Bearings for steering components

Abstract

The present disclosure provides a bearing (300) for being arranged between a housing and a rotating member, the bearing (300) comprising: at least one leaf spring element (340), the at least one leaf spring element providing a biasing force in the Y direction; wherein the bearing has a first stiffness S1 in the Y direction and a second stiffness S2 in the X direction perpendicular to the Y direction, wherein S2 ≥ S1, and wherein the bearing (300) comprises a metal substrate and a low friction layer, the low friction layer covering at least one surface of the substrate and being suitable for contacting the rotating member.

Description

Technical Field

[0001] The present disclosure relates to bearings and bearing assemblies, and more particularly, the present disclosure relates to steering assemblies. Background Art

[0002] Many vehicles use steering assemblies to convert motion from a steering wheel to a turning wheel on the road. In some cases, the steering assembly may include a power steering assembly that assists the vehicle in steering by applying an auxiliary torque to provide better vehicle performance. To help achieve this function, in many cases, the power steering assembly includes a worm and worm wheel, which is used to transfer torque from the electric motor to the steering column or an output shaft operably connected thereto. One problem with these assemblies is the rattle between the worm and the worm wheel, which is particularly noticeable to the driver when driving on a rough road or when the steering wheel is swaying from side to side under low load. If the worm and worm wheel teeth are not always properly meshed, a noise may be generated, which may be heard by the driver. This incorrect meshing may occur due to deformation caused by manufacturing tolerances, thermal changes in dimensions, torsional loads, and wear during use. Therefore, the industry continues to demand improved steering assemblies. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings.

[0004] Figure 1 Includes a step-by-step manufacturing method;

[0005] Figure 2A Included are illustrations of materials from which bearings may be formed according to various embodiments.

[0006] Figure 2B includes illustrations of composite materials that may form bearings according to various embodiments;

[0007] Figure 2C includes illustrations of composite materials that may form bearings according to various embodiments;

[0008] Figure 2D includes illustrations of composite materials that may form bearings according to various embodiments;

[0009] Figure 2E includes illustrations of composite materials that may form bearings according to various embodiments;

[0010] Figure 3A Included are illustrations of top perspective views of bearings according to various embodiments.

[0011] Figure 3B Included are illustrations of end views of bearings within assemblies according to various embodiments.

[0012] Figure 4A Included are illustrations of side perspective views of bearings according to various embodiments.

[0013] Figure 4B Included are illustrations of end views of bearings within assemblies according to various embodiments.

[0014] Figure 5A A side cross-sectional view of a bearing according to embodiments herein for use in a steering assembly according to one embodiment is included.

[0015] Figure 5B A cross-sectional view of a bearing according to embodiments herein for use in an exemplary steering assembly according to one embodiment is included.

[0016] The use of the same reference symbols in different drawings indicates similar or identical items. DETAILED DESCRIPTION

[0017] The following description in conjunction with the accompanying drawings is provided to help understand the teachings disclosed herein. The following discussion will focus on the specific implementation and embodiments of the teachings. This emphasis is provided to help describe the teachings and should not be interpreted as limiting the scope or applicability of the teachings. However, other embodiments may be used based on the teachings disclosed in the present invention.

[0018] The terms "consisting of," "comprising," "including," "containing," "having," "having," or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited to only those features but may include other features not expressly listed or inherent to such method, article, or apparatus. In addition, unless expressly stated otherwise, "or" refers to an inclusive "or" and not an exclusive "or." For example, any of the following may satisfy condition A or B: A is true (or exists) and B is false (or does not exist), A is false (or does not exist) and B is true (or exists), and both A and B are true (or exist).

[0019] Furthermore, "a" or "an" is used to describe the elements and components described herein. This is done only for convenience and to give a general sense of the scope of the invention. Unless it is obvious that it is otherwise intended, this description should be understood to include one, at least one, or the singular also includes the plural, or vice versa. For example, when a single item is described herein, more than one item can be used to replace the single item. Similarly, where more than one item is described herein, a single item can replace more than one item.

[0020] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. The materials, methods, and examples are illustrative only and not limiting. To the extent not described herein, many details regarding specific materials and processing methods are conventional and can be found in textbooks and other sources in the field of bearing assemblies or steering assemblies.

