Thrust Washer Roller Coating for Uniform Edge Coverage
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Solution Overview
Problem
Existing methods for applying anti-friction coatings to axial plain bearing elements, such as thrust washers, often result in uneven coating thickness and excess varnish running down the edges, leading to contamination and inefficiencies.
Innovation Solution
A roller printing process using a metering roller and an application roller to apply a uniform anti-friction coating, ensuring coverage up to the edges without excess varnish, with adjustable parameters for precise control of roller gap and contact pressure, and optional double coating for enhanced adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spraying is used to apply sliding lacquer beyond the edge to achieve sufficient thickness, then the sliding lacquer layer thickness is improved, but the lacquer runs down the lateral edges causing contamination
Solution Approach 1:
A screen printing stencil is introduced as an intermediary element between the sliding lacquer and the circuit board section. The stencil acts as a mediator that controls the flow and distribution of lacquer, allowing sufficient thickness to be achieved while preventing uncontrolled running down the edges.
Solution Approach 2:
The application method is changed from spraying to screen printing, which fundamentally alters how the lacquer is deposited. This parameter change in the application process enables precise control over lacquer distribution, achieving the desired thickness without edge running.
2Object-generated harmful factors
If screen printing with stencil is used to prevent lacquer from running down edges, then contamination is reduced, but the stencil overlaps the edge areas preventing complete coating coverage
Solution Approach 1:
The application method is changed from screen printing to roller printing. This parameter change allows the application roller to precisely control lacquer deposition right up to the geometric edges of the circuit board section without the need for overlapping stencils, thereby achieving complete coverage without edge running.
Solution Approach 2:
The mechanical system of screen printing with stencils is replaced by a roller printing system. The roller mechanism provides continuous, precise control over lacquer application, eliminating the need for stencil overlap and enabling coating right up to the edges.
3Device complexity
If conventional coating methods are used, then the coating process is simple, but the coating thickness is uneven and contamination occurs
Solution Approach 1:
A metering roller is introduced as an intermediary between the lacquer supply and the application roller. This mediator precisely controls the amount of lacquer transferred to the application roller, ensuring uniform coating thickness while maintaining a relatively simple overall process structure.
Solution Approach 2:
The coating method is changed from conventional spraying or screen printing to roller printing with metering control. This parameter change in the application mechanism provides precise control over coating thickness and uniformity while keeping the process straightforward and industrially viable.
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
Achieves a uniformly thick anti-friction coating across the entire surface, including edges, with high precision and efficiency, preventing contamination and ensuring consistent performance.
Implementation Method 1
the sliding varnish is applied to the blank section in a roller printing process using an application roller rolling against the blank section, and that a metering roller is rolled against the application roller to apply the sliding varnish to the application roller and the sliding varnish is introduced into a roller gap formed thereby
Implementation Method 2
when the application roller rolls against the blank section, a coating of the blank section is achieved up to a front and rear edge with respect to the rolling direction and up to both sides of the blank section
Implementation Method 3
the lacquer then typically runs down the lateral edges of the circuit board section due to gravity, which is obviously undesirable
Data Source
Figure 1~2
AI summary
The invention relates to a method for producing an axial sliding bearing element, in particular a thrust washer for a crankshaft of an internal combustion engine, with a supporting layer, in particular of steel, and a bearing metal layer of bronze, brass or aluminium alloy applied on top, and a polymer-based anti-friction lacquer layer (6), optionally with fillers improving the tribological properties, applied on top, wherein a composite material comprising the supporting layer and the bearing metal layer is provided as a flat metal material and wherein a metal blank (3) corresponding to the geometry of the axial sliding bearing to be produced is punched out from this flat material, and wherein this metal blank (3) is coated with an anti-friction lacquer to form the anti-friction lacquer layer (6), characterized in that the anti-friction lacquer is applied to the metal blank (3) in a roller printing process by using an application roller (14) that rolls against the metal blank (3) and in that, for applying the anti-friction lacquer to the application roller (14), a metering roller (12) is rolled against the application roller (14) and the anti-friction lacquer is introduced into a roller nip formed thereby, and in that, when the application roller (14) rolls against the metal blank (3), a coating of the metal blank (3) is achieved as far as a front edge (26) and rear edge (28) with respect to the rolling direction and as far as edges on each side of the metal blank (3).