Synchronizer Hub Double-Molding Different Sintered Materials
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current synchronizer hubs for vehicles face challenges in reducing costs and improving mechanical properties due to limitations in material selection and manufacturing complexity, with existing solutions either increasing product failure or being difficult to manufacture and maintain.
Innovation Solution
A synchronizer hub is formed by double-molding an inner spline and an outer spline using different materials, with the inner spline made of a carbon, molybdenum, and chromium alloy and the outer spline made of a carbon, molybdenum, nickel, and copper alloy, through a process involving press-molding and sintering, allowing for optimized structural characteristics and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sintered material is used for the synchronizer hub to handle complicated structure and friction, then wear resistance and structural integrity are improved, but manufacturing cost increases and stiffness reaches a limit under increased transmission torque
Solution Approach 1:
The patent applies different materials to different parts of the synchronizer hub based on their specific functional requirements. The inner spline uses a first sintered material optimized for engagement strength, while the outer spline uses a second sintered material optimized for wear resistance. This local differentiation allows each component to perform optimally without requiring expensive comprehensive treatments on the entire hub structure.
Solution Approach 2:
The patent employs composite construction by combining two different sintered materials within a single synchronizer hub. The inner spline is formed from a first sintered material with specific properties, while the outer spline is formed from a second sintered material with different properties. This composite approach enables optimization of each region for its specific function, improving overall performance while controlling manufacturing costs.
2Reliability
If the boss undergoes high-frequency heating or entire surface carburizing to enhance wear resistance, then friction resistance is improved, but product cost increases
Solution Approach 1:
Instead of applying expensive surface treatments like high-frequency heating or carburizing to the entire boss, the patent selectively applies different sintered materials to specific regions. The outer spline material is specifically chosen and formulated during manufacturing to provide the required friction resistance, eliminating the need for subsequent expensive surface hardening processes on the entire component.
3Adaptability or versatility
If a double structure with separate internal insertion part and outer ring body is used, then functional optimization is improved, but number of components increases and product failure possibility increases
Solution Approach 1:
The patent merges the inner spline and outer spline into a single integrated synchronizer hub component. The inner spline and outer spline are formed from different sintered materials but are manufactured as one unified piece through a single molding process, eliminating the need for separate assembly of internal insertion parts and outer ring bodies. This reduces component count and assembly complexity while maintaining the functional benefits of material differentiation.
Solution Approach 2:
The patent creates a composite material structure within a single component by forming the inner spline from a first sintered material and the outer spline from a second sintered material during the same molding process. This achieves functional optimization through material differentiation without requiring separate parts, as the different materials are integrated into one unified synchronizer hub structure.
4Reliability
If different materials are used for inner spline and outer spline, then mechanical properties and wear resistance are improved, but manufacturing complexity may increase
Solution Approach 1:
The patent combines the manufacturing of two different materials into a single molding operation. The inner spline and outer spline are formed from different sintered materials simultaneously in one molding process, rather than requiring separate manufacturing and assembly steps. This integration simplifies the overall manufacturing process despite using multiple materials.
Solution Approach 2:
The patent employs composite sintered materials that can be molded together in a single process. The first sintered material for the inner spline and the second sintered material for the outer spline are formulated and processed to be compatible during simultaneous molding, achieving material differentiation without proportionally increasing manufacturing 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 solution significantly improves wear resistance by 800% and reduces costs by 20% compared to conventional hubs, while maintaining excellent mechanical properties and simplifying the manufacturing process.
Implementation Method 1
press-molding and sintering
Implementation Method 2
press-molding and sintering
Data Source
AI summary
A synchronizer hub for vehicles and a method for manufacturing the same forms an inner spline and an outer spline of a transmission synchronizer hub for vehicles by using different materials.The synchronizer hub may be manufactured by filling inner powders for forming the inner spline, molding the inner spline, filling outer powders for forming the outer spline, molding the outer spline, separating the double molded object obtained by integrally forming the inner spline and the outer spline from a mold, and performing sintering, post-processing, and high-frequency heating processes.