[0021] For illustrative purposes, Figure 1 A diagram is included showing a step-by-step manufacturing method 10 for forming a bearing. The forming method 10 may include a first step 12 of providing a material or composite material including a substrate. The forming method 10 may further include a second step 14 of manipulating an end of the material or composite material to form a bearing.

[0022] Figure 2A An illustration of a material 1000 that may be formed into a bearing for the first step 12 of forming method 10. The bearing may include a substrate 119. In one embodiment, substrate 119 may at least partially include a metal. According to certain embodiments, the metal may include iron, copper, titanium, tin, aluminum, an alloy thereof, or may be another type of metal. More particularly, substrate 119 may at least partially include a steel, such as stainless steel, carbon steel, or spring steel. For example, substrate 119 may at least partially include stainless steel. The stainless steel may be annealed 1 / 4 hard, 1 / 2 hard, 3 / 4 hard, or full hard. In addition, the steel may include stainless steel that includes chromium, nickel, or a combination thereof. In a certain embodiment, substrate 119 may include a woven mesh or an expanded metal grid. The woven mesh or expanded metal grid may include a metal or a metal alloy, such as aluminum, steel, stainless steel, bronze, etc. Alternatively, the woven mesh may be a woven polymer mesh. In an alternative embodiment, substrate 119 may not include a mesh or a grid. In addition, the substrate 119 may include a Vickers pyramid hardness value VPN, which may be ≧350, such as ≧375, ≧400, ≧425, or ≧450. The VPN may also be ≦500, ≦475, or ≦450. The VPN may also be in a range between any VPN values ​​described herein, and include any VPN values ​​described. In another aspect, the substrate 119 may be treated to improve its corrosion resistance. Specifically, the substrate 119 may be passivated. For example, the substrate 119 may be passivated according to ASTM standard A967. The substrate 119 may be formed by at least one of chamfering, turning, reaming, forging, extrusion, molding, sintering, rolling, or casting.

[0023] The substrate 119 may have a thickness Ts between about 10 microns and about 1500 microns, such as between about 50 microns and about 1000 microns, such as between about 100 microns and about 750 microns, such as between about 350 microns and about 650 microns. In multiple embodiments, the substrate 119 may have a thickness Ts between about 700 microns and 800 microns. In multiple embodiments, the substrate 119 may have a thickness Ts between about 950 microns and 1050 microns. It should be further understood that the thickness Ts of the substrate 119 may be any value between any of the minimum and maximum values ​​described above. The thickness of the substrate 119 may be uniform, that is, the thickness of the substrate 119 at a first position may be equal to the thickness at a second position along it. The thickness of the substrate 119 may be non-uniform, that is, the thickness of the substrate 119 at a first position may be different from the thickness at a second position along it.

[0024] Figure 2B An illustration of a composite material 1001 (as an alternative to material 1000) that may be formed as a bearing in the first step 12 of forming method 10. For purposes of illustration, Figure 2B 1 shows a layer-by-layer construction of a composite material 1001 of a bearing. In various embodiments, the composite material 1001 may include a substrate 119 (as described above) and a low friction layer 104 coupled to or covering the substrate 119. In more specific embodiments, the composite material 1001 may include a substrate 119 and a plurality of low friction layers 104 covering the substrate 119. Figure 2B As shown, the low friction layer 104 can be coupled to at least a portion of the substrate 119. In certain embodiments, the low friction layer 104 can be coupled to a surface of the substrate 119 so as to form an interface with another surface of another component. The low friction layer 104 can be coupled to a radially inner surface of the substrate 119. Alternatively, the low friction layer 104 can be coupled to a radially outer surface of the substrate 119.

