Title of Invention	A PROCESS FOR MANUFACTURE OF SELF-LUBRICATING CARBON-GRAPHITE THRUST BEARING COLLAR AND THRUST BEARING PAD
Abstract	Self-lubricating carbon-graphite, adhesive bonded to the thrust collar and thrust pad in the thrust bearing assembly designed to operate only on its axis, the critical part of numerouS mechanical devices including submersible pumps, in the existing process, suffers serious drawbacks and material wastages, involving numerous costly, manual, imperfect and time consuming processes, with up to 30% bonding failures during severe thrust pressure, diminished life during dry run, rendering frequent submersible pump failures, with costly and torturous replacement processes. My process of manufacture is a single and simple process, directly moulding self-lubricating carbon-graphite on thrust collar and the thrust pad by extending the mould into created mould space cavities, created on the thrust collar and the thrust pad, for a strong and compact self-adhering moulding. Thus eliminating the numerous drawbacks, manual and imperfect processes and preventing wastages, with either nil or negligible carbon-graphite bonding failures and increased quality, quantity and highly cost-effective uniform productions, simultaneously enhancing the thrust bearing life even during the dry running.

Title of Invention

A PROCESS FOR MANUFACTURE OF SELF-LUBRICATING CARBON-GRAPHITE THRUST BEARING COLLAR AND THRUST BEARING PAD

Abstract

Self-lubricating carbon-graphite, adhesive bonded to the thrust collar and thrust pad in the thrust bearing assembly designed to operate only on its axis, the critical part of numerouS mechanical devices including submersible pumps, in the existing process, suffers serious drawbacks and material wastages, involving numerous costly, manual, imperfect and time consuming processes, with up to 30% bonding failures during severe thrust pressure, diminished life during dry run, rendering frequent submersible pump failures, with costly and torturous replacement processes. My process of manufacture is a single and simple process, directly moulding self-lubricating carbon-graphite on thrust collar and the thrust pad by extending the mould into created mould space cavities, created on the thrust collar and the thrust pad, for a strong and compact self-adhering moulding. Thus eliminating the numerous drawbacks, manual and imperfect processes and preventing wastages, with either nil or negligible carbon-graphite bonding failures and increased quality, quantity and highly cost-effective uniform productions, simultaneously enhancing the thrust bearing life even during the dry running.

