Resin Roller Bearing Segment Design for Mold Release
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Solution Overview
Problem
Large-sized roller bearings face challenges in producing cages with high accuracy and mechanical strength, leading to issues like cracking, chipping, and abrasion, which affect their performance and longevity, especially when used in supporting heavy loads.
Innovation Solution
The roller bearing is designed with segments having a circumferential angle of 5° to 30° and a slope inclination of 15° or less to facilitate smooth mold-release and maintain strength, using resin materials reinforced with carbon or glass fibers, and incorporating a coupling member for easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the segment is thickened to provide mechanical strength for heavy loads, then the strength increases, but the elastic deformation amount decreases making forcible extraction from molds more likely to cause cracking or chipping
Solution Approach 1:
The patent changes the geometric parameters of the segment by limiting the circumferential angle to 30° or less and the slope inclination to 15° or less. These parameter changes allow the segment to have sufficient mechanical strength while maintaining adequate elastic deformation capability for safe extraction from molds without cracking or chipping.
2Ease of manufacture
If a draft is provided to the pocket surface to enable smooth mold-release, then the ease of manufacture improves, but the cross-sectional area of the pillar portion decreases reducing the strength of the segment
Solution Approach 1:
The patent optimizes the slope inclination angle to 15° or less, which provides sufficient draft for smooth mold-release while minimizing the reduction in cross-sectional area of the pillar portion. This parameter optimization balances ease of manufacture with structural strength requirements.
Solution Approach 2:
The patent applies a moderate draft angle (15° or less) that is sufficient for mold-release but not excessive, thereby avoiding unnecessary reduction in pillar portion thickness and maintaining segment strength while still enabling easy manufacturing.
3Device complexity
If the circumferential angle of the segment is increased to reduce the number of segments, then the device complexity decreases, but the manufacturing precision and assembly accuracy become more difficult to maintain
Solution Approach 1:
The patent sets the circumferential angle to 30° or less, which optimizes the balance between the number of segments and manufacturing precision. This parameter limitation ensures that each segment can be manufactured with high accuracy while keeping the overall device complexity manageable through a reasonable number of segments.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A segment 10 is an injection molded product of a resin material integrally comprising: a plurality of pillar portions 13 arranged spaced apart in a circumferential direction; a pair of arcuate portions 11 and 12 arranged spaced apart in an axial direction and coupled to each other through intermediation of the plurality of pillar portions 13; and claw portions 15 and 16 provided to the pillar portion 13, and a circumferential angle θ corresponding to a circumferential dimension of the segment 10 is 5° or more and 30° or less.