[0025] In a number of embodiments, the low friction layer 104 may include a low friction material. The low friction material may include, for example, a polymer, such as polyketone, polyaramide, polyphenylene sulfide, polyethersulfone, polyphenylsulfone, polyamideimide, ultra-high molecular weight polyethylene, fluoropolymer, polybenzimidazole, polyacetal, polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyimide (PI), polyetherimide, polyetheretherketone (PEEK), polyethylene (PE), polysulfone, polyamide (PA), polyphenylene oxide, polyphenylene sulfide (PPS), polyurethane, polyester, liquid crystal polymer (LCP) or any combination thereof. In a certain example, the low friction layer 104 includes a polyketone, such as polyetheretherketone (PEEK), polyetherketone, polyetherketoneketone, polyetherketoneetherketone, derivatives thereof or combinations thereof. In a certain additional example, the low friction layer 104 may be ultra-high molecular weight polyethylene. In another example, the low friction layer 104 may include a fluoropolymer including fluorinated ethylene propylene (FEP), polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), perfluoroalkoxy (PFA), a terpolymer of tetrafluoroethylene, hexafluoropropylene and vinylidene fluoride (THV), chlorotrifluoroethylene (PCTFE), ethylene tetrafluoroethylene copolymer (ETFE) or ethylene chlorotrifluoroethylene copolymer (ECTFE). The low friction layer 104 may include a solid material including lithium soap, graphite, boron nitride, molybdenum disulfide, tungsten disulfide, polytetrafluoroethylene, carbon nitride, tungsten carbide or diamond-like carbon, a metal (such as aluminum, zinc, copper, magnesium, tin, titanium, tungsten, iron, bronze, steel, spring steel, stainless steel), a metal alloy (including the listed metals), anodized metal (including the listed metals) or any combination thereof. According to a specific embodiment, a fluoropolymer may be used. In an embodiment, the low friction layer 104 may include a woven mesh or an expanded metal mesh. The woven mesh or expanded metal grid may include a metal or metal alloy, such as aluminum, steel, stainless steel, bronze, etc. Alternatively, the woven mesh may be a woven polymer mesh. In alternative embodiments, the low friction layer 104 may not include a mesh or grid.

[0026] In various embodiments, the low friction layer 104 may further include a filler including glass, carbon fiber, silicon, PEEK, aromatic polyester, carbon particles, bronze, fluoropolymer, thermoplastic filler, aluminum oxide, polyamideimide (PAI), PPS, polyphenylene sulfone (PPSO2), LCP, aromatic polyester, molybdenum disulfide, tungsten disulfide, graphite, graphene, expanded graphite, boron nitride, talc, calcium fluoride, or any combination thereof. In addition, the filler may include aluminum oxide, silicon dioxide, titanium dioxide, calcium fluoride, boron nitride, mica, wollastonite, silicon carbide, silicon nitride, zirconium oxide, carbon black, pigment, or any combination thereof. The filler may be in the form of beads, fibers, powders, meshes, or any combination thereof. Based on the total weight of the low friction layer, the filler may be at least 10 wt%, such as at least 15 wt%, 20 wt%, 25 wt%, or even 30 wt%.

[0027] In some embodiments, the low friction layer 104 may include a damping material. The damping material may include natural polyisoprene, synthetic polyisoprene, polybutadiene, chloroprene rubber, butyl rubber, styrene-butadiene rubber, nitrile rubber, ethylene propylene rubber, epichlorohydrin rubber, polyacrylate rubber, silicone rubber, fluorosilicone rubber, fluoroelastomer, perfluoroelastomer, polyether block amide, asphalt, polyethylene, chlorosulfonated polyethylene, ethyl vinyl acetate (EVA), EVA foam, low-density polyethylene foam, nitrile rubber foam, polychloroprene foam, polyimide foam, polypropylene foam, polyurethane foam, polystyrene foam, polyvinyl chloride foam, silicone foam, foam rubber, polyurethane foam, XPS foam, epoxy resin foam, phenolic foam, or any combination thereof. The low friction layer 104 may include a solid-based material including lithium soap, graphite, boron nitride, molybdenum disulfide, tungsten disulfide, polytetrafluoroethylene, carbon nitride, tungsten carbide or diamond-like carbon, a metal (such as aluminum, zinc, copper, magnesium, tin, titanium, tungsten, iron, bronze, steel, spring steel, stainless steel), a metal alloy (including the listed metals), anodized metal (including the listed metals), or any combination thereof.

[0028] In one embodiment, the low friction layer 104 may have a thickness T between about 1 micron and about 500 microns. SL , such as between about 10 microns and about 350 microns, such as between about 30 microns and about 300 microns, such as between about 40 microns and about 250 microns. In many embodiments, the low friction layer 104 may have a thickness T between about 50 microns and 300 microns. SL It should be further understood that the thickness T of the low friction layer 104 LFLIt can be any value between any of the minimum and maximum values ​​mentioned above. The thickness of the low friction layer 104 can be uniform, that is, the thickness of the low friction layer 104 at a first position can be equal to the thickness along it at a second position. The thickness of the low friction layer 104 can be non-uniform, that is, the thickness of the low friction layer 104 at a first position can be different from the thickness along it at a second position. It is understood that different low friction layers 104 can have different thicknesses. The low friction layer 104 can cover one main surface of the substrate 119 shown, or cover both main surfaces. The substrate 119 can be at least partially encapsulated by the low friction layer 104. That is, the low friction layer 104 can cover at least a portion of the substrate 119.

