Starter Gear Antifriction Coating for Noise Reduction
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Solution Overview
Problem
Existing starter motor systems for internal combustion engines face issues with volatile friction-reducing agents, such as greases, which can lead to wear, noise, and failure due to consumption or pastiness from dust and dirt, especially in start-stop systems where low noise and high temperature performance are critical.
Innovation Solution
The use of non-volatile anti-friction coatings, such as Teflon, MoS2, WS2, or graphite, applied as bonded coatings on the drive and driven parts of the planetary gear system, providing a durable and temperature-resistant lubrication solution that prevents pastiness and blockages, ensuring consistent performance and longer service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If volatile friction-reducing agents (greases) are used in the planetary gear system, then initial lubrication is provided, but they are consumed during operation or become pasty due to dust and dirt, leading to wear, noise, and failure
Solution Approach 1:
The patent changes the physical and chemical parameters of the lubricating material from volatile grease to non-volatile solid friction-reducing agents (Teflon, MoS2, WS2, graphite). This fundamental parameter change eliminates consumption and pastiness issues while maintaining friction reduction capabilities throughout the starter's operational life
Solution Approach 2:
The invention uses composite material structures where solid friction-reducing agents are incorporated into coating matrices or applied as layered composites on gear surfaces. This combines the low friction properties of solid lubricants with the adhesion and protective properties of coating materials, creating a durable lubrication system that resists dust and dirt contamination
2Reliability
If solid lubricating layers are applied through carburizing and chemical conversion, then friction is reduced, but the process requires bonder or chemical conversion steps and additional molybdenum application
Solution Approach 1:
The patent extracts and eliminates the complex chemical conversion and bonder application steps from the coating process. By using direct physical vapor deposition or simple bonding methods for solid friction-reducing agents, the invention maintains effective friction reduction while significantly simplifying the manufacturing process
Solution Approach 2:
The invention replaces complex chemical processes (carburizing, chemical conversion, multiple coating steps) with simpler physical deposition methods or direct bonding techniques. This substitution maintains the friction-reducing functionality while reducing process complexity and eliminating the need for multiple sequential steps
3Ease of operation
If grease is used as lubricant, then friction is reduced initially, but it becomes pasty and blocks the gear system during prolonged operation or high temperature
Solution Approach 1:
The patent changes the physical state parameter of the lubricating material from liquid/grease phase to solid phase. Solid friction-reducing agents maintain their structural integrity and friction-reducing properties across a wide temperature range and prolonged operation, eliminating the pastiness and blockage problems associated with grease
Solution Approach 2:
The invention replaces the consumable, short-lived grease lubricant with durable, long-lasting solid friction-reducing coatings. These coatings are applied once and provide continuous friction reduction throughout the starter's service life, eliminating the need for periodic replacement or replenishment
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 non-volatile anti-friction coatings maintain optimal friction properties across a broad temperature range, reducing noise and ensuring reliable operation even at high temperatures, thereby extending the service life and maintaining performance in smaller installation spaces with increased loads.
Implementation Method 1
non-volatile friction-reducing agents are used as friction-reducing agents. The non-volatile friction reducing agents eliminate this failure mechanism.
Data Source
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AI summary
The object of the present invention relates to a reduction gear (83) of a starter motor (13) for internal combustion engines, comprising a drive part (44, 80) and a driven part (22, 132) in functional tribological connection with the drive part, wherein a friction-reducing means is provided between the drive part and the driven part for operation, wherein the friction reducing means is designed as a non-volatile friction-reducing means.