Full Text	Field of invention: This invention relates to self-lubricating carbon-graphite thrust collar and thrust pad of thrust bearing assemblies. Background of invention with regard to the drawback associated with prior art: Thrust bearing is a bearing designed to operate with loading only on its axis with normal flat contact or tilting contact actions between two flat faces. An automotive clutch release bearing is an example of a specialized thrust bearing and the self-lubricating carbon-graphite flat face or faces with an opposite flat face or faces, in submersible pump are example of numerous types of thrust bearings. Basically, in a thrust bearing assembly, both the thrust collar and thrust pad mean the same. Actually it is a single component with two different names, depending upon the assembly direction of the thrust bearing. The difference in the name is only to indicate the different manner in which they are fixed to the submersible pump or any other mechanical device. If the thrust bearing part, which holds the self-lubricating carbon-graphite, is fixed on the top, it is termed as thrust collar and if fixed at the bottom by a vertical flip, it is termed as thrust pad. Thrust bearing assemblies with self-lubricating carbon-graphite fixed to thrust collar and thrust pad are used in numerous mechanical devices including submersible pumps. Submersible pump is being used as a perfect example for the numerous advantages of invention of this process, in this document, as against the drawbacks and disadvantages in the existing process. The thrust bearing assembly plays a very critical role in the submersible pumps and other mechanical devices, as an alternative to regular bearings. The regular bearings require external lubricants, such as oil and grease, which tend to get washed away in the water, as submersible pumps work in water, and cannot take the severe thrust pressure that they are subjected to, during deep submersible pump operations, rendering them to fail totally. On the contrary Carbon-graphite thrust bearings are self-lubricating, not requiring external lubricating greases or oils and accommodating the thrust impacts, operate with loading only on its axis, making them the most-fit bearing types for submersible pumps. In the existing process, the self-lubricating carbon-graphite is externally bonded to the thrust collar and the thrust pad to form the crucial part of the thrust bearing assembly and in tum, making it the critical part of the thrust bearing assembly of submersible pumps or other numerous mechanical devices. Thus the thrust bearing assemblies are the lifelines of the submersible pumps and other numerous mechanical devices. According to this process, this is a single and simple process, directly moulding self-lubricating carbon-graphite on thrust collar and thrust pad by extending the mould into mould extension space and spaces, created on the surface or surfaces of the thrust collar and the thrust pad, to facilitate a compact and strong self-adhering self-lubricating carbon-graphite extended moulding, by various moulding processes. Thus eliminating the drawbacks, numerous manual and imperfect processes and preventing wastages, with either nil or negligible carbon-graphite bonding failures and increased quality, quantity and highly cost-effective uniform productions, in total contrast to the existing technique. Existing technique: Self-lubricating Carbon-graphite, either individually or in their various combinations with or without additive or with various additives, as per their required physical, chemical and mechanical properties, in different required shapes, are either moulded separately or cut, machined and machine finished, from pre-moulded solids, rods, squares, round tubes, square tubes or other solid or other tubular shapes of the above carbon-graphite moulds, to form dry lubricating part of the thrust bearing assembly in submersible pumps. Then the above, finished self-lubricating carbon-graphite part is externally bonded with different kinds of adhesives or resins, to adhere them to the thrust collar or the thrust pad to form the crucial part of thrust bearing assemblies, which in turn form crucial parts of submersible pumps. The thrust collar and the thrust pad, usually consist of metals or metal alloys or their castings cast by various methods, or other material or other materials or their combinations, which are again generally either cut or forged or machined or machine finished or without any machining, or mould cast in different sizes and shapes as required. Each individual self-lubricating carbon-graphite part has to be machined individually, both to the pre and post external adhesive bonding to the thrust collar and the thrust pad, where each individual thrust collar and thrust pad, is individually externally bonded to the self-lubricating carbon-graphite part, with individual fasteners for compaction, during each individual bonding. Drawbacks of the existing technique: The failures of the thrust bearing assemblies manufactured by the existing technique are very high as the technique is highly risky. The entire process of external bonding is manual and with no guarantee of self-lubricating carbon-graphite bonding to the thrust collar and the thrust pad of the thrust bearing assembly against abnormally high rates of bonding failures. The very name " thrust bearing assembly " operating with loading only on its axis, explains the function that it has to undergo severe thrust pressure during the operations of the submersible pumps, which can again render the self-lubricating carbon-graphite adhesive bonding to split or break off, from the thrust collar and thrust pad of the assembly frequently. Thus frequent failures of thrust bearing assemblies, in turn, the frequent failures of submersible pumps create heavy agricultural, financial and industrial losses, both to the end user and to the nation. The percentage of failures in thrust bearing assemblies is, at times about 30%. The failure, painstakingly and mercilessly results in the total replacement of the thrust bearing assembly and which can be done only by removing the submersible pump from the well, at times even up to a 1000 feet below the ground, for which the entire pipe line has to be removed as the submersible pump lies at the bottom of the well fixed to the bottom end of the pipe line, where the time consumption to rectify the failure can run even up to a few days with costly replacement process incurring further agricultural, industrial losses and inconveniences for common man. The existing technique also increases the production time dramatically and highly escalates the manufacturing cost as numerous undesired processes are involved. Self-lubricating carbon-graphite pre-cast moulds have to undergo machining, external bonding to the thrust collar and the thrust pad, and again machining, post to the external bonding process. Both these pre and post machining processes add to losses of up to 50% of self-lubricating carbon-graphite material when machined from pre-cast solids or tubular moulds in the existing technique and require added investments for additional machineries, tools and space requirements. Furthermore, the existing technique adds further to the cost escalation, by additional laborers, additional energy, adhesive or resin bonding, protective materials to prevent the damages to carbon-graphite during the adhesive bonding, adhesive costs and fasteners for compact adhering during the adhesive bonding process, as the processes are purely manual. The production rate is extremely slow, as each individual self-lubricating carbon-graphite part has to be machined individually both to the pre and post adhesive bonding process and each individual thrust collar and thrust pad, has to be individually externally adhesive bonded to the carbon-graphite part with individual fasteners for compact adhering each bonding. Hence this existing technique, rendering every stage of production manual, is extremely slow in production, with huge variations in specifications and with very high rejections. And with all the above risks and complications, the percentage of failure is dramatically high, with added goodwill damages and losses to the submersible pump manufacturers and losses, sufferings and agony to end users. During dry run of the pump, undesired heat is generated on the self-lubricating carbon-graphite, which in turn heats the thin layer of adhesive, bonding the self-lubricating carbon-graphite to the thrust collar and the thrust pad. This results in expansions of carbon-graphite and the adhesive, and the expansions are unequal, as both the materials have