Next steps in the development of bearings with bioplastic cages

Bearings with the new bioplastic cage have now been adopted for use in air conditioner fan motors. Air conditioners have a built-in fan to generate air flow, and bearings are used in the fan motor to help it rotate smoothly, which in turn reduces the motor's electrical use and saves energy. Since air conditioners are used in living spaces, the equipment needs to be as quiet as possible. This is why the bearings must rotate smoothly and silently. Reliability is also important because longer bearing life means allows the air conditioner to operate quietly over a span of several years.

In the air conditioner market, the COVID-19 pandemic has fueled greater interest in indoor air quality. Demand for replacement air conditioners with advanced features such as ventilation and purification is expected to increase in developed countries. Air conditioner ownership in China, India, and other emerging countries is also expected to increase as incomes rise. Air conditioners often have a high market penetration rate and use a lot of electricity, which makes them a good target for eco-friendly initiatives. By offering bearings with bioplastic cages for air conditioners, we can not only provide the same quietness, high reliability, and energy saving as bearings with conventional plastic cages, but also deliver added value in the form of environmentally friendly materials.

Changing to a bioplastic material can have a huge impact on productivity and the accuracy of molding dimensions, so the shift represented a major product modification. By utilizing NSK's digital twin technology, we were able to simulate conditions at the time of molding and any potential problems that could arise when using conventional production equipment. We then verified and confirmed the product quality through test production and evaluation. As a result, we were able to develop a bioplastic cage with the same performance as a conventional one in just six months. Moreover, we maintained the same performance as the conventional plastic, including the lightweight, low-friction properties and the dynamic molding capability.