Solid-Lubrication Rolling Bearing with Amorphous Carbon Skeleton
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Solution Overview
Problem
The existing solid-lubrication rolling bearings with graphite-based solid lubricants suffer from low material strength, hardness, impact resistance, and wear resistance, leading to shortened life and instability at elevated temperatures.
Innovation Solution
A solid-lubrication rolling bearing is developed using a solid lubricant composed of amorphous and self-sintering carbon material powder, graphite powder, and a binder, with a preferred weight ratio of 50-60% carbon material powder to 25-40% graphite powder, and optionally including W, Mo, MoS2, carbon fiber, or carbon nanotubes to enhance strength and wear resistance, along with a unique separator design to prevent uneven distribution and rotational locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If graphite powder and binder are used as solid lubricant, then lubrication performance at elevated temperatures is improved, but material strength and hardness are reduced
Solution Approach 1:
The patent uses a composite material consisting of graphite powder (20-40 wt%), amorphous carbon powder (40-60 wt%), and binder (10-30 wt%). The amorphous carbon forms a sintered skeleton structure that provides strength and hardness, while graphite particles embedded in this skeleton provide lubrication at elevated temperatures. This composite structure resolves the contradiction by combining materials with complementary properties.
Solution Approach 2:
The invention creates different local structures within the solid lubricant: the amorphous carbon forms a sintered skeleton structure in certain regions providing mechanical strength, while graphite particles are distributed in other regions providing lubrication. This local differentiation of material properties allows simultaneous achievement of strength and lubrication performance.
2Temperature
If graphite-based solid lubricant is used, then lubrication at elevated temperatures is achieved, but wear resistance and impact resistance are reduced
Solution Approach 1:
The composite structure combines amorphous carbon with sintered skeleton properties for wear and impact resistance, and graphite particles for lubrication. The binder holds graphite particles firmly in the sintered skeleton, preventing particle loss during wear and impact. This composite approach simultaneously achieves elevated temperature lubrication and improved reliability.
Solution Approach 2:
The amorphous carbon sintered skeleton acts as an intermediary structure that provides mechanical support and holds graphite particles in place. This skeleton structure transfers and distributes mechanical stresses, protecting the graphite particles from direct impact and wear, thereby improving overall reliability while maintaining lubrication function.
3Productivity
If separator size is reduced to increase rolling element density, then basic rated load is improved, but uneven distribution and rotational locking may occur
Solution Approach 1:
The restricting members are pre-installed in the separator to define specific movement ranges for rolling elements before operation begins. These restricting members create predetermined pathways and stop positions that guide rolling element distribution, preventing uneven clustering and rotational locking while allowing sufficient density for high basic rated load.
Solution Approach 2:
The restricting members allow controlled dynamic movement of rolling elements within defined ranges rather than complete freedom of movement. This dynamic constraint system enables rolling elements to adjust positions during operation while maintaining overall uniform distribution, preventing both excessive density and rotational locking.
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 new solid lubricant achieves high material strength, hardness, and wear resistance, extending the life of the bearing and preventing unintended disassembly, while the separator design ensures stable operation and increased basic rated load without the need for connecting members.
Implementation Method 1
amorphous and self-sintering carbon material powder... forms a skeleton structure in which adjacent carbon material particles are combined with each other after firing due to the self-sintering property
Implementation Method 2
The graphite particles are held by the skeleton structure and thus, are hard to fall off. This can increase material strength and improve impact resistance and wear resistance
Data Source
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AI summary
A solid lubricant 11 is formed by molding and firing powder that includes amorphous and self-sintering carbon material powder 12, graphite powder 13, and a binder 14. The solid lubricant has high material strength and hardness, and also excellent impact resistance and wear resistance.