different properties. This unequal expansion causes the adhesive layer to develop cracks, thereby the adhesive bonding breaks off releasing the self-lubricating carbon graphite, again rendering the thrust bearing to fail. The best of the adhesives and resins fail under high temperature conditions and lose their bonding properties. As the bonding adhesive is in direct contact with the self-lubricating carbon-graphite, the transfer of heat is maximized on the adhesive, rendering it to crack and lose its bonding properties due to the heat. The thrust collar and the thrust pad material can absorb the heat and permit smooth heat escape from the self-lubricating carbon-graphite, if they are in direct contact to the self-lubricating carbon-graphite. But the bonding adhesive layer acts as a barrier for the smooth escape of the heat. Thus the externally bonded adhesive or resin layer in-between the self-lubricating carbon-graphite and the thrust collar or thrust pad is a big drawback and destructive, acting as a barrier for the escape of heat, failing the thrust bearing completely during dry run of submersible pump. Object of invention: The principal object of this new process is a single and highly advantageous simple process, ensuring that either nil or negligible failures occur in submersible pumps due to the external bonding failures of self-lubricating carbon-graphite to the thrust collar and the thrust pad of the thrust bearing assembly, eliminating the drawbacks, material wastages and numerous complicated and imperfect processes with the existing process of externally self-lubricating carbon-graphite adhesive bonding to the thrust collar and thrust pad in the thrust bearing assembly, and keep the submersible pumps alive and pouring. Another object of this invention is to bring down the manufacturing costs of the thrust bearing assembly and produce uniform quality and quantity with either nil or negligible rejections, eliminating all the costly complicated numerous imperfect manual processes, material wastages and associated drawbacks and increasing the life even during the dry run of the pumps. A further object of this invention is to produce lower trouble and maintenance in the submersible pumps, saving precious time and money, reaping bumper crops to the farmer, happiness to common man, increased industrial production and minimize hardships to the end user of submersible pumps, rendering further success to submersible pump industry while contributing to the progress and prosperity of farmers, common man, industries and economy of the nation. A summary of invention: This invention is a single and simple process, directly moulding self-lubricating carbon-graphite on thrust collar and thrust pad of the thrust bearing assembly by extending the mould into mould extension space and spaces, or in-between protrusions, created on the surface or surfaces of the thrust collar and the thrust pad, to facilitate a compact and strong self-adhering extended self-lubricating carbon-graphite moulding, by various moulding processes. Thus completely eliminating the existing complicated process of external adhesive bonding of self-lubricating carbon-graphite to the thrust collar and thrust pad and the drawbacks associated with numerous imperfect manual and time consuming processes and preventing wastages, with either nil or negligible carbon-graphite bonding failures and increased quality, quantity, time saving and cost-effective uniform productions, at the same time securing additional life of thrust bearings even during dry running of the pumps. A brief description of the accomoanvina drawino: Specifications of the drawings: The thrust bearing assembly part, if fixed as appearing upright, as appearing in the drawing figures 2, 5, 7, 8, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 23, 24, 25 and 27, is termed as thrust pad, as it occupies the bottom portion of the thrust bearing. And the same part, if fixed with a vertical flip, as appearing in the drawing figures 3, 4, 26 and 28, is termed as thrust collar, as it occupies the upper portion in the thrust bearing. Figures 1 and 6, show the surface of the thrust collar and thrust pad, post to external adhesive bonding, shows the self-lubricating carbon-graphite as appearing on the thrust collar and the thrust pad of the thrust bearing assembly, in the existing process, which is also similar to the appearance as executed by this process, as shown in figure 17. Figures 2,5 and 7 show the cross section of the thrust pad and figures 3 and 4, the cross sections of the thrust collar, show the self-adhesive carbon-graphite bonding to the thrust collar and the thrust pad, by external adhesive bonding, as in the existing process. Figure 8, the cross section of the thrust pad, shows the blank surface of the thrust pad, on which the self-lubricating carbon-graphite is bonded with adhesive in the existing process. Figures 9, 10, 11, 12, 13, and 14, the surface and surfaces on the cross section of the thrust collar and the thrust pad, shows drilling and grooves on the surface and surfaces, a few types of numerous possible created mould extension space and spaces, for the self-lubricating carbon-graphite mould to extend into these space or spaces, for a compact, strong and firm self-adherence of self-lubricating carbon-graphite, as per this process. Figures 15 and 16, the cross section of the thrust collar and the thrust pad, shows protruding extensions on the surface and surfaces, a few types of numerous possible created mould extension space and spaces for the self-lubricating carbon-graphite mould to extend into these space or spaces, for a compact, strong and firm self-adherence of self-lubricating carbon-graphite, as per this process. Figure 17, the surface of the thrust collar, post to direct moulding of self-lubricating carbon-graphite on to the surface of the thrust collar or the thrust pad, with the mould extending into the mould extension space or spaces created on the thrust collar and the thrust pad, and compactly adhering the self-lubricating carbon-graphite firmly to the thrust collar and the thrust pad, as per this process, which is again similar to the appearance as in the existing process, as shown in figure 1. Figure 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, and 28, the cross sections of the thrust collar and thrust pad, post to the direct moulding of self-lubricating carbon-graphite onto the surface and surfaces of the thrust collar and thrust pad, shows the mould extending into the mould extension space and spaces created on the surface and surfaces of the thrust collar and the thrust pad, with a strong and compact adherence along with the desired self-lubricating carbon-graphite mould, as per this process. Detailed description of the invention: The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed. This new process involves extended moulding self-lubricating carbon-graphite, either individually or in their various combinations, with or without additive or with various additives, as per their required physical, chemical and mechanical properties, directly on to the thrust collar and the thrust pad of the thrust bearing assembly, by various moulding processes in a moulding die. The thrust collar and thrust pad is made of or usually consists of metal or metals or metal alloys or metal alloy castings or other material or other materials or their combinations, cast by various methods, or by milling and machining, which are again generally either cut or forged or machined or machine finished or without any machining, or mould cast, in different sizes and shapes as required. Mould extension space or spaces are created on the surface or surfaces of the thrust collar and the thrust pad, by drilling an angular hole or angular holes, or by creating an angular groove or angular grooves, the grooves being either circular or straight or in any other size, shape, angle and form, or by creating other types of mold extension space and spaces in different forms, shapes, sizes, forms and angles, or by casting or machining metal or metal alloys with the above mould space cavity or cavities, or by providing protruding extensions in different shapes or forms, on the surface or surfaces of the thrust collar and the thrust pad, so as to provide mould extension space either inside or on the surface or surfaces of the thrust collar and the thrust pad, or by creating mould extension space by any other method or methods, to facilitate the mould extension into these mould extension space. The purpose of providing these mould extension space or spaces on the thrust collar and the thrust pad is to facilitate the extension of the