Composite Bronze Bearing With Thermal-Sprayed Carrier Layer
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Solution Overview
Problem
Current bronze bearings are costly and heavy, limiting their efficiency in weight-sensitive applications such as space travel and aviation, and do not effectively utilize materials with better specific heat conduction or strength.
Innovation Solution
A composite bronze bearing is created with a bearing layer of bronze material and a metal carrier layer, cohesively connected through thermal spraying, allowing for material savings and the use of lighter, stronger materials, with optional radial openings for solid lubricants and a material gradient for enhanced adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bronze bearings are made solid made of bearing bronze, then the bearing surface properties are maintained, but the weight and material cost increase
Solution Approach 1:
The bearing is divided into two distinct layers: a bearing bronze layer providing surface properties and a metal carrier layer providing structural support. This segmentation allows each layer to be optimized for its specific function, reducing overall weight while maintaining performance.
Solution Approach 2:
The invention uses a composite structure combining bearing bronze material with another metal material. The composite design leverages the advantages of both materials - the bearing bronze provides low friction and wear resistance, while the carrier layer provides strength and reduces weight.
2Reliability
If bearing bronze material is used throughout the entire bearing, then the bearing surface functionality is ensured, but material cost and weight increase
Solution Approach 1:
The bearing bronze material is applied locally only where it is needed - specifically as a surface layer providing bearing functionality. The rest of the bearing structure uses a different metal material, optimizing material usage and reducing the quantity of expensive bearing bronze required.
Solution Approach 2:
The bearing is segmented into a functional bearing layer and a structural carrier layer, allowing selective application of bearing bronze only to the surface where it provides value, rather than using it throughout the entire component.
3Weight of moving object
If a metal carrier layer is applied to the bearing layer, then material savings and weight reduction are achieved, but the connection between layers must be ensured
Solution Approach 1:
The bearing layer is prepared in advance by thermal spraying onto a mandrel before the metal carrier layer is applied. This preliminary preparation ensures proper surface characteristics and adhesion properties are established before the carrier layer is deposited, securing stable connection between layers.
Solution Approach 2:
The thermal spraying process acts as an intermediary method that creates a cohesive connection between the bearing layer and metal carrier layer. The thermal spraying process embeds the layers together, creating a strong bond that ensures stability of the composite structure.
4Ease of manufacture
If thermal spraying process is used to apply the metal carrier layer, then material savings and design flexibility are achieved, but precise pretreatment of the bearing layer surface is not required
Solution Approach 1:
The thermal spraying process replaces the need for precise mechanical surface pretreatment. Instead of requiring carefully controlled mechanical preparation of the bearing layer surface, the thermal spraying process can directly apply the metal carrier layer to the as-sprayed bearing layer surface, simplifying the manufacturing process.
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 composite design significantly reduces material usage and weight while maintaining or improving performance, enabling better load absorption and wear behavior, particularly suitable for non-prismatic or non-cylindrical applications.
Implementation Method 1
the bearing layer is made by thermal spraying on the core and the elements of solid lubricants. In an additional embodiment, the cylindrical elements are disposed of solid lubricants in openings in the bearing layer and the support layer is prepared by thermal spraying of material of the metal carrier layer on the bearing layer and the elements of solid lubricants
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a composite bronze bearing (2), having a bearing layer (4) that consists of a bearing bronze material and a metal support layer (6) that is bonded to the bearing layer (4).