Thrust Washer Phenolic Resin Coating Friction Reduction
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Solution Overview
Problem
Thrust washers for torque converters, which are typically made of plastic or metal, face challenges in reducing wear and friction between rotating components, and existing coatings do not effectively address the need for low friction and wear prevention.
Innovation Solution
A thrust washer with a phenolic resin layer coating the outer surface of a wet friction material, which may include surface pores filled by the resin and grooves for fluid passage, and optionally a metal layer, is used, along with a method of applying the phenolic resin using a hot press to cure it onto the wet friction material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a thrust washer is made of plastic or metal, then structural strength is provided, but friction and wear between rotating components increase
Solution Approach 1:
The thrust washer combines wet friction material with a phenolic resin coating to create a composite structure that leverages the strength of the substrate while the resin coating provides low-friction, wear-resistant properties, resolving the contradiction between structural strength and friction/wear resistance
Solution Approach 2:
The phenolic resin coating changes the surface friction parameter of the thrust washer, transforming the high-friction metal or plastic surface into a low-friction coated surface that reduces wear and improves reliability while maintaining the underlying structural strength
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 phenolic resin coating reduces friction and wear between components by providing a low coefficient of friction and preventing fluid flow, enhancing the performance and longevity of torque converters.
Implementation Method 1
The wet friction material may include surface pores and the phenolic resin may fill the surface pores
Implementation Method 2
The providing the layer of phenolic resin on the outer surface of the wet friction material may include curing the phenolic resin layer onto the wet friction material after the layer of non-stick material is provided on top of the phenolic resin. The curing may include pressing the phenolic resin layer onto the wet friction material with a hot press.
Implementation Method 3
The phenolic resin coating reduces friction and wear between components by providing a low coefficient of friction
Data Source
AI summary
A thrust washer is provided. The thrust washer includes a wet friction material and a phenolic resin layer coating an outer surface of the wet friction material. A torque converter comprising the thrust washer is also provided. A method of forming a thrust washer is further provided. The method includes providing a layer of phenolic resin on an outer surface of a wet friction material.