self-lubricating carbon-graphite moulding into the created mould extension space or spaces, or in-between the protrusions, created on the surface and surfaces of the thrust collar and the thrust pad after their insertion as insert or inserts in the mould die, during the self-lubricating carbon-graphite moulding by various moulding processes, along with the actually required self-lubricating carbon-graphite mould. A few types of created mould extension space and spaces, of the numerous possible, on the surface or surfaces of the thrust collar and thrust pad for a strong and compact self-adhering of self-lubricating carbon-graphite to the thrust collar and the thrust pad, in their cross sections, are shown as appearing in figures 9, 10, 11, 12, 13, 14, 15 and 16 in the drawing sheets. The moulding die is provided with both, the thrust collar or thrust pad insert cavity or cavities and the required self-lubricating carbon-graphite mould cavity. The thrust collar and thrust pad, is inserted into the moulding die, as an insert or inserts, for which insert cavity or cavities are provided in the moulding die along with the self-lubricating carbon-graphite mould, for the moulding process by various moulding processes. Once the insert or inserts created with different kinds of mould extension space or spaces, is inserted in the moulding die, the actual self-lubricating carbon-graphite moulding process is started, by any of the various moulding processes. The self-lubricating carbon-graphite moulding takes place in moulding die, directly on the thrust collar or thrust pad insert or inserts by various moulding processes. During this process the self-lubricating carbon-graphite mould takes not only the actual desired external mould size and shape required for the thrust bearing assembly, but it also extends in the extension mould space and spaces created on the surface and surfaces of the thrust collar and thrust pad or extends in-between the angular or different kinds of protruding extensions created on the surface or surfaces of the thrust collar or thrust pad. Thereby, forming a strong and compact adhering the entire self-lubricating carbon-graphite moulded material firmly and strongly to the thrust collar and the thrust pad by the mould extension, without any involvement of external adhesive or resin bonding. Thus ensuring the self-lubricating carbon-graphite mould to stay strongly and compactly self-adhered with the thrust collar and the thrust pad, and not come off or sheer off from the thrust collar and thrust pad, even during severe thrust pressure and dry running of the pumps. A few types of mould extensions, among numerous possible, created after the completion of extended self-lubricating carbon-graphite moulding along with the desired self-lubricating carbon-graphite moulding bearing a strong and compact adhering of the self-lubricating carbon-graphite to the thrust collar and the thrust pad, are shown in their cross sections as appearing in drawing figures 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, and 28 in the drawing sheets. The part numbers and their descriptive matter, respectively, marked on the figures in the drawing sheets are as follows: Parts marked 1 - Show the Self-lubricating carbon-graphite, as appears on the thrust collar and the thrust pad, both, as in the existing process and this process. Parts marked 2 - show the thin layer of adhesive or resin, which bonds the self-lubricating carbon-graphite to the thrust collar and thrust pad, as in the existing process. Parts marked 3 -show the thrust collar and thrust pad, which holds the self-lubricating carbon-graphite, by the adhesive bonding as in the existing process visible in figures 2, 3, 4, 5 and 6 in drawing sheets, in figure 7 of the drawing sheet part marked 3 shows a blank thrust collar or thrust pad used in the existing process, while the figureslO, 11, 12, 13, 14, 15, and 16 show the blank thrust collar and the thrust pad with created mold extension space and spaces on the surface or surfaces of the thrust collar and the thrust pad in this process, and finally the parts marked 3 in the figures 18, 19, 20, 21, 22, 23 and 24 in the drawing sheets show the self-lubricating carbon-graphite compactly and strongly self-adhered to the thrust collar and the thrust pad, post to the moulding process with the extension of the self-lubricating carbon-graphite mould into the mould extension space and spaces, as in this process Parts marked 4 - show the created mould extension spaces, a few different types of numerous possible mould extension spaces, by drilling and making grooves created on the surface and surfaces of the thrust collar and the thrust pad to facilitate the extension of the self-lubricating carbon-graphite mould, as per this process, for self-adhering carbon-graphite to the thrust collar and thrust pad. Parts marked 5 - show the created mould extension spaces, a few different types of numerous possible mould extension spaces, by protrusions created on the surface and surfaces the thrust collar and the thrust pad to facilitate the extension of the self-lubricating carbon-graphite mould, as per this process, for self-adhering carbon-graphite to the thrust collar and thrust pad. Parts marked 6 - show the extension of the self-lubricating carbon-graphite mould into the mould extension spaces created on the surface and surfaces of the thrust collar and thrust pad, facilitating a strong and compact adhering of the self-lubricating carbon-graphite onto the thrust collar and the thrust pad. Parts marked 7 - show the extension of the self-lubricating carbon-graphite mould into the mould extension spaces created by protrusions on the surface and surfaces of the thrust collar and thrust pad, facilitating a strong and compact adhering of the self-lubricating carbon-graphite onto the thrust collar and the thrust pad. This invention is in no way restricted to and shall be appreciated from the foregoing description, that various embodiments and variants, proposed herein are possible, without departing from the scope and ambit of this invention. I claim: - 1. A process for manufacture of self-lubricating carbon-graphite thrust collar and thrust pad, in thrust bearing assembly by directly moulding self-lubricating carbon-graphite either individually or in their various combinations, with or without additive or with various additives, as per their required physical, chemical and mechanical properties, onto the thrust collar and thrust pad of thrust bearing assembly, wherein the thrust collar and thrust pad surface or surfaces are provided with mould extension space or spaces, by drilling either straight or angular hole or holes, wherein the holes bearing any size, angle, shape and form, or by creating an angular groove or angular grooves, wherein the grooves being either circular, straight or in any other size, angle, shape and form, or by creating different type or types of mould extension space cavity or cavities in different forms, shapes, sizes and angles, or by casting or milling or machining, metal or metal alloys or other material or materials either individually or in their varied combinations forming the thrust collar and the thrust pad, with the above mould extension space or spaces, or by providing protruding extension or extensions, in different sizes, angles, shapes and forms, on the surface or surfaces of the thrust collar and thrust pad of the thrust bearing assembly by milling or various machining processes, to facilitate an extended self-lubricating carbon-graphite mould into these mould extension space and spaces, along with the desired self-lubricating carbon-graphite mould as required on the thrust pad and the thrust collar, and moulding by accommodating the thrust collar and thrust pad as an insert or inserts in the moulding die, which is provided with insert cavity or cavities for thrust collar and thrust pad insertion or insertions, prior to the moulding by any of the various moulding processes. 2. A process of manufacturing according to claim 1, wherein the self-lubricating carbon-graphite is moulded in moulding die, directly onto the thrust collar and thrust pad of the thrust bearing assembly, with created mould extension spaces, by various moulding processes, extending the moulding further into the created mould extension space or spaces created on the surface or surfaces to facilitate compact adhering self-lubricating carbon-graphite moulded material to the thrust collar and the thrust pad by its extension into the created mould extension space or spaces and onto the thrust collar and thrust pad along with the desired self-lubricating carbon-graphite moulding.

