Profiled Polymer Thrust Washer Oil Distribution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thrust washers in automotive engines face challenges with inadequate lubrication during engine start-up and increased wear due to frequent start-stop cycles, leading to manufacturing complexity and waste disposal issues with bi-metallic materials.
Innovation Solution
A thrust washer with a polymer layer of profiled thickness on a substrate, featuring oil distribution grooves that are more resilient and accurately formed, reducing wear and manufacturing costs, and simplifying waste disposal by avoiding bi-metallic swarf.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bi-metal thrust washers are used with machined or embossed oil distribution grooves, then lubrication is provided during operation, but manufacturing complexity increases and manufacturing precision deteriorates due to significant tolerances relative to groove depth
Solution Approach 1:
The invention changes the manufacturing approach from mechanical machining/embossing to material deposition with controlled thickness. By controlling the thickness parameter of the polymer layer during deposition, the oil distribution groove geometry is achieved with much higher precision, eliminating the tolerance issues inherent in traditional machining methods.
Solution Approach 2:
The invention replaces the mechanical machining or embossing system with a material deposition system. Instead of removing or deforming material through mechanical forces, the oil distribution groove is formed by selectively depositing polymer material to specific thicknesses, eliminating the precision limitations of mechanical processes.
2Productivity
If bi-metal thrust washers are manufactured by stamping blanks, then production is efficient, but bi-metal waste is generated that is difficult to recycle
Solution Approach 1:
The invention enables recovery and recycling of the polymer material. Unlike bi-metal waste that is difficult to separate and recycle, the polymer layer can be recovered and potentially reused, transforming a waste disposal problem into a recoverable resource scenario.
Solution Approach 2:
The invention uses a composite structure of substrate and polymer layer that can be manufactured without the waste associated with bi-metal stamping. The polymer-substrate composite can be produced through deposition processes that generate minimal waste compared to traditional bi-metal blank stamping and assembly.
3Use of energy by moving object
If frequent start-stop operating schemes are implemented to save fuel, then energy consumption decreases, but wear on thrust washer running surfaces increases due to increased contact frequency
Solution Approach 1:
The invention changes the material parameter of the running surface from traditional bi-metal to polymer layer. The polymer material provides superior wear resistance and lower friction coefficients, allowing the thrust washer to withstand the increased contact frequency from frequent start-stop operation without proportionally increasing wear and extending service life.
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 polymer layer provides enhanced wear resistance, lower friction, and easier recycling, while reducing manufacturing costs and waste disposal complexities compared to traditional bi-metallic thrust washers.
Implementation Method 1
providing a hydrodynamic wedge of lubrication oil to assist in maintaining separation of the thrust washer and the counterface of the web
Implementation Method 2
The ramp region provides a tapered clearance between the thrust washer and the counterface of the crankshaft web, in use, assisting to draw lubricating oil out of the grooves across the axial face of the thrust washer
Data Source
Figure 1A~1B
Figure 2A
Figure 2B
AI summary
A thrust washer (200') for a sliding bearing, comprising a thrust washer substrate having an axial face, and a polymer layer of profiled thickness on the axial face of the substrate, wherein the profiled polymer layer is provided with at least one oil distribution groove.