Constructions for load-bearing structures; advantageous metal-plastic composite constructions; methods of preparation and assembly; systems and methods

Patent metadata

Field	Value
Publication number	US-2016003344-A1
Application number	US-201514854511-A
Country	US
Kind code	A1
Filing date	Sep 15, 2015
Priority date	Mar 15, 2013
Publication date	Jan 7, 2016
Grant date	—

Abstract

Improved hybrid construction and techniques for forming them are described. They are particularly applicable to generate load-bearing structures. Examples described include load-bearing housings. Methods of preparation, assembly and systems of methods of use are described.

First claim

What is claimed:

1 . A load-bearing housing assembly comprising:
(a) a hybrid component including a metal portion and a plastic portion;
(i) the plastic portion being non-separable from the metal portion; and,
(ii) the hybrid component being configured to support a maximum load of a least 1000 N in a portion thereof.

2 . A load-bearing housing assembly according to claim 1 wherein:
(a) the hybrid component is configured to support a maximum load of at least 1500 N.

3 . A load-bearing housing assembly according to any one of claims 1 - 2 wherein:
(a) the hybrid component is configured to support a maximum load of at least 2500 N.

4 . A load-bearing housing assembly according to any one of claims 1 - 3 wherein:
(a) the load-bearing housing assembly is a differential housing and the hybrid component is configured to withstand a maximum torque of at least 300 N-m.

5 . A load-bearing housing assembly according to claim 4 wherein:
(a) the load-bearing housing assembly is a differential housing and the hybrid component is configured to withstand a maximum torque of at least 1,000 N-m.

6 . A load-bearing housing assembly according to claim 4 wherein:
(a) the load-bearing assembly is a differential housing and the hybrid component is configured to withstand a maximum torque of at least 5,000 N-m.

7 . A load-bearing housing assembly according to any one of claims 1 - 6 wherein:
(a) the metal portion is iron.

8 . A load-bearing housing assembly according to any one of claims 1 - 7 wherein:
(a) the plastic portion comprises fiber reinforced thermoplastic.

9 . A load-bearing housing assembly according to any one of claims 1 - 8 wherein:
(a) the metal portion includes selected voids therein that are closed by the plastic portion.

10 . A load-bearing housing assembly according to any one of claims 1 - 9 wherein:
(a) the metal portion includes at least one anchor bore therethrough that does not communicate with an interior of the metal portion; and,
(b) the plastic portion includes resin that has been hardened after flowing through at least one anchor bore.

11 . A load-bearing housing assembly according to any one of claims 1 - 10 wherein:
(a) the metal portion comprises a mounting flange section and a hub section;
(i) the hub section being integral with the mounting flange section; and,
(ii) the flange section having a plurality of bores therethrough.

12 . A load-bearing housing assembly according to claim 11 wherein:
(a) the hub section includes radially alternating thick and thin sections of metal.

13 . A load-bearing housing assembly according to any one of claims 11 and 12 wherein:
(a) the hub section includes a plurality of anchor bores therethrough that do not communication with an interior of the housing.

14 . A load-bearing housing assembly according to any one of claims 11 - 13 wherein:
(a) the hub section is joined to the flange section by a plurality of radially spaced engagement sections having voids therebetween.

15 . A load-bearing housing assembly according to any one of claims 1 - 14 wherein:
(a) the load-bearing housing assembly is a housing having a gear mounted thereon.

16 . An load-bearing housing assembly according to any one of claims 1 - 15 wherein:
(a) the load-bearing housing assembly is a housing having a speed ring mounted thereon.

17 . A load-bearing assembly according to any one of claims 1 - 16 wherein:
(a) the load-bearing housing assembly is a housing having at least one bearing mounted thereon.

18 . A load-bearing housing assembly according to any one of claims 1 - 17 wherein:
(a) the load-bearing housing assembly is a differential housing that includes each of a ring gear; a speed ring; and, two bearings mounted on an exterior thereof.

19 . A load-bearing housing assembly according to claim 18 wherein:
(a) each one of the: ring gear; speed ring; and, two bearings is secured in position on a metal portions of the differential housing.

20 . A load-bearing housing assembly according to any one of claims 1 - 3 wherein:
(a) the metal portion comprises one of iron; steel; and, aluminum.

21 . A load-bearing housing assembly according to any one of claims 1 - 3 and 20 wherein:
(a) the plastic portion comprises fiber reinforced plastic.

22 . A load-bearing housing assembly according to any one of claims 1 - 3 ; and 20 wherein:
(a) the plastic portion comprises thermoplastic material.

23 . A load-bearing housing assembly according to claim 22 wherein:
(a) the plastic portion is selected from polyethylene sulfide(s); polycarbonate(s); polystyrene(s); acrylonitrile-butanene-styrene(s); and, polyvinyl chlorides.

24 . A load-bearing housing assembly according to any one of claims 1 - 3 ; 20 and 21 wherein:
(a) the plastic portion comprises thermoset material.

25 . A load-bearing housing assembly to claim 24 wherein:
(a) the plastic portion is selected from polyester(s); vinyl ester(s); epoxy or epoxies; polyurethane(s); penolics and amine resins; bismaleimide(s); and, polyimide(s).

26 . A load-bearing housing assembly according to any one of claims 1 - 25 wherein:
(a) the plastic portion is compression molded onto the metal portion.

27 . A load-bearing housing assembly according to any one of claims 1 - 3 wherein:
(a) the hybrid component is configured to support a maximum load of at least 10,000 N.

28 . A load-bearing housing assembly according to any one of claims 1 - 3 wherein:
(a) the hybrid component is configured to support a maximum load of at least 20,000 N.

29 . A load-bearing housing assembly according to any one of claims 1 - 3 wherein:
(a) the hybrid component is configured to support a maximum load of at least 30,000 N.

30 . A load-bearing assembly comprising:
(a) a hybrid component including a metal portion and a plastic portion;
(i) the plastic portion being non-separable from the metal component; and,
(ii) the hybrid component being configured to support a maximum load of a least maximum 1000 N in a portion thereof.

31 . A load-bearing assembly according to claim 30 wherein:
(a) the hybrid component is configured to support a maximum load of at least 3,000 N.

32 . A load-bearing assembly according to claim 30 wherein:
(a) the hybrid component is configured to support a maximum load of at least 10,000 N.

33 . A method of designing a hybrid component for a load-bearing assembly; the method including steps of:
(a) defining a corresponding component as a subject component; (b) identifying at least one exempt portion of the subject component to be retained in metal; (c) performing a load distribution analysis on the subject component; and, (d) based on the results of the load distribution analysis, selecting portions of the eventual hybrid component to be made of metal and portions to be made of plastic.

34 . A method according to claim 33 further including:
(a) constructing the hybrid component by:
(i) generating a metal piece that corresponds to: the portion of eventual hybrid component selected to be made of metal; and, the exempt portion; and,
(ii) applying plastic to the metal piece to form the region in a r

Assignees

• Eaton Corp

Inventors

• Mapkar Javed Abdurrazzaq
• Williams Kelly Ann

Classifications

• F16H57/037

  Gearboxes for accommodating differential gearings (rotating cases for differential gearings F16H48/40) · CPC title

• F16H57/032 Primary

  characterised by the materials used · CPC title

• F16H2057/02017

  characterised by special features related to the manufacturing of the gear case, e.g. special adaptations for casting · CPC title

• G06F30/00

  Computer-aided design [CAD] · CPC title

• H05K5/0217

  Mechanical details of casings (covers, lids, hoods or members for covering apertures H05K5/03) · CPC title