Full Text

Field of invention:
This invention relates to self-lubricating carbon-graphite thrust collar and thrust pad of thrust bearing assemblies.
Background of invention with regard to the drawback associated with prior art:
Thrust bearing is a bearing designed to operate with loading only on its axis with normal flat contact or tilting contact actions between two flat faces. An automotive clutch release bearing is an example of a specialized thrust bearing and the self-lubricating carbon-graphite flat face or faces with an opposite flat face or faces, in submersible pump are example of numerous types of thrust bearings.
Basically, in a thrust bearing assembly, both the thrust collar and thrust pad mean the same. Actually it is a single component with two different names, depending upon the assembly direction of the thrust bearing. The difference in the name is only to indicate the different manner in which they are fixed to the submersible pump or any other mechanical device. If the thrust bearing part, which holds the self-lubricating carbon-graphite, is fixed on the top, it is termed as thrust collar and if fixed at the bottom by a vertical flip, it is termed as thrust pad.
Thrust bearing assemblies with self-lubricating carbon-graphite fixed to thrust collar and thrust pad are used in numerous mechanical devices including submersible pumps. Submersible pump is being used as a perfect example for the numerous advantages of invention of this process, in this document, as against the drawbacks and disadvantages in the existing process.
The thrust bearing assembly plays a very critical role in the submersible pumps and other mechanical devices, as an alternative to regular bearings. The regular bearings require external lubricants, such as oil and grease, which tend to get washed away in the water, as submersible pumps work in water, and cannot take the severe thrust pressure that they are subjected to, during deep submersible pump operations, rendering them to fail totally. On the contrary Carbon-graphite thrust bearings are self-lubricating, not requiring external lubricating greases or oils and accommodating the thrust impacts, operate with loading only on its axis, making them the most-fit bearing types for submersible pumps. In the existing process, the self-lubricating carbon-graphite is externally bonded to the thrust collar and the thrust pad to form the crucial part of the thrust bearing assembly and in tum, making it the critical part of the thrust bearing assembly of submersible pumps or other numerous mechanical devices. Thus the thrust bearing assemblies are the lifelines of the submersible pumps and other numerous mechanical devices.
According to this process, this is a single and simple process, directly moulding self-lubricating carbon-graphite on thrust collar and thrust pad by extending the mould into mould extension space and spaces, created on the surface or surfaces of the thrust collar and the thrust pad, to facilitate a compact and strong self-adhering self-lubricating carbon-graphite extended moulding, by various moulding processes. Thus eliminating the drawbacks, numerous manual and imperfect processes and preventing wastages, with either nil or negligible carbon-graphite bonding failures and increased quality, quantity and highly cost-effective uniform productions, in total contrast to the existing technique.

Existing technique:
Self-lubricating Carbon-graphite, either individually or in their various combinations with or without additive or with various additives, as per their required physical, chemical and mechanical properties, in different required shapes, are either moulded separately or cut, machined and machine finished, from pre-moulded solids, rods, squares, round tubes, square tubes or other solid or other tubular shapes of the above carbon-graphite moulds, to form dry lubricating part of the thrust bearing assembly in submersible pumps.
Then the above, finished self-lubricating carbon-graphite part is externally bonded with different kinds of adhesives or resins, to adhere them to the thrust collar or the thrust pad to form the crucial part of thrust bearing assemblies, which in turn form crucial parts of submersible pumps.
The thrust collar and the thrust pad, usually consist of metals or metal alloys or their castings cast by various methods, or other material or other materials or their combinations, which are again generally either cut or forged or machined or machine finished or without any machining, or mould cast in different sizes and shapes as required.
Each individual self-lubricating carbon-graphite part has to be machined individually, both to the pre and post external adhesive bonding to the thrust collar and the thrust pad, where each individual thrust collar and thrust pad, is individually externally bonded to the self-lubricating carbon-graphite part, with individual fasteners for compaction, during each individual bonding.
Drawbacks of the existing technique:
The failures of the thrust bearing assemblies manufactured by the existing technique are very high as the technique is highly risky. The entire process of external bonding is manual and with no guarantee of self-lubricating carbon-graphite bonding to the thrust collar and the thrust pad of the thrust bearing assembly against abnormally high rates of bonding failures.
The very name " thrust bearing assembly " operating with loading only on its axis, explains the function that it has to undergo severe thrust pressure during the operations of the submersible pumps, which can again render the self-lubricating carbon-graphite adhesive bonding to split or break off, from the thrust collar and thrust pad of the assembly frequently. Thus frequent failures of thrust bearing assemblies, in turn, the frequent failures of submersible pumps create heavy agricultural, financial and industrial losses, both to the end user and to the nation.
The percentage of failures in thrust bearing assemblies is, at times about 30%. The failure, painstakingly and mercilessly results in the total replacement of the thrust bearing assembly and which can be done only by removing the submersible pump from the well, at times even up to a 1000 feet below the ground, for which the entire pipe line has to be removed as the submersible pump lies at the bottom of the well fixed to the bottom end of the pipe line, where the time consumption to rectify the failure can run even up to a few days with costly replacement process incurring further agricultural, industrial losses and inconveniences for common man.
The existing technique also increases the production time dramatically and highly escalates the manufacturing cost as numerous undesired processes are involved.

