Bearing Lubricating Layer via Elastic Solid Forming
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Solution Overview
Problem
Conventional bearings with lubricating layers require a significant minimum bearing load for initial operation and have high manufacturing costs due to the need for spacers to create non-lubricating spaces, which complicates the assembly process.
Innovation Solution
A bearing design with a tubular retainer and rollers, where the lubricating layer is not provided between the inscribed circle and the minimum inner periphery face of the retainer, allowing for a non-lubricating space, and a method involving a forming die with a thermoplastic resin and an elastic solid to form the lubricating layer, reducing the need for spacers and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a lubricating layer is provided uniformly in the bearing, then smooth rotation and friction reduction are achieved, but the minimum bearing load required for initial operation increases significantly
Solution Approach 1:
The patent applies local quality by creating a non-uniform lubricating layer distribution. Specifically, a non-lubricating space is formed between the inscribed circle of the rollers and the minimum inner periphery face of the retainer, while lubricating layers are provided in other areas. This localized differentiation allows the bearing to operate smoothly where lubrication is present while reducing initial load requirements through the non-lubricating space that prevents excessive contact pressure.
2Reliability
If spacers are used to create non-lubricating spaces, then the lubricating layer is prevented from entering the gap between rollers and shaft, but manufacturing costs and assembly complexity increase
Solution Approach 1:
The patent extracts the spacer component entirely from the bearing structure. Instead of using physical spacers to create non-lubricating spaces, the invention forms the non-lubricating space directly through the bearing's geometric design - specifically, by ensuring there is no lubricating layer between the inscribed circle and the minimum inner periphery face of the retainer. This eliminates the need for additional spacer parts and simplifies both manufacturing and assembly processes while maintaining the function of preventing lubricating layer intrusion into the roller-shaft gap.
3Manufacturing precision
If spacers are used to create non-lubricating spaces, then proper lubrication distribution is achieved, but manufacturing costs increase
Solution Approach 1:
The patent removes the spacer component from the manufacturing process. The non-lubricating space is created through the inherent geometry of the bearing components - specifically, by designing the retainer and roller arrangement such that a space exists between the inscribed circle and the minimum inner periphery face of the retainer where no lubricating layer is provided. This geometric approach achieves precise lubrication distribution without requiring additional spacer parts, thereby reducing manufacturing costs while maintaining proper lubrication control.
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
This design reduces the minimum bearing load required for initial operation and significantly lowers manufacturing costs by eliminating the need for spacers, while maintaining a non-lubricating space, enabling smoother rolling and reducing torque.
Implementation Method 1
the entire forming die 7 is heated to about 150° C., thermally setting the thermoplastic resin included in the fluid lubricant 9
Implementation Method 2
pressing an elastic solid into an inscribed circle in which the plurality of rollers are inscribed
Data Source
AI summary
A method for forming a lubricating layer, comprising the steps of a process for inserting a bearing, which has a tubular-shaped retainer holding a plurality of rollers and inserted in an outer ring, in a forming die having an inner diameter greater than an outer diameter of the outer ring of the bearing; a process for feeding a fluid lubricant including a thermoplastic resin into the forming die; a process for reducing pressure in the forming die with the fluid lubricant fed therein to remove air bubbles included in the fluid lubricant; a process for pressing a cylindrical elastic solid, which has an outer shape greater than a minimum inner diameter of the retainer, into an inscribed circle in which the plurality of rollers are inscribed; and a process for heating and setting the thermoplastic resin to form a lubricating layer.