Ceramic Bearing Component Structure Using Recycled Core Material

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Solution Overview

Problem

Recycled materials, due to impurities, are not suitable for forming surface portions of components like rolling-element bearings, as they have less desirable properties compared to virgin materials, posing challenges in achieving high efficiency and cost-effectiveness, especially for large quantities and medium to large component sizes.

Innovation Solution

A component design incorporating a first region made from recycled ceramic silicon nitride, surrounded by a second region of unrecycled silicon nitride, where the recycled material is used in a central portion of the component, and the unrecycled material forms the surface, utilizing a pressing method to integrate the regions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If recycled material is used for the entire component, then cost is reduced, but material properties and reliability deteriorate due to impurities

Engineering Contradiction:

ImprovecostVSAvoidmaterial properties

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The component is divided into regions with different material qualities: a first region made from recycled material with impurities, and a second region made from unrecycled material with better properties. This allows each region to have the appropriate material quality for its specific function, reducing overall cost while maintaining reliability where needed.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The component uses a composite structure combining recycled material and unrecycled material in different regions. This composite approach allows the component to benefit from the cost advantages of recycled material while maintaining the performance advantages of unrecycled material in critical areas.

Inventive Principle:

Principle #40Composite materials

2Ease of manufacture

If recycled material is used for surface portions, then cost is reduced, but surface quality and performance deteriorate

Engineering Contradiction:

ImprovecostVSAvoidsurface quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

3Reliability

If unrecycled material is used for the entire component, then material properties and reliability are improved, but cost increases

Engineering Contradiction:

Improvematerial propertiesVSAvoidcost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

Inventive Principle:

Principle #40Composite materials

4Productivity

If high quantities of components are produced, then economies of scale reduce cost, but material quality requirements become more stringent

Engineering Contradiction:

Improveproduction quantityVSAvoidmaterial quality consistency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11639737B2Component and method for manufacturing a component

Publication Date: 2023.05.02 AB SKF SKF PATENT DEPARTMENT

AI summary

A bearing component, such as a bearing roller or a bearing ring, has an exterior surface and includes at least one interior region made of a recycled material which region is spaced from and does not form any part of the exterior surface. The recycled material and the unrecycled material may each include silicon nitride and/or sialon and/or silicon carbide and/or a ceramic material. Also a method of forming the component.