Self-lubricating carbon-graphite pre-cast moulds have to undergo machining, external bonding to the thrust collar and the thrust pad, and again machining, post to the external bonding process. Both these pre and post machining processes add to losses of up to 50% of self-lubricating carbon-graphite material when machined from pre-cast solids or tubular moulds in the existing technique and require added investments for additional machineries, tools and space requirements.
Furthermore, the existing technique adds further to the cost escalation, by additional laborers, additional energy, adhesive or resin bonding, protective materials to prevent the damages to carbon-graphite during the adhesive bonding, adhesive costs and fasteners for compact adhering during the adhesive bonding process, as the processes are purely manual.
The production rate is extremely slow, as each individual self-lubricating carbon-graphite part has to be machined individually both to the pre and post adhesive bonding process and each individual thrust collar and thrust pad, has to be individually externally adhesive bonded to the carbon-graphite part with individual fasteners for compact adhering each bonding. Hence this existing technique, rendering every stage of production manual, is extremely slow in production, with huge variations in specifications and with very high rejections. And with all the above risks and complications, the percentage of failure is dramatically high, with added goodwill damages and losses to the submersible pump manufacturers and losses, sufferings and agony to end users.
During dry run of the pump, undesired heat is generated on the self-lubricating carbon-graphite, which in turn heats the thin layer of adhesive, bonding the self-lubricating carbon-graphite to the thrust collar and the thrust pad. This results in expansions of carbon-graphite and the adhesive, and the expansions are unequal, as both the materials have different properties. This unequal expansion causes the adhesive layer to develop cracks, thereby the adhesive bonding breaks off releasing the self-lubricating carbon graphite, again rendering the thrust bearing to fail. The best of the adhesives and resins fail under high temperature conditions and lose their bonding properties. As the bonding adhesive is in direct contact with the self-lubricating carbon-graphite, the transfer of heat is maximized on the adhesive, rendering it to crack and lose its bonding properties due to the heat. The thrust collar and the thrust pad material can absorb the heat and permit smooth heat escape from the self-lubricating carbon-graphite, if they are in direct contact to the self-lubricating carbon-graphite. But the bonding adhesive layer acts as a barrier for the smooth escape of the heat. Thus the externally bonded adhesive or resin layer in-between the self-lubricating carbon-graphite and the thrust collar or thrust pad is a big drawback and destructive, acting as a barrier for the escape of heat, failing the thrust bearing completely during dry run of submersible pump.

Object of invention:
The principal object of this new process is a single and highly advantageous simple process, ensuring that either nil or negligible failures occur in submersible pumps due to the external bonding failures of self-lubricating carbon-graphite to the thrust collar and the thrust pad of the thrust bearing assembly, eliminating the drawbacks, material wastages and numerous complicated and imperfect processes with the existing process of externally self-lubricating carbon-graphite adhesive bonding to the thrust collar and thrust pad in the thrust bearing assembly, and keep the submersible pumps alive and pouring.
Another object of this invention is to bring down the manufacturing costs of the thrust bearing assembly and produce uniform quality and quantity with either nil or negligible rejections, eliminating all the costly complicated numerous imperfect manual processes, material wastages and associated drawbacks and increasing the life even during the dry run of the pumps.
A further object of this invention is to produce lower trouble and maintenance in the submersible pumps, saving precious time and money, reaping bumper crops to the farmer, happiness to common man, increased industrial production and minimize hardships to the end user of submersible pumps, rendering further success to submersible pump industry while contributing to the progress and prosperity of farmers, common man, industries and economy of the nation.
A summary of invention:
This invention is a single and simple process, directly moulding self-lubricating carbon-graphite on thrust collar and thrust pad of the thrust bearing assembly by extending the mould into mould extension space and spaces, or in-between protrusions, created on the surface or surfaces of the thrust collar and the thrust pad, to facilitate a compact and strong self-adhering extended self-lubricating carbon-graphite moulding, by various moulding processes. Thus completely eliminating the existing complicated process of external adhesive bonding of self-lubricating carbon-graphite to the thrust collar and thrust pad and the drawbacks associated with numerous imperfect manual and time consuming processes and preventing wastages, with either nil or negligible carbon-graphite bonding failures and increased quality, quantity, time saving and cost-effective uniform productions, at the same time securing additional life of thrust bearings even during dry running of the pumps.
A brief description of the accomoanvina drawino:
Specifications of the drawings:
The thrust bearing assembly part, if fixed as appearing upright, as appearing in the drawing figures 2, 5, 7, 8, 10, 11, 12, 13, 14, 15, 16, 18, 19, 20, 21, 22, 23, 24, 25 and 27, is termed as thrust pad, as it occupies the bottom portion of the thrust bearing. And the same part, if fixed with a vertical flip, as appearing in the drawing figures 3, 4, 26 and 28, is termed as thrust collar, as it occupies the upper portion in the thrust bearing.
Figures 1 and 6, show the surface of the thrust collar and thrust pad, post to external adhesive bonding, shows the self-lubricating carbon-graphite as appearing on the thrust collar and the thrust pad of the thrust bearing assembly, in the existing process, which is also similar to the appearance as executed by this process, as shown in figure 17.

