Tolerance Ring Structure for Controlled Slip and Breakaway Torque
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Solution Overview
Problem
Existing tolerance rings do not effectively provide desired slip performance while maintaining tolerance compensation and assembly longevity in applications like automotive components, where precise torque transmission and assembly alignment are critical.
Innovation Solution
A tolerance ring design featuring a composite material with radially extending projections and an unformed region, where the first type of projections provides tolerance compensation and the second type engages more aggressively to enhance breakaway torque, allowing desired slip at specific interfaces, thereby ensuring robust torque performance and assembly stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a tolerance ring is designed with uniform structure to maintain assembly alignment, then manufacturing precision is improved, but slip performance cannot be controlled at specific interfaces
Solution Approach 1:
The tolerance ring incorporates different types of projections (first type with lower breakaway torque and second type with higher breakaway torque) at different circumferential locations. This local differentiation allows the ring to provide controlled slip at specific interfaces while maintaining overall assembly alignment, resolving the contradiction between uniform manufacturing precision and localized slip performance control.
2Strength
If the tolerance ring engages aggressively with both inner and outer components, then torque transmission is improved, but slip control at desired interfaces becomes difficult
Solution Approach 1:
The tolerance ring uses first type projections that engage less aggressively (providing lower breakaway torque) at interfaces where slip is desired, and second type projections that engage more aggressively (providing higher breakaway torque) at interfaces where torque transmission is prioritized. This local differentiation enables both strong torque transmission and controlled slip at appropriate locations.
3Reliability
If the tolerance ring is designed to prevent overload through slip, then reliability is improved, but manufacturing complexity increases due to multiple projection types
Solution Approach 1:
The tolerance ring segments its engagement surfaces into different types of projections (first type and second type) with distinct geometric characteristics and breakaway torque properties. This segmentation allows the ring to provide reliable overload protection through controlled slip while maintaining a manageable structural complexity that can be manufactured using conventional techniques.
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 tolerance ring achieves improved slip performance at desired interfaces, maintaining assembly alignment and extending the assembly's lifetime by providing differential breakaway torques between the tolerance ring and the components, thus preventing overload and ensuring consistent torque transmission.
Implementation Method 1
the tolerance ring provides a first break-away torque, τ1, defined as the breakaway torque between the tolerance ring projections and an inner component or an outer component, wherein the tolerance ring provides a second break-away torque, τ2, defined as the breakaway torque between the unformed region and the other of the inner component or the outer component
Data Source
AI summary
A tolerance ring including a sidewall including a plurality of radially extending projections on a first radial surface and an unformed region on a second radial surface opposite the first radial surface, where the tolerance ring provides a first break-away torque, τ1, defined as the breakaway torque between the tolerance ring projections and an inner component or an outer component, where the tolerance ring provides a second break-away torque, τ2, defined as the breakaway torque between the unformed region and the other of the inner component or the outer component, and wherein 1.1 τ2≤τ1.