Lead-Free Sliding Layer Composition for Bearing Wear Resistance
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Solution Overview
Problem
Existing sliding members with resin-based coatings face challenges in achieving improved elastic modulus and abrasion resistance to prevent deformation and maintain effective contact area under external forces, particularly in lead-free alternatives.
Innovation Solution
A resin composition incorporating a zinc compound, iron oxide, and carbon fiber is used to enhance the elastic modulus of the sliding layer, preventing deformation and maintaining contact area, with specific volume percentages of these additives ensuring optimal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a resin-based sliding layer is used to eliminate lead, then environmental safety is improved, but the elastic modulus and deformation resistance deteriorate
Solution Approach 1:
The patent applies composite materials by combining resin base material with multiple additives (zinc powder, iron oxide, carbon fiber) to create a sliding layer that maintains both environmental safety (lead-free) and mechanical strength (high elastic modulus). The zinc powder provides base reinforcement, iron oxide enhances hardness and wear resistance, and carbon fiber adds tensile strength, collectively achieving the desired elastic modulus without lead.
Solution Approach 2:
The patent applies parameter changes by optimizing the content ratios of different additives in the resin composition. Specifically, it controls zinc powder content at 5-50 wt%, iron oxide at 1-30 wt%, and carbon fiber at 0.1-10 wt%, along with adjusting particle size distributions. These parameter optimizations enable the sliding layer to achieve sufficient elastic modulus and deformation resistance while remaining lead-free.
2Object-affected harmful factors
If a resin-based sliding layer is used to eliminate lead, then environmental safety is improved, but the abrasion resistance deteriorates
Solution Approach 1:
The patent applies composite materials by combining resin base material with multiple additives (zinc powder, iron oxide, carbon fiber) to create a sliding layer that maintains both environmental safety (lead-free) and mechanical strength (high elastic modulus). The zinc powder provides base reinforcement, iron oxide enhances hardness and wear resistance, and carbon fiber adds tensile strength, collectively achieving the desired elastic modulus without lead.
Solution Approach 2:
The patent applies local quality by creating a multi-component composite structure where each additive serves specific local functions: zinc powder provides base reinforcement and lubricity, iron oxide specifically enhances surface hardness and abrasion resistance, while carbon fiber provides tensile strength and crack resistance. This localized functional distribution within the composite achieves superior abrasion resistance.
3Ease of operation
If the sliding layer is made softer to improve sliding performance, then sliding performance is improved, but the contact area stability under external force deteriorates
Solution Approach 1:
The patent applies composite materials by combining resin base material with multiple additives (zinc powder, iron oxide, carbon fiber) to create a sliding layer that maintains both environmental safety (lead-free) and mechanical strength (high elastic modulus). The zinc powder provides base reinforcement, iron oxide enhances hardness and wear resistance, and carbon fiber adds tensile strength, collectively achieving the desired elastic modulus without lead.
Solution Approach 2:
The patent applies parameter changes by optimizing the content ratios of different additives in the resin composition. Specifically, it controls zinc powder content at 5-50 wt%, iron oxide at 1-30 wt%, and carbon fiber at 0.1-10 wt%, along with adjusting particle size distributions. These parameter optimizations enable the sliding layer to achieve sufficient elastic modulus and deformation resistance while remaining lead-free.
Data Source
Figure 1~2
Figure 3~4
AI summary
Provided is a sliding member having improved various characteristics such as elastic modulus, and a bearing using the sliding member. The sliding member 1 includes a metallic substrate 2, a porous layer 3 formed on a surface of the metallic substrate 2, and a sliding layer 5 that covers the porous layer 3. The sliding layer 5 is made of a lead-free resin composition 4, the resin composition 4 contains a zinc compound as an essential additive and further contains, as an essential additive, either of a carbon fiber or an iron oxide or both of the carbon fiber and the iron oxide. A content of the essential additive is 10 vol% or more and 35 vol% or less in the resin composition, and the remainder is a fluororesin.