Figures 2,5 and 7 show the cross section of the thrust pad and figures 3 and 4, the cross sections of the thrust collar, show the self-adhesive carbon-graphite bonding to the thrust collar and the thrust pad, by external adhesive bonding, as in the existing process.
Figure 8, the cross section of the thrust pad, shows the blank surface of the thrust pad, on which the self-lubricating carbon-graphite is bonded with adhesive in the existing process.
Figures 9, 10, 11, 12, 13, and 14, the surface and surfaces on the cross section of the thrust collar and the thrust pad, shows drilling and grooves on the surface and surfaces, a few types of numerous possible created mould extension space and spaces, for the self-lubricating carbon-graphite mould to extend into these space or spaces, for a compact, strong and firm self-adherence of self-lubricating carbon-graphite, as per this process.
Figures 15 and 16, the cross section of the thrust collar and the thrust pad, shows protruding extensions on the surface and surfaces, a few types of numerous possible created mould extension space and spaces for the self-lubricating carbon-graphite mould to extend into these space or spaces, for a compact, strong and firm self-adherence of self-lubricating carbon-graphite, as per this process.
Figure 17, the surface of the thrust collar, post to direct moulding of self-lubricating carbon-graphite on to the surface of the thrust collar or the thrust pad, with the mould extending into the mould extension space or spaces created on the thrust collar and the thrust pad, and compactly adhering the self-lubricating carbon-graphite firmly to the thrust collar and the thrust pad, as per this process, which is again similar to the appearance as in the existing process, as shown in figure 1.
Figure 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, and 28, the cross sections of the thrust collar and thrust pad, post to the direct moulding of self-lubricating carbon-graphite onto the surface and surfaces of the thrust collar and thrust pad, shows the mould extending into the mould extension space and spaces created on the surface and surfaces of the thrust collar and the thrust pad, with a strong and compact adherence along with the desired self-lubricating carbon-graphite mould, as per this process.
Detailed description of the invention:
The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed.
This new process involves extended moulding self-lubricating carbon-graphite, either individually or in their various combinations, with or without additive or with various additives, as per their required physical, chemical and mechanical properties, directly on to the thrust collar and the thrust pad of the thrust bearing assembly, by various moulding processes in a moulding die.
The thrust collar and thrust pad is made of or usually consists of metal or metals or metal alloys or metal alloy castings or other material or other materials or their combinations, cast by various methods, or by milling and machining, which are again generally either cut or forged or machined or machine finished or without any machining, or mould cast, in different sizes and shapes as required.

Mould extension space or spaces are created on the surface or surfaces of the thrust collar and the thrust pad, by drilling an angular hole or angular holes, or by creating an angular groove or angular grooves, the grooves being either circular or straight or in any other size, shape, angle and form, or by creating other types of mold extension space and spaces in different forms, shapes, sizes, forms and angles, or by casting or machining metal or metal alloys with the above mould space cavity or cavities, or by providing protruding extensions in different shapes or forms, on the surface or surfaces of the thrust collar and the thrust pad, so as to provide mould extension space either inside or on the surface or surfaces of the thrust collar and the thrust pad, or by creating mould extension space by any other method or methods, to facilitate the mould extension into these mould extension space. The purpose of providing these mould extension space or spaces on the thrust collar and the thrust pad is to facilitate the extension of the self-lubricating carbon-graphite moulding into the created mould extension space or spaces, or in-between the protrusions, created on the surface and surfaces of the thrust collar and the thrust pad after their insertion as insert or inserts in the mould die, during the self-lubricating carbon-graphite moulding by various moulding processes, along with the actually required self-lubricating carbon-graphite mould. A few types of created mould extension space and spaces, of the numerous possible, on the surface or surfaces of the thrust collar and thrust pad for a strong and compact self-adhering of self-lubricating carbon-graphite to the thrust collar and the thrust pad, in their cross sections, are shown as appearing in figures 9, 10, 11, 12, 13, 14, 15 and 16 in the drawing sheets.
The moulding die is provided with both, the thrust collar or thrust pad insert cavity or cavities and the required self-lubricating carbon-graphite mould cavity. The thrust collar and thrust pad, is inserted into the moulding die, as an insert or inserts, for which insert cavity or cavities are provided in the moulding die along with the self-lubricating carbon-graphite mould, for the moulding process by various moulding processes.
Once the insert or inserts created with different kinds of mould extension space or spaces, is inserted in the moulding die, the actual self-lubricating carbon-graphite moulding process is started, by any of the various moulding processes. The self-lubricating carbon-graphite moulding takes place in moulding die, directly on the thrust collar or thrust pad insert or inserts by various moulding processes. During this process the self-lubricating carbon-graphite mould takes not only the actual desired external mould size and shape required for the thrust bearing assembly, but it also extends in the extension mould space and spaces created on the surface and surfaces of the thrust collar and thrust pad or extends in-between the angular or different kinds of protruding extensions created on the surface or surfaces of the thrust collar or thrust pad. Thereby, forming a strong and compact adhering the entire self-lubricating carbon-graphite moulded material firmly and strongly to the thrust collar and the thrust pad by the mould extension, without any involvement of external adhesive or resin bonding. Thus ensuring the self-lubricating carbon-graphite mould to stay strongly and compactly self-adhered with the thrust collar and the thrust pad, and not come off or sheer off from the thrust collar and thrust pad, even during severe thrust pressure and dry running of the pumps. A few types of mould extensions, among numerous possible, created after the completion of extended self-lubricating carbon-graphite moulding along with the desired self-lubricating carbon-graphite moulding bearing a strong and compact adhering of the self-lubricating carbon-graphite to the thrust collar and the thrust pad, are shown in

