2:
The friction lining is formed in advance during the sintering process before final machining operations. By pre-forming the lining with the appropriate material properties and geometry during sintering, the need for subsequent complex adhesive-coating processes is eliminated, thereby simplifying the overall production process while ensuring strong bonding.
2Ease of manufacture
If the entire flat blank is sintered to create the friction lining, then the metallic friction lining is integrated early, but the area intended for toothing becomes sintered and unsuitable for its function
Solution Approach 1:
The patent applies selective sintering only to specific regions of the blank - the outer annular region for the friction lining and the inner annular region for the toothing area. This localized approach ensures that each region receives the appropriate treatment: the friction lining area is sintered to create the metallic friction surface, while the toothing area remains unsintered to maintain its ductility and formability for subsequent machining operations.
3Strength
If adhesive-coating process is used to attach friction lining, then the lining can be fixed to the carrier surface, but the connection strength is insufficient compared to metallic connection
Solution Approach 1:
The patent replaces the chemical adhesive-coating process with a metallurgical sintering process. By using selective sintering to directly form the friction lining from the blank material, the invention substitutes the weak adhesive bond with a strong metallic bond, achieving both superior connection strength and improved production efficiency by eliminating the multi-step adhesive application and curing process.
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 method simplifies the production of high-performance conical synchronizer rings by integrating the metallic friction lining during the forming process, resulting in a stronger and more efficient friction layer.
Implementation Method 1
a flat blank (9) is pre-punched, provided with a sintered friction lining (5)
Implementation Method 2
is then formed in several stages together with the sintered lining into a finished conical outer synchronizer ring (1)
Data Source
Figure 1~2
AI summary
The method involves pre-stamping a flat blank (9), covering an outer annular surface area (10) of a ring body, and sintering an inner annular surface area (11) of the ring body to form a sintered coating. Another sintered inner surface area is formed into a conical shape, where an external gearing is pre-stamped and index tabs are bent.