[0029] Figure 2C An illustration of an alternative embodiment includes a composite material 1002 (as an alternative to materials 1000, 1001) that can be formed as a bearing in the first step 12 of the forming method 10. For illustrative purposes, Figure 2C The composite material 1002 of the bearing is shown layer by layer. According to this particular embodiment, the composite material 1002 can be similar to Figure 2B The composite material 1002 is different from the composite material 1001, except that the composite material 1002 may also include: at least one adhesive layer 121, which can couple the low friction layer 104 to the substrate 119; and the low friction layer 104. In another alternative embodiment, the substrate 119 may be embedded between the at least one adhesive layer 121, which is included between the low friction layer 104 and the substrate 119 as a solid component, a woven mesh or an expanded metal mesh.

[0030] The adhesive layer 121 may include any known adhesive material commonly used in the field of bearings, including but not limited to fluoropolymers, epoxy resins, polyimide resins, polyether / polyamide copolymers, ethylene vinyl acetate, ethylene tetrafluoroethylene (ETFE), ETFE copolymers, perfluoroalkoxy (PFA) or any combination thereof. In addition, the adhesive may include at least one functional group selected from -C=O, -COR, -COH, -COOH, -COOR, -CF2=CF-OR or any combination thereof, wherein R is a cyclic or linear organic group containing 1 to 20 carbon atoms. In addition, the adhesive may include a copolymer.

[0031] Filler particles (functional and / or non-functional) may be added to the adhesive layer 121, such as carbon fillers, carbon fibers, carbon particles, graphite, metal fillers (such as bronze, aluminum and other metals and their alloys), metal oxide fillers, metal-coated carbon fillers, metal-coated polymer fillers, or any combination thereof.

[0032] In one embodiment, the hot melt adhesive may have a melting temperature of no greater than 250° C., such as no greater than 220° C. In another embodiment, the adhesive may decompose at above 200° C., such as above 220° C. In other embodiments, the melting temperature of the hot melt adhesive may be higher than 250° C. or even higher than 300° C. The adhesive layer 121 may have a thickness T between about 1 micron and about 80 microns, such as between about 10 microns and about 50 microns, such as between about 20 microns and about 40 microns. AL In various embodiments, adhesive layer 121 may have a thickness T between about 3 microns and 20 microns. AL In various embodiments, adhesive layer 121 may have a thickness T between about 10 microns and 60 microns. AL It should be further understood that the thickness T of the adhesive layer 121 AL It can be any value between any of the above minimum and maximum values. The thickness of the adhesive layer 121 can be uniform, that is, the thickness of the adhesive layer 121 at the first position can be equal to its thickness at the second position. The thickness of the adhesive layer 121 can be non-uniform, that is, the thickness of the adhesive layer 121 at the first position can be different from the thickness at the second position along it.

[0033] Figure 2D An illustration of an alternative embodiment of a composite material 1003 (as an alternative to materials 1000, 1001, 1002) that can be formed as a bearing of the first step 12 of the forming method 10. For illustrative purposes, Figure 2D The composite material 1003 of the bearing is shown layer by layer. According to this particular embodiment, the composite material 1003 can be similar to Figure 2C The composite material 1002 may include, in addition, at least one anti-corrosion layer 103 and 105; and a corrosion-resistant coating 125, which may include an adhesion promoter layer 127 and an epoxy resin layer 129, which may be connected to the substrate 119 and the low friction layer 104.

[0034] Substrate 119 may be coated with anti-corrosion layers 103 and 105 including anti-corrosion materials to prevent corrosion of composite material 1003 before processing. In addition, functional layer 107 may be applied above layer 103. Each of layers 103, 105 and 107 may have a thickness of about 1 to 50 microns, such as about 7 to 15 microns. Layers 103 and 105 may include anti-corrosion materials including phosphates of zinc, iron, manganese or any combination thereof, or nano-ceramic layers. In addition, layers 103 and 105 may include anti-corrosion materials including passivated surfaces, commercially available zinc (mechanical / electroplating) or zinc-nickel coatings or any combination thereof. Layer 107 may include functional silanes, primers based on nano-scale silanes, hydrolyzed silanes, organic silane adhesion promoters, silane primers based on solvents / water. Anti-corrosion layers 103 and 105 may be removed or retained during processing.

