Composite Bearing Seal Ring for Lightweight Labyrinth Sealing
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Solution Overview
Problem
Existing bearing assemblies face challenges in effectively protecting components from contaminants using single-piece solid metal seal rings, which are heavy and require additional sealing elements, leading to inefficiencies in manufacturing and increased costs.
Innovation Solution
A seal ring design comprising a metal inner sleeve and a metal outer labyrinth ring with crests and troughs, where the labyrinth ring is fixed to the sleeve, forming a sealed interior volume, and a polymeric material is applied to the labyrinth ring's interior surface to form the inner sleeve, with a rubber bonded coating on the sleeve's inner surface for enhanced sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-piece solid metal seal ring is used, then the seal ring provides structural strength, but it increases weight and requires additional sealing elements
Solution Approach 1:
The seal ring is divided into two main segments: an outer labyrinth ring and an inner sleeve. The inner sleeve is further segmented into a polymeric material layer applied to the interior surface and a metal core structure. This segmentation allows each part to be optimized for its specific function while reducing overall weight compared to a solid metal construction.
Solution Approach 2:
The seal ring utilizes composite materials by applying a polymeric material to the interior surface of the metal inner sleeve. This composite structure combines the strength of metal with the sealing properties of polymeric materials, eliminating the need for additional sealing elements while reducing weight compared to solid metal.
2Stability of the object's composition
If a single-piece solid metal seal ring is used, then the seal ring provides structural integrity, but it increases manufacturing complexity and costs
Solution Approach 1:
The manufacturing process is segmented into distinct steps: providing the inner sleeve, applying the polymeric material to its interior surface, and fixing the outer labyrinth ring. This segmentation simplifies manufacturing compared to creating a single-piece solid metal seal ring, as each component can be manufactured and prepared separately before assembly.
Solution Approach 2:
The polymeric material is applied to the interior surface of the inner sleeve before the outer labyrinth ring is fixed. This preliminary action ensures that sealing surfaces are prepared in advance, eliminating the need for additional sealing elements and reducing overall manufacturing complexity.
3Reliability
If additional sealing elements are added to the seal ring, then sealing capability is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The sealing function is merged into the inner sleeve itself by applying the polymeric material directly to its interior surface. This integration eliminates the need for separate sealing elements such as O-rings or gaskets, reducing component count while maintaining or improving sealing capability.
Solution Approach 2:
The polymeric material layer on the inner sleeve provides sealing capabilities that would otherwise require additional sealing elements. This composite construction combines structural metal with sealing polymeric material in a single integrated component, reducing overall device complexity.
4Reliability
If the inner sleeve and outer labyrinth ring are fixed together, then a sealed interior volume is created, but manufacturing steps increase
Solution Approach 1:
The polymeric material is applied to the interior surface of the inner sleeve before the outer labyrinth ring is fixed. This preliminary preparation of sealing surfaces allows for efficient assembly and ensures proper sealing without requiring additional manufacturing steps after assembly.
Solution Approach 2:
The fixation process is segmented into specific locations: the outer labyrinth ring is fixed to the inner sleeve at defined positions to create the sealed interior volume. This segmented fixation approach allows for efficient manufacturing while ensuring effective sealing.
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 design provides a lightweight, cost-effective seal ring with improved manufacturing efficiency and enhanced sealing capabilities, reducing the need for additional sealing elements and minimizing contaminant ingress.
Implementation Method 1
applying a polymeric material to the interior surface of the outer labyrinth ring for the forming of an inner sleeve
Implementation Method 2
the outer labyrinth ring is welded to the inner sleeve
Implementation Method 3
a rubber bonded coating applied to the inner surface of the inner sleeve
Data Source
AI summary
A seal ring for a bearing assembly includes an inner sleeve having an inner surface that defines a hollow for receiving a shaft therethrough, and an outer labyrinth ring fixed to the inner sleeve and including an interior surface that faces the inner sleeve and an exterior surface opposite the interior surface. The exterior surface forms a plurality of crests and at least one trough.