Plastic Progressive Distributor With Reduced Dead Space Volume
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Solution Overview
Problem
Existing progressive lubricant distributors are heavy, expensive to produce, prone to material separation and blockages due to dead spaces, and inefficient in lubricant exchange, especially when used on dynamically moving machines.
Innovation Solution
A progressive distributor designed with a modular, injection-molded plastic structure featuring non-rotating pistons and optimized channel geometry to minimize dead spaces and weight, allowing for variable dosages and efficient lubricant distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If progressive distributors are made from metal through machining, then manufacturing precision and strength are improved, but weight and production cost increase significantly
Solution Approach 1:
The patent changes the material parameter from metal to plastic, enabling injection molding manufacturing. This parameter change reduces weight by approximately 70% compared to metal construction while maintaining functional requirements through appropriate plastic material selection and design optimization.
Solution Approach 2:
The patent replaces the traditional mechanical machining process with injection molding. This substitution eliminates complex machining operations, reduces material waste, lowers production costs, and enables more consistent manufacturing precision through mold-based replication of channel geometries.
2Strength
If metal machining is used for progressive distributors, then structural strength is improved, but production cost and manufacturing complexity increase
Solution Approach 1:
The patent changes the manufacturing method parameter from machining to injection molding. This enables production of complex three-dimensional channel geometries and metering plate structures in a single process step, dramatically reducing manufacturing complexity and cost while achieving consistent structural strength through optimized plastic material properties and design.
3Ease of operation
If connecting lines are used to redirect lubricant in progressive distributors, then lubricant distribution is improved, but dead space volume increases causing grease separation and blockages
Solution Approach 1:
The patent extracts and eliminates the connecting lines (redirection lines) from the distributor structure. By integrating the channel geometry directly into the metering plates and housing, the design removes the dead space volumes where grease separation and blockages occur, while maintaining effective lubricant distribution to all bearing points.
Solution Approach 2:
The patent merges the connecting lines with the main channel system by integrating all lubricant pathways directly into the metering plates. This consolidation eliminates separate redirection lines and their associated dead spaces, ensuring continuous lubricant flow and preventing grease separation throughout the entire distribution system.
4Productivity
If redirection lines with volume greater than metering volume are used, then lubricant flow is improved, but lubricant exchange efficiency decreases causing long-term grease separation
Solution Approach 1:
The patent extracts the excessive volume from the lubricant pathways by eliminating redirection lines. The remaining channel volume is optimized to be proportional to the metering volume, ensuring that lubricant is completely exchanged during each operational cycle and preventing the conditions that lead to grease separation and degradation.
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 results in a lightweight, cost-effective distributor with improved lubricant exchange, reduced material separation, and enhanced precision in lubrication, suitable for dynamically moving components.
Implementation Method 1
A progressive distributor designed with a modular, injection-molded plastic structure featuring non-rotating pistons and optimized channel geometry to minimize dead spaces and weight
Implementation Method 2
A progressive distributor designed with a modular, injection-molded plastic structure featuring non-rotating pistons and optimized channel geometry to minimize dead spaces and weight
Data Source
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AI summary
A disc-shaped lubricant distributor, which can be manufactured from plastic, is proposed. This results in optimized lubricant flow, improved space utilization, and reduced weight. At the same time, manufacturing is simplified.