Composite Linear Guide With Metal Running Sheets for Bearing Wear
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Solution Overview
Problem
Existing linear guides made of metal materials face issues with thermal stability, rigidity, weight, and compatibility with bearings due to the hardness difference between composite materials and traditional bearings, leading to rapid wear and delamination problems during manufacturing.
Innovation Solution
A linear guide comprising tubular elements made of composite material with integrated thin metal sheets, where rolling bearings slide on these sheets, and a manufacturing process involving photogravure engraving and co-molding to ensure precise positioning and prevent delamination, using thermosetting resins and fibrous reinforcement for enhanced bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal materials are used for linear guides, then mechanical resistance is improved, but thermal stability and rigidity deteriorate
Solution Approach 1:
The patent applies composite materials consisting of a thermosetting resin matrix and fibrous reinforcement (such as carbon fibers, glass fibers, or basalt fibers) to manufacture the track and slide. This composite structure provides both high mechanical resistance and excellent thermal stability, resolving the contradiction between strength and thermal stability that plagues traditional metal linear guides.
2Stability of the object's composition
If composite materials are used for track and slide, then thermal stability and rigidity are improved, but hardness deteriorates
Solution Approach 1:
The patent applies local quality by integrating thin metal sheets (0.5-3mm thick) specifically at the contact surfaces where bearings slide, while the main body remains composite material. This creates a localized hard surface (50-60 HRC) for bearing compatibility while maintaining the overall thermal stability and low weight of composite materials.
Solution Approach 2:
The patent creates a hybrid composite structure combining composite material (for thermal stability and low weight) with metal sheets (for hardness and bearing compatibility). This multi-material composite approach resolves the contradiction between thermal stability and surface hardness.
3Strength
If metal sheets are glued to composite surfaces, then hardness is improved, but positioning accuracy and bonding durability deteriorate
Solution Approach 1:
The patent merges the metal sheet integration process with the composite molding process into a single co-molding operation. The metal sheets are positioned and bonded simultaneously with composite material curing, eliminating separate gluing steps and achieving both high positioning accuracy and bonding durability through the integrated 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 solution provides a lightweight, mechanically resistant, and thermally stable linear guide with high rigidity, preventing quick wear and malfunction, while maintaining cost-effectiveness and precision in manufacturing.
Implementation Method 1
b) engraving a surface of each thin sheet by means of photogravure
Implementation Method 2
c) co-molding the first thin sheets to the inner tubular element and the second thin sheets to the outer tubular element
Implementation Method 3
due to the significant difference in the thermal dilation coefficient between the composite material and the metal material. In fact, the cooling, which follows the molding, needed for the hardening of the composite resin, creates thermal tensioning for the interface between the two materials
Implementation Method 4
a means is interposed for reducing friction, such as ball cages, rolling pins, or other types of bearings
Data Source
Figure 1a~2b
Figure 3~4
Figure 5
AI summary
The present invention relates to a linear guide (1) comprising an outer tubular element (2), an inner tubular element (3), adapted to slide telescopically in said outer tubular element (2), and friction reduction means interposed between said inner tubular element (3) and said outer tubular element (2), said friction reduction means comprising n rolling bearings (4), wherein n ≥ 1, each rolling bearing (4) being provided with rolling elements, wherein the outer tubular element (2) and the inner tubular element (3) are made of a composite material and wherein said rolling elements slide on two thin sheets (6a, 6b), a first thin sheet (6a) positioned on an outer face of the inner tubular element (3) and a second thin sheet (6b) positioned on a corresponding inner face of the outer tubular element (2). The present invention also relates to a process of manufacturing such a linear guide (1), and more generally, to a method of manufacturing an element made of a composite material provided with at least one thin sheet at at least an outer surface thereof.