Elastomeric Support Element Coating With Controlled Shell Thickness
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Solution Overview
Problem
Manufacturing a fire-resistant coating on elastomeric spring elements for rail vehicles is challenging due to difficulties in bonding the rubber compounds and achieving defined layer thicknesses, leading to a complex and costly production process.
Innovation Solution
A method involving an injection molding process with movable mold parts and a removable mold core to create a fire-resistant shell, followed by vulcanization and cooling, allowing for the formation of a fire-resistant coating on a support element made of elastomeric material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fire-resistant coating is applied to elastomeric spring elements, then fire protection properties are improved, but manufacturing complexity increases due to bonding difficulties and layer thickness control
Solution Approach 1:
The patent combines the coating application and vulcanization processes into a single integrated injection molding operation. The coating material is injected into the mold cavity around the spring element, and both the coating and spring element are vulcanized simultaneously in the same mold, eliminating separate bonding steps and simplifying the manufacturing process while ensuring fire protection properties
Solution Approach 2:
The patent uses composite material technology by injecting a two-component coating mixture (polyol and isocyanate) that reacts and cures in situ to form a fire-resistant coating layer. This composite approach allows the coating to be formed as an integrated part of the spring element assembly, reducing manufacturing complexity while achieving the required fire protection
2Reliability
If a fire-resistant coating is applied to elastomeric spring elements, then fire protection properties are improved, but manufacturing precision is reduced due to difficulty in achieving defined layer thicknesses
Solution Approach 1:
The patent replaces traditional mechanical coating application methods (such as spraying or dipping) with an injection molding process. The coating material is injected under controlled pressure and temperature conditions directly into the mold cavity, allowing precise control of the coating layer thickness through mold design and injection parameters, thereby achieving defined layer thicknesses consistently
Solution Approach 2:
The patent controls the coating layer thickness by adjusting injection parameters such as injection pressure, temperature, and material viscosity. By optimizing these parameters, the process achieves consistent and defined layer thicknesses, ensuring both fire protection properties and manufacturing precision
3Device complexity
If the shell is cooled outside the injection molding machine, then device complexity is reduced by eliminating built-in cooling systems, but production time increases due to external cooling requirements
Solution Approach 1:
The patent extracts the cooling function from the injection molding machine itself and performs cooling externally after demolding. The shell is removed from the mold while still warm, then cooled separately using external cooling methods. This separation eliminates the need for complex built-in cooling systems in the mold, reducing device complexity while accepting external cooling time
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
Enables the production of high-quality, fire-resistant coated support elements in an efficient and reproducible manner, eliminating the need for complex cooling systems in the production device.
Implementation Method 1
A first mixture, in particular an elastomeric mixture, is then inserted into the gap. The first mixture is preferably plasticized by closing the molded parts and fills the gap
Implementation Method 2
The shell is then partially vulcanized before cooling. This means the vulcanization process is started but not yet completed, so that at least the surface of the shell is hardened
Implementation Method 3
The shell is then cooled until its stiffness is increased and its dimensional stability is achieved. That is, the shell is cooled, preferably below its glass transition temperature, until its stiffness is increased
Implementation Method 4
a second mixture, in particular an elastomeric mixture different from the first mixture, is injected into the cavity. The injection preferably takes place through one or more openings in the molded parts. The second mixture is preferably plasticized and forms a support body
Implementation Method 5
The bearing body and the shell are then vulcanized together in the cavity. During this process, the bearing body and the shell are fused together, so that the shell forms the coating of the bearing body
Data Source
Figure 1~2
AI summary
A method for producing a bearing element (3) coated with a coating (1) from elastomer material is shown and described, comprising the steps of: - providing an injection molding device (5) which, in the closed position, encloses a cavity (9), - inserting a mold core (11) into the cavity (9) so that a gap (13) remains, which corresponds to the shape of the coating (1) of the bearing element (3) to be produced, - inserting a first mixture (15) into the gap (13) so that the first mixture (15) fills the gap (13) and forms a shell (17) which has the shape of the coating (1), - cooling the shell (17) until its stiffness is increased and dimensional stability is achieved, - removing the mold core (11), - injecting a second mixture (19) into the cavity (9) so that it forms a bearing body (23) which rests against the inside of the shell (17), - vulcanizing the support body (23) together with the shell (17),so that they are connected to each other and the shell (17) forms the coating (1) of the support body (23).