Metal Plastic Composite Sliding Bearing Material
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Solution Overview
Problem
Existing plain bearing composite materials for lubricated applications, particularly in diesel injection pumps, face issues with friction behavior and seizing due to the use of carbon fibers and hard materials, which affect their wear resistance and adaptability, especially under low flow conditions.
Innovation Solution
A plain bearing composite material with a sliding layer containing 1-40% by weight of spherical aluminum silicate and 5-40% by weight of a solid lubricant, such as zinc sulfide or graphite, without fibrous additives or hard materials with Mohs hardness greater than 5, anchored in a porous carrier layer or microstructured surface, to improve friction and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If carbon fibers and hard materials are used in the sliding layer, then wear resistance is improved, but friction behavior deteriorates and seizing tendency increases
Solution Approach 1:
The patent removes carbon fibers and hard materials (Mohs hardness >5) from the sliding layer composition. This extraction eliminates the harmful friction and seizing tendencies caused by these materials while retaining wear resistance through alternative mechanisms involving spherical aluminum silicate particles and solid lubricants.
Solution Approach 2:
The patent changes the particle morphology parameter from fibrous (carbon fibers) to spherical (aluminum silicate). This parameter change improves friction behavior and reduces seizing tendency while maintaining wear resistance. The spherical shape allows for better lubrication and reduced mechanical interlocking compared to fibrous structures.
2Strength
If hard materials with Mohs hardness greater than 5 are used, then strength is improved, but friction characteristics worsen
Solution Approach 1:
The patent applies parameter changes by limiting the Mohs hardness of materials in the sliding layer to 5 or less. This parameter constraint prevents the use of overly hard materials that would increase friction, while still providing adequate strength through the metal support layer and optimized composite structure.
Solution Approach 2:
The patent uses a composite material system combining metal support layer with a sliding layer containing spherical aluminum silicate and solid lubricants. This composite structure provides the necessary strength from the metal substrate while the sliding layer composition optimizes friction characteristics through softer, lubricating materials.
3Strength
If carbon fibers are used for reinforcement, then mechanical strength is improved, but surface quality deteriorates leading to increased seizing
Solution Approach 1:
The patent extracts removes carbon fibers from the sliding layer composition. This extraction eliminates the surface quality issues and seizing problems associated with carbon fiber reinforcement, while mechanical strength is maintained through the metal support layer and alternative reinforcement strategies.
Solution Approach 2:
The patent replaces fibrous reinforcement with spherical aluminum silicate particles. This spheroidality change improves surface quality by eliminating the irregular fibrous structure that causes surface defects and seizing, while the spherical particles provide smooth rolling contact and better surface finish.
4Strength
If traditional materials are used, then wear resistance is achieved, but adaptability to low flow conditions deteriorates
Solution Approach 1:
The patent changes the material composition parameters by using spherical aluminum silicate and solid lubricants instead of traditional carbon fiber composites. This parameter change enables the bearing to adapt to low flow conditions by providing better lubrication characteristics and reduced friction, while maintaining wear resistance.
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 material exhibits enhanced wear resistance and reduced seizing tendencies, with improved forming behavior and friction characteristics, as demonstrated by reduced wear and lower starting torque in comparison to traditional materials.
Implementation Method 1
a sliding layer with a sliding layer material that is in sliding contact with a sliding partner based on a fluorine-free thermoplastic, in particular PAEK (polyaryl ether ketones) or PEEK (polyether ether ketones), and with fillers that improve the tribological properties
Implementation Method 2
5 - 40% by weight of a solid lubricant, in particular in the form of a or more of the following substances zinc sulfide, tungsten disulfide, barium sulfate, kaolin, calcium fluoride, graphite, chalk or talc
Implementation Method 3
the sliding layer material is anchored in a porous carrier layer formed on the metallic support layer, in particular in a carrier layer sintered on from metallic particles
Implementation Method 4
or that the sliding layer material is glued to the metallic supporting layer by means of an adhesive adhesion-promoting layer
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a metal/plastic composite sliding bearing material (2) for producing sliding bearing elements for lubricated applications, comprising a metal protective layer (4), in particular of steel, and a sliding layer (10), which is in sliding contact with a sliding partner and comprises a sliding layer material (8) on the basis of a fluorine-free thermoplastic, in particular PAEK or PEEK, and comprising fillers that improve the tribological properties; according to the invention, it is proposed that the sliding layer material comprises as fillers 1-40% by weight aluminium silicate in the form of substantially spherical particles and 5-40% by weight solid lubricant, in particular in the form of one or more of the following substances: zinc sulphide, tungsten disulphide, barium sulphate, kaolin, calcium fluoride, graphite, chalk or talc, and is formed free from fibrous additives and strength-increasing hard materials that have a Mohs hardness of greater than 5.