[0035] As described above, the composite material 1003 may further include a corrosion-resistant coating 125. The corrosion-resistant coating 125 may have a thickness of about 1 to 50 microns, such as about 5 to 20 microns, and such as about 7 to 15 microns. The corrosion-resistant coating 125 may include an adhesion promoter layer 127 and an epoxy resin layer 129. The adhesion promoter layer 127 may include an anti-corrosion material including a phosphate of zinc, iron, manganese, tin, or any combination thereof, or a nano-ceramic layer. The adhesion promoter layer 127 may include an anti-corrosion material including a functional silane, a layer based on nano-scale silane, a hydrolyzed silane, an organic silane adhesion promoter, a solvent / water-based silane primer, a chlorinated polyolefin, a passivated surface, a commercially available zinc (mechanical / electroplating) or zinc-nickel coating, or any combination thereof. The adhesion promoter layer 127 may be applied by spraying, electrophoretic spraying, dip-spin coating, electrostatic spraying, flow coating, roller coating, scraping, coil coating, etc.

[0036] The epoxy resin layer 129 may be an anti-corrosion material including a heat-cured epoxy resin, a UV-cured epoxy resin, an IR-cured epoxy resin, an electron beam-cured epoxy resin, a radiation-cured epoxy resin, or an air-cured epoxy resin. Further, the epoxy resin layer 129 may include an anti-corrosion material including polyglycidyl ether, diglycidyl ether, bisphenol A, bisphenol F, ethylene oxide, oxirane, ethylene oxide, 1,2-propylene oxide, 2-methyloxirane, 9,10-epoxy-9,10-dihydroanthracene, or any combination thereof. The epoxy resin layer 129 may further include a hardener. The hardener may include an amine, an anhydride, a phenol novolac hardener such as phenol novolac poly[N-(4-hydroxyphenyl)maleimide] (PHPMI), a resol phenol formaldehyde, an aliphatic amine compound, a polycarbonic anhydride, a polyacrylate, an isocyanate, an encapsulated polyisocyanate, a boron trifluoride amine complex, a chromium-based hardener such as chromium, a polyamide, or any combination thereof. Generally, the anhydride may conform to the formula RC=OOC=O-R', wherein R may be CXHYXZAU as described above. The amine may include: an aliphatic amine such as monoethylamine, diethylenetriamine, triethylenetetramine, etc.; an alicyclic amine; an aromatic amine such as a cyclic aliphatic amine, a cycloaliphatic amine, an amidoamine, a polyamide, dicyandiamide, an imidazole derivative, etc., or any combination thereof. Generally, the amine may be a primary amine, a secondary amine, or a tertiary amine conforming to the formula R1R2R3N, wherein R may be CXHYXZAU as described above. In one embodiment, the epoxy layer 129 may include fillers that improve electrical conductivity, such as carbon fillers, carbon fibers, carbon particles, graphite, metal fillers (such as bronze, aluminum and other metals and their alloys), metal oxide fillers, metal-coated carbon fillers, metal-coated polymer fillers, or any combination thereof. Conductive fillers can allow current to pass through the epoxy coating, which can increase the conductivity of the composite material compared to a composite material without conductive fillers. In one embodiment, the epoxy layer 129 can be applied by spraying, electrophoresis, dip-spin coating, electrostatic spraying, flow coating, roller coating, blade coating, coil coating, etc. In addition, the epoxy layer 129 can be cured by, for example, thermal curing, UV curing, IR curing, electron beam curing, radiation curing, or any combination thereof. Preferably, curing can be completed without raising the temperature of the component above the breakdown temperature of any of the low friction layer 104, the adhesive layer 121, the substrate 119, or the adhesion promoter layer 127. Therefore, the epoxy resin can be cured at less than about 250°C, or even less than about 200°C.