their cross sections as appearing in drawing figures 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, and 28 in the drawing sheets.
The part numbers and their descriptive matter, respectively, marked on the figures in the drawing sheets are as follows:
Parts marked 1 - Show the Self-lubricating carbon-graphite, as appears on the thrust collar and the thrust pad, both, as in the existing process and this process.
Parts marked 2 - show the thin layer of adhesive or resin, which bonds the self-lubricating carbon-graphite to the thrust collar and thrust pad, as in the existing process.
Parts marked 3 -show the thrust collar and thrust pad, which holds the self-lubricating carbon-graphite, by the adhesive bonding as in the existing process visible in figures 2, 3, 4, 5 and 6 in drawing sheets, in figure 7 of the drawing sheet part marked 3 shows a blank thrust collar or thrust pad used in the existing process, while the figureslO, 11, 12, 13, 14, 15, and 16 show the blank thrust collar and the thrust pad with created mold extension space and spaces on the surface or surfaces of the thrust collar and the thrust pad in this process, and finally the parts marked 3 in the figures 18, 19, 20, 21, 22, 23 and 24 in the drawing sheets show the self-lubricating carbon-graphite compactly and strongly self-adhered to the thrust collar and the thrust pad, post to the moulding process with the extension of the self-lubricating carbon-graphite mould into the mould extension space and spaces, as in this process
Parts marked 4 - show the created mould extension spaces, a few different types of numerous possible mould extension spaces, by drilling and making grooves created on the surface and surfaces of the thrust collar and the thrust pad to facilitate the extension of the self-lubricating carbon-graphite mould, as per this process, for self-adhering carbon-graphite to the thrust collar and thrust pad.
Parts marked 5 - show the created mould extension spaces, a few different types of numerous possible mould extension spaces, by protrusions created on the surface and surfaces the thrust collar and the thrust pad to facilitate the extension of the self-lubricating carbon-graphite mould, as per this process, for self-adhering carbon-graphite to the thrust collar and thrust pad.
Parts marked 6 - show the extension of the self-lubricating carbon-graphite mould into the mould extension spaces created on the surface and surfaces of the thrust collar and thrust pad, facilitating a strong and compact adhering of the self-lubricating carbon-graphite onto the thrust collar and the thrust pad.
Parts marked 7 - show the extension of the self-lubricating carbon-graphite mould into the mould extension spaces created by protrusions on the surface and surfaces of the thrust collar and thrust pad, facilitating a strong and compact adhering of the self-lubricating carbon-graphite onto the thrust collar and the thrust pad.
This invention is in no way restricted to and shall be appreciated from the foregoing description, that various embodiments and variants, proposed herein are possible, without departing from the scope and ambit of this invention.

I claim: -
1. A process for manufacture of self-lubricating carbon-graphite thrust collar and
thrust pad, in thrust bearing assembly by directly moulding self-lubricating
carbon-graphite either individually or in their various combinations, with or
without additive or with various additives, as per their required physical,
chemical and mechanical properties, onto the thrust collar and thrust pad of
thrust bearing assembly, wherein the thrust collar and thrust pad surface or
surfaces are provided with mould extension space or spaces, by drilling either
straight or angular hole or holes, wherein the holes bearing any size, angle,
shape and form, or by creating an angular groove or angular grooves,
wherein the grooves being either circular, straight or in any other size, angle,
shape and form, or by creating different type or types of mould extension
space cavity or cavities in different forms, shapes, sizes and angles, or by
casting or milling or machining, metal or metal alloys or other material or
materials either individually or in their varied combinations forming the thrust
collar and the thrust pad, with the above mould extension space or spaces, or
by providing protruding extension or extensions, in different sizes, angles,
shapes and forms, on the surface or surfaces of the thrust collar and thrust
pad of the thrust bearing assembly by milling or various machining processes,
to facilitate an extended self-lubricating carbon-graphite mould into these
mould extension space and spaces, along with the desired self-lubricating
carbon-graphite mould as required on the thrust pad and the thrust collar,
and moulding by accommodating the thrust collar and thrust pad as an insert
or inserts in the moulding die, which is provided with insert cavity or cavities
for thrust collar and thrust pad insertion or insertions, prior to the moulding
by any of the various moulding processes.
2. A process of manufacturing according to claim 1, wherein the self-lubricating
carbon-graphite is moulded in moulding die, directly onto the thrust collar and
thrust pad of the thrust bearing assembly, with created mould extension
spaces, by various moulding processes, extending the moulding further into
the created mould extension space or spaces created on the surface or
surfaces to facilitate compact adhering self-lubricating carbon-graphite
moulded material to the thrust collar and the thrust pad by its extension into
the created mould extension space or spaces and onto the thrust collar and
thrust pad along with the desired self-lubricating carbon-graphite moulding.

Documents:

043-che-2004-claims duplicate.pdf

043-che-2004-claims original.pdf

043-che-2004-correspondnece-others.pdf

043-che-2004-correspondnece-po.pdf

043-che-2004-description(complete) duplicate.pdf

043-che-2004-description(complete) original.pdf

043-che-2004-drawings.pdf

043-che-2004-form 1.pdf

043-che-2004-form 19.pdf

43-che-2004 abstract.pdf

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Patent Number

200981

Indian Patent Application Number

43/CHE/2004

PG Journal Number

8/2007

Publication Date

23-Feb-2007

Grant Date

16-Jun-2006

Date of Filing

21-Jan-2004

Name of Patentee

SHRI. SURYAKANT B ASOPA

Applicant Address

92 KALEESWARA NAGAR KATOOR, COIMBATORE 641 009 TAMILNADU

Inventors:

#	Inventor's Name	Inventor's Address
1	SURYAKANT B ASOPA	92 KALEESWARA NAGAR KATOOR, COIMBATORE 641009 TAMILNADU

PCT International Classification Number

F16C13/00

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1			NA