Integrated Foil Member Thrust Bearing Design
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Solution Overview
Problem
Leaf type thrust foil bearings require numerous components, complex assembly, and have insufficient load capacity, leading to increased costs and instability under high-speed, high-temperature conditions in gas turbines and superchargers.
Innovation Solution
A thrust foil bearing design featuring a foil member with integrated leaves and coupling portions, along with magnets for enhanced load capacity, and a configuration that includes circumferentially long protrusions or grooves to manage fluid flow and pressure, reducing the number of components and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If leaf type thrust foil bearing uses multiple separate leaves, then load capacity is improved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent merges multiple separate leaves into a single integrated foil member with multiple bearing surfaces. This integration maintains the load capacity benefits of multiple leaves while eliminating the complexity of assembling and managing multiple separate components. The foil member is formed as one piece through processes like rolling or forming, creating a unified structure that provides multiple thrust bearing surfaces without requiring separate leaf assembly.
2Force
If leaf type thrust foil bearing uses multiple separate leaves, then load capacity is improved, but assembly time and cost increase
Solution Approach 1:
The patent combines multiple leaves into a single integrated foil member, transforming a multi-step assembly process into a single installation operation. The unified foil member can be installed as one component, dramatically reducing assembly time and eliminating the need for sequential assembly of multiple leaves. This integration directly addresses the time loss associated with complex assembly procedures while preserving the load capacity advantages.
3Manufacturing precision
If rigid bearing surfaces are used in air dynamic pressure bearing, then manufacturing precision is improved, but stability deteriorates under thermal expansion
Solution Approach 1:
The patent employs a flexible foil member that can dynamically adapt its shape and bearing surfaces in response to thermal expansion and operational conditions. Unlike rigid bearing surfaces that maintain fixed geometry, the flexible foil deforms to accommodate temperature changes and load variations, automatically maintaining optimal bearing gaps without requiring precise manufacturing tolerances. This dynamic adaptation ensures stable operation across varying thermal conditions.
Solution Approach 2:
The patent utilizes the flexibility of the foil member to change its physical parameters (shape, curvature, position) in response to operational conditions. The foil can alter its configuration based on thermal expansion, rotational speed, and load, allowing the bearing gap to self-adjust. This parameter change capability enables the bearing to maintain stability under thermal expansion without relying on tight manufacturing precision.
4Ease of manufacture
If larger bearing gaps are used in foil bearing, then ease of manufacture is improved, but load capacity deteriorates
Solution Approach 1:
The patent uses the flexible foil member to dynamically optimize the bearing gap during operation. Although the foil can accommodate larger initial gaps due to its flexibility, the foil deforms under load and rotational speed to create an optimal fluid film thickness. This dynamic adjustment allows the bearing to start with easier manufacturing tolerances while achieving the necessary load capacity through operational deformation and fluid film formation.
Solution Approach 2:
The patent allows the bearing gap parameter to change during operation. The flexible foil member adjusts the effective gap size based on operational conditions such as load, speed, and temperature. This parameter change enables the bearing to be manufactured with larger, more tolerant gaps while still achieving optimal load capacity through the foil's ability to deform and create the appropriate fluid film thickness during operation.
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 reduces component count, simplifies assembly, increases load capacity, and stabilizes the bearing under high-speed, high-temperature conditions by optimizing fluid pressure and flow, thereby enhancing the performance and efficiency of thrust foil bearings.
Implementation Method 1
a thrust bearing gap is formed between bearing surfaces of the leaves and an opposing end surface of the rotary member, and a fluid film in the thrust bearing gap supports the rotary member in the thrust direction in a non-contact manner
Implementation Method 2
Along with rotation of the rotary member, a thrust bearing gap is formed between bearing surfaces of the leaves and an opposing end surface of the rotary member, and a fluid film in the thrust bearing gap supports the rotary member
Data Source
AI summary
A thrust foil bearing includes a thrust member, and a foil member mounted to an end surface of the thrust member and having a thrust bearing surface that forms a thrust bearing gap. The foil member includes a foil that integrally includes a plurality of leaves each having a free end on one side in a circumferential direction and the thrust bearing surface, and a coupling portion for coupling the plurality of leaves to each other.