Metallic Rolling Bearing Cage with Plastic Coating for Wear Resistance
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Solution Overview
Problem
Existing methods for producing rolling bearing cages for large rolling bearings face challenges such as high production costs, inadequate strength, and wear sensitivity, particularly in tapered-roller bearings, where plastics cages are not suitable due to high cage forces and complex manufacturing requirements.
Innovation Solution
A method involving the formation of a ring or ring segments from metallic solid materials like steel or aluminum, followed by deformation and cutting processes to create a stable main body with integrated openings and coatings, using a thermoplastic powder in a fluidized bed for uniform and adhesive coating, ensuring strength and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastics cages are used for large rolling bearings, then production costs are reduced, but strength and wear resistance become inadequate
Solution Approach 1:
The invention uses a composite structure combining a metallic main body (steel or aluminum) for structural strength with a plastic coating (polyamide or polyethylene) for wear resistance and friction reduction. This composite approach allows the cage to meet both strength requirements and cost-effectiveness for large rolling bearings.
2Strength
If steel cages are used for large rolling bearings, then strength is improved, but wear sensitivity increases
Solution Approach 1:
The metallic cage body provides the necessary structural strength while the plastic coating layer (polyamide or polyethylene) provides wear resistance and reduces friction. This composite structure eliminates the wear sensitivity of bare steel cages.
Solution Approach 2:
The plastic coating is applied specifically to the contact surfaces of the cage where it interacts with the rolling bodies and raceways. This localized application provides wear resistance exactly where needed while maintaining the overall structural integrity of the metallic cage.
3Ease of manufacture
If plastics cages are used for tapered-roller bearings, then manufacturing simplicity is improved, but adequacy for high cage forces deteriorates
Solution Approach 1:
The metallic main body provides the structural capacity to withstand high cage forces from tapered rollers, while the plastic coating maintains manufacturing simplicity through a single-step fluidized bed coating process. This composite structure enables the cage to handle high forces while remaining cost-effective.
4Manufacturing precision
If coating is applied to punched parts before connection, then coating uniformity is improved, but transition damage risk increases
Solution Approach 1:
The cage components are coated with plastic in a fluidized bed before the final assembly and deformation steps. This preliminary coating ensures uniform coverage on all surfaces including those that will later form transition zones, eliminating the risk of damaged transitions while maintaining coating uniformity.
Solution Approach 2:
The fluidized bed coating process uses controlled temperature and fluidization parameters to ensure the plastic coating uniformly covers all surfaces of the cage components before assembly. The thermal and flow parameters are optimized to achieve complete, defect-free coating coverage.
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 method enables the production of a strong, durable, and cost-effective rolling bearing cage suitable for large rolling bearings, with improved wear resistance and reduced friction, capable of handling intense loads and axial forces.
Implementation Method 1
the main body is then immersed in a fluidized bed with the thermoplastic powder
Implementation Method 2
a continuous coating is formed
Implementation Method 3
the plastic powder adheres to the main body and melts on, whereby a continuous coating is formed
Data Source
AI summary
Disclosed is an axial-radial rolling bearing having an inner ring, an outer ring disposed around the inner ring, and a plurality of rolling bodies in the form of rollers arranged into at least one row disposed between and separating the inner ring and the outer ring. The rolling bearing further includes at least one rolling bearing cage disposed around at least part of the rollers and configured to maintain a predetermined spacing of each of the rollers from each adjacent roller in the at least one row, wherein the rolling bearing cage comprises a plastic coated main body that is at least one of ring-shaped or segmented. The main body has openings for receiving the respective rolling elements.