Stepped Flanged Composite Bearing for Axial Tolerance Compensation
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Solution Overview
Problem
Existing flanged bearings in the automotive and non-automotive industries face challenges with limited lifetime, effectiveness, and performance within assemblies, particularly due to wear and tear and lack of axial tolerance compensation.
Innovation Solution
A composite bearing is developed with a substrate and a low friction layer, including a corrosion-resistant layer, where the bearing is formed with a flange having a stepped transition region for enhanced axial tolerance compensation and improved torque performance, using a manufacturing process involving a substrate, low friction layer, and adhesive layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional flanged bearings are used, then the assembly structure is simple, but the bearing lifetime is limited due to wear and tear
Solution Approach 1:
The bearing is constructed as a composite structure with a substrate layer and a low friction material layer overlay, combining the structural integrity of the substrate with the wear-resistant and low-friction properties of the overlay layer, thereby extending bearing lifetime while maintaining reliability
Solution Approach 2:
The friction coefficient parameter is changed by applying a low friction material layer, which reduces wear and tear on the bearing surfaces, directly extending the bearing's operational lifetime while maintaining its load-bearing effectiveness
2Manufacturing precision
If conventional flanged bearings are used, then the manufacturing process is simple, but axial tolerance compensation is insufficient
Solution Approach 1:
A flange with a stepped transition region is added to the bearing structure, introducing a new geometric dimension that enables axial tolerance compensation through the stepped configuration, improving manufacturing precision while accepting increased structural complexity
Solution Approach 2:
The flange is segmented into different regions including a stepped transition region with varying thickness, allowing each segment to serve specific functions such as axial tolerance compensation and load distribution, thereby improving precision without excessive complexity
3Object-affected harmful factors
If conventional flanged bearings are used, then the structure is simple, but noise, harshness, and vibration are reduced
Solution Approach 1:
Different regions of the bearing are given different properties: the low friction material layer provides wear resistance and noise reduction, while the flange with stepped transition region provides vibration damping and harshness reduction, locally optimizing each region to address specific harmful factors
Solution Approach 2:
The composite structure combining substrate and low friction overlay, along with the multi-region flange design, creates a bearing that simultaneously addresses noise, harshness, and vibration through the combined effects of different materials and geometric features
4Power
If conventional flanged bearings are used, then the assembly is simple, but torque performance is limited
Solution Approach 1:
The flange structure is extended in the axial dimension with a stepped transition region, creating additional leverage and load distribution pathways that improve torque transmission capability while accepting increased structural complexity
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 composite bearing design significantly reduces noise, harshness, and vibration, while providing improved axial preload and extended lifetime, enhancing the assembly's performance and effectiveness.
Implementation Method 1
flanged bearings made of composite materials consisting of a substrate layer and a low friction material layer overlay
Implementation Method 2
manufacturing process involving a substrate, low friction layer, and adhesive layers
Data Source
AI summary
A bearing including a body having a first axial end and a second axial end; and at least one flange projecting radially from the second axial end of the body, where the at least one flange includes a first region, second region, and a stepped transition region between the first and second regions, where the second region is elevated axially above the first region so as to protrude axially outwardly, where 1) the second region extends partially circumferentially around the flange to form at least one segment, and/or 2) the first region extends from the body to the stepped transition region.