Sliding Resin Composition for Engine Bearing Seizing Resistance
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Solution Overview
Problem
Current resin compositions used in vehicle engine bearings face challenges with increased friction and seizing due to frequent start-stop cycles, reduced engine oil viscosity, and heavier loads, leading to potential deformation and breakage, which can result in welding between the bearing and shaft.
Innovation Solution
A sliding resin composition is developed with a harder and more brittle reinforcing agent, combined with a solid lubricant, to absorb and distribute load stress, preventing resin binder deformation and maintaining an oil film, thereby enhancing seizing resistance while maintaining abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin composition layer is used to improve seizing resistance, then seizing resistance is improved, but under heavy loads the resin composition may be deformed beyond its limitation causing breakage or separation from the base material
Solution Approach 1:
The invention uses a composite resin composition containing multiple components including resin binder, solid lubricant, and protecting/reinforcing particles with specific hardness and brittleness characteristics. This composite structure allows the material to exhibit both high seizing resistance and maintained structural integrity under heavy loads by distributing stress across different components with complementary properties.
Solution Approach 2:
The invention specifies precise parameter ranges for the protecting and reinforcing particles, including hardness (0.5 to 2.0 GPa) and brittleness (0.05 to 0.20), to optimize the balance between seizing resistance and structural strength. By controlling these physical parameters, the resin composition maintains its integrity under heavy loads while providing effective seizure protection.
2Use of energy by moving object
If the viscosity of engine oil is reduced to reduce shear resistance, then shear resistance is reduced, but the oil film between shaft and bearing becomes insufficient leading to increased friction
Solution Approach 1:
The resin composition layer acts as an intermediary between the base material and the shaft, providing boundary lubrication when the oil film becomes insufficient. The solid lubricant components (graphite, MoS2, WS2) in the resin composition compensate for the reduced oil film thickness, maintaining low friction and preventing metal-to-metal contact even when engine oil viscosity is reduced.
3Use of energy by moving object
If a heavier specific load is applied to the bearing to achieve lower fuel consumption, then fuel consumption is reduced, but it becomes more difficult to maintain an oil film between shaft and bearing
Solution Approach 1:
The resin composition layer is applied beforehand to the base material surface to create a protective cushion that maintains lubrication under heavy loads. The protecting and reinforcing particles with optimized hardness and brittleness provide a resilient layer that prevents direct metal-to-metal contact, compensating for the difficulty of maintaining oil film under the heavier specific loads required for fuel-efficient operation.
4Ease of manufacture
If a rougher surface shaft is used to reduce cost, then cost is reduced, but it becomes more difficult to maintain an oil film
Solution Approach 1:
The resin composition layer serves as an intermediary between the rough shaft surface and the bearing, providing a smooth, lubricious interface. The solid lubricant components and protecting particles in the resin composition compensate for the surface roughness, maintaining adequate oil film thickness and reducing friction despite the cost-effective rougher shaft surface.
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 composition effectively reduces friction and prevents seizing by allowing the reinforcing agent to deform before the resin binder, maintaining the resin's structure and ensuring improved durability and lubrication, thus enhancing the bearing's performance under heavy loads and frequent start-stop conditions.
Implementation Method 1
the solid lubricant itself is deformed (e.g., cleaved), more specifically, slip occurs between its crystal planes so that the stress of the resin composition is relaxed
Implementation Method 2
slip occurs between its crystal planes so that the stress of the resin composition is relaxed
Implementation Method 3
nano-ordered silica particles (20 to 50 nm in diameter) are used as the protecting and reinforcing particles to improve the abrasion resistance of the entire resin composition
Implementation Method 4
The sliding surface of a bearing applied to the engine of a vehicle is required to have high abrasion resistance and seizing resistance... a layer of a resin composition is formed by coating the inner peripheral surface (sliding surface)
Data Source
AI summary
A resin composition for use in a sliding member, which has higher seizing resistance while maintaining abrasion resistance. The sliding resin composition includes: a resin binder; a solid lubricant; and a protecting and reinforcing agent that is harder and brittler than the resin binder. As the protecting and reinforcing agent, aggregates of particles harder than the resin binder are used. The amount of the protecting and reinforcing agent contained is 1 vol. % or more but 20 vol. % or less of the entire sliding resin composition. The particles harder than the resin binder have an average particle diameter of 10 nm or more but 100 nm or less that is smaller than that of the solid lubricant.