Process for producing an encoder

Abstract

Methods for producing an encoder are disclosed. In one example, a method may include introducing an insert part into a mold, wherein the insert part is a support part, a metal foil, or a metal-coated foil. A first component may be injected into the mold, wherein the first component is an adhesion promoter. The first component is then cooled, wherein the first component joins with the insert part. A second component is injected into the mold, wherein the second component includes a material which comprises polyamide 6, polyamide 12, or polyphenylene sulfide and at least one magnetic filler. The second component is then cooled, wherein the second component joins with the first component and forms the encoder.

Claims

1. A method for producing an encoder for bearing units, comprising the following steps: introducing an insert part into a mold, wherein the insert part is a support part, a metal foil, or a metal-coated foil, injecting a first component into the mold, wherein the first component is an adhesion promoter, cooling the first component, wherein the first component joins with the insert part, injecting a second component into the mold, wherein the second component includes a material which comprises polyamide 6, polyamide 12, or polyphenylene sulfide and at least one magnetic filler, and cooling the second component, wherein the second component joins with the first component and forms the encoder.

2. The method as claimed in claim 1, wherein: injecting the first component is performed by a first device and injecting the second component is performed by a second device.

3. A method for producing an encoder for bearing units, comprising the following steps: introducing an insert part into a mold, wherein the insert part is a support part, a metal foil, or a metal-coated foil, injecting a melt into the mold, wherein the melt includes a material which comprises polyamide 6, polyamide 12 or polyphenylene sulfide and at least one magnetic filler, and compressing the melt, wherein the melt joins with the insert part to form the encoder on cooling of the melt.

4. The method as claimed in claim 3, wherein: injecting the melt is performed by a first device.

5. The method as claimed in claim 3, wherein: injecting the melt into the mold is performed while the mold is not fully closed, and so an embossing gap is formed in the mold, and pressure is applied on the mold to close the mold until the embossing gap is eliminated.

6. A method for producing an encoder for bearing units, comprising the following steps: introducing an insert part into a mold, wherein the insert part is a support part, a metal foil, or a metal-coated foil, injecting a melt using a first device into the mold, wherein the melt includes a material which comprises polyamide 6, polyamide 12 or polyphenylene sulfide and at least one magnetic filler, and compressing the melt, wherein the melt joins with the insert part to form the encoder on cooling of the melt.

7. (canceled)

8. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0061] The disclosure is now illustrated by way of example using figures, wherein:

[0062] FIG. 1a to 1d show an example production method for an encoder,

[0063] FIGS. 2a to 2d show an alternative example production method for an encoder, and

[0064] FIGS. 3a to 3e show a further alternative example production method for an encoder.

DETAILED DESCRIPTION

[0065] FIG. 1a to FIG. 3e show example embodiments. The disclosure is not confined to these example embodiments. The encoders produced by the methods may all have a magnet part including a material which comprises polyamide 6, polyamide 12 or polyphenylene sulfide and at least one magnetic filler.

[0066] FIG. 1a to 1d show a first production method for an encoder 40, according to an embodiment. The production method is a two-component injection molding process.

[0067] The first method for producing the encoder 40 for bearing units comprises the following steps:

[0068] introducing insert part into a mold 20, with the insert part being a support part 42,

[0069] injecting a first component 25 into the mold 20, where the first component 25 is an adhesion promoter,

[0070] cooling the first component 25, where the first component 25 joins with the support part 42,

[0071] injecting a second component 26 into the mold 20, where the second component 26 includes a material which comprises polyamide 6, polyamide 12 or polyphenylene sulfide and at least one magnetic filler, and

[0072] cooling the second component 26, where the second component 26 joins with the first component 25 and in this way the encoder 40 is formed.

[0073] The support part 42 here may have been pretreated mechanically or by phosphating. The first component 25 and the second component 26 are injected under the action of pressure. Both components are flowable, and may be melts. After cooling has taken place, the encoder 40 can be ejected or removed from the mold 20. In this case the mold 20, the first device 21, and the second device 22 are parts of an injection molding machine.

[0074] FIGS. 2a to 2d show a second production method for an encoder 40, according to an embodiment. The production method is an in-mold foil coating process.

[0075] The second method for producing the encoder 40 for bearing units comprises the following steps:

[0076] introducing an insert part into a mold 20, with the insert part being a metal foil 44,

[0077] injecting a melt 30 into the mold 20, where the melt 30 includes a material which comprises polyamide 6, polyamide 12 or polyphenylene sulfide and at least one magnetic filler, and

[0078] compressing the melt 30, where the melt 30 joins with the metal foil 44 to form the encoder 40 on cooling of the melt 30.

[0079] Furthermore, an adhesion promoter may also have been provided on the metal foil 44. When the mold 20 is pressed together, the metal foil 44 inserted into the mold 20 is embossed in accordance with the shape of the mold 20. The melt 30 is injected under the action of pressure. After cooling has taken place, the encoder 40 can be ejected or removed from the mold 20. In this case the mold 20, the first device 21, and the second device 22 are parts of an injection molding machine.

[0080] FIGS. 3a to 3e show a third production method for an encoder 40, according to an embodiment. The production method is an injection-compression molding process.

[0081] The third method for producing the encoder 40 for bearing units comprises the following steps:

[0082] introducing an insert part into a mold 20, where the insert part is a support part 42,

[0083] injecting a melt 30 using a first device 21 into the mold 20, where the melt 30 includes a material which comprises polyamide 6, polyamide 12 or polyphenylene sulfide and at least one magnetic filler, and

[0084] compressing the melt 30, where the melt 30 joins with the support part 42 to form the encoder 40 on cooling of the melt 30.

[0085] The support part 42 here may have been pretreated mechanically or by phosphating. Furthermore, an adhesion promoter may also have been provided on the support part 42. On injection of the melt 30 into the mold 20, the mold 20 is not fully closed, and so on embossing gap 24 is able to form in the mold 20. As a result of an action of pressure, 23, on the mold 20, the melt 30 is compressed in the mold 20. As soon as the mold 20 is closed, the embossing gap 24 no longer exists. After cooling has taken place, the encoder 40 can be ejected or removed from the mold 20. In this case the mold 20, the first device 21, and the second device 22 are parts of an injection machine.

[0086] A fourth production method, but one which is not shown, is a fluidized sintering process.

[0087] The fourth method for producing the encoder 40 for bearing units comprises the following steps:

[0088] heating a support part,

[0089] introducing the support part into a bath of plastics powder, where the plastics powder comprises polyamide 6, polyamide 12 or polyphenylene sulfide and at least one magnetic filler, more particularly magnetic particles, and where the plastics powder is fluidized by an airstream, and

[0090] impinging the magnetic particles onto the support part, with the plastics powder remaining adhering on the support part.

[0091] Furthermore, there are also other methods envisaged for producing an encoder for bearing units. Processes include the following:

[0092] PVD processes (physical vapor deposition processes),

[0093] CVD processes (chemical vapor deposition processes),

[0094] electroplating or vapor deposition (e.g., electron beam, sputtering, etc.).

[0095] The provision of these methods highlights various possibilities of producing an encoder for bearing units.

LIST OF REFERENCE NUMERALS

[0096] 20 mold

[0097] 21 device

[0098] 22 device

[0099] 33 action of pressure

[0100] 24 embossing gap

[0101] 25 component

[0102] 26 component

[0103] 30 melt

[0104] 40 encoder

[0105] 42 support part

[0106] 44 metal foil