[0037] Figure 2E An illustration of an alternative embodiment includes a composite material 1004 (as an alternative to materials 1000, 1001, 1002, and 1003) that can be formed as a bearing in the first step 12 of forming method 10. According to this particular embodiment, composite material 1004 can be similar to Figure 2CThe composite material 1002 may include a substrate 119 and a plurality of low friction layers 1104, 1104' coupled to the substrate 119 via a plurality of adhesive layers 1121, 1121'. It is understood that Figure 2D Any of the intermediate layers of the composite material 1003 shown (i.e., the anti-corrosion layers 1704, 1705, and 1708, or the corrosion-resistant layer 1125 which may include an adhesion promoter layer 1127 and / or an epoxy resin layer 1129) may be included in any orientation or stacking manner. Figure 2E between any of the layers shown.

[0038] In various embodiments, the material or composite material 1000, 1001, 1002, 1003, 1004 may have a specific thickness T B According to an embodiment, the material or composite material 1000, 1001, 1002, 1003, 1004 may have a thickness T of at least about 0.1 mm, or at least about 0.2 mm, or at least about 0.5 mm, or at least about 0.8 mm, or even at least about 1.5 mm. B According to still other embodiments, the bearings 1000 , 1001 , 1002 , 1003 , 1004 may have a thickness T of not greater than about 2 mm, such as not greater than about 1.5 mm, or even not greater than about 1.0 mm. B It should be understood that the thickness T of the bearings 1000, 1001, 1002, 1003, 1004 is B It should be further understood that the thickness T of the material or composite material 1000, 1001, 1002, 1003, 1004 is within a range between any of the minimum and maximum values ​​noted above. B It can be any value between any of the minimum and maximum values ​​mentioned above. It can also be understood that the thickness T of the material or composite material 1000, 1001, 1002, 1003, 1004 B It can also be understood that the thickness T of the material or composite material 1000, 1001, 1002, 1003, 1004 B It may vary along its circumference and may vary across multiple materials or composite materials.

[0039] In one embodiment, Figure 1Under step 12, as described above, any layer on the material or composite material 1000, 1001, 1002, 1003, 1004 can be individually arranged in a roll and peeled therefrom to connect these layers together under pressure, high temperature (hot pressing or cold pressing or hot rolling or cold rolling) by an adhesive or by any combination thereof. As described above, any layer of the material or composite material 1000, 1001, 1002, 1003, 1004 can be laminated together so that they at least partially overlap each other. As described above, any layer on the material or composite material 1000, 1001, 1002, 1003, 1004 can be applied together using a coating technique (such as, for example, physical or vapor deposition, spraying, electroplating, powder coating) or by other chemical or electrochemical techniques. In a specific embodiment, the low friction layer 104 can be applied by a roll-to-roll coating process (including, for example, extrusion coating). The low friction layer 104 may be heated to a molten or semi-molten state and extruded by slot die coating onto a major surface of the substrate 119. In one embodiment, the material or composite material 1000, 1001, 1002, 1003, 1004 may be a single, integral strip of material.

[0040] In other embodiments, Figure 1 Under step 12, as described above, any layer on the material or composite material 1000, 1001, 1002, 1003, 1004 can be applied by a coating technique (such as, for example, physical or vapor deposition, spraying, electroplating, powder coating) or by other chemical or electrochemical techniques. In a specific embodiment, the low friction layer 104 can be applied by a roll-to-roll coating process (including, for example, extrusion coating). The low friction layer 104 can be heated to a molten or semi-molten state and extruded onto the main surface of the substrate 119 by slot extrusion coating. In another embodiment, the low friction layer 104 can be cast or molded.

[0041] In one embodiment, the low friction layer 104 or any layer may be bonded to the substrate 119 using a molten adhesive layer 121 to form a laminate. In one embodiment, any intermediate or protruding layer on the material or composite material 1000, 1001, 1002, 1003, 1004 may form an intermediate material, such as a laminate. The intermediate material may be cut into strips or blanks that may form a bearing. Cutting the intermediate material may include using a die, a press, a punch, a saw, or may be machined in a different manner. Cutting the intermediate material may form a cut edge that includes an exposed portion of the substrate 119.

[0042] In one embodiment, Figure 1In the second step 14, the blank (formed from the material or composite material 1000, 1001, 1002, 1003, 1004) can be formed into a bearing by manipulating the ends of the laminated strips or blanks. The bearing can be formed by stamping, pressing, punching, sawing, rolling, flanging, deep drawing, or can be machined in different ways. After the semi-finished bearing is formed, the semi-finished bearing can be cleaned to remove any lubricants and oils used in the forming and shaping process. In addition, cleaning can prepare the exposed surface of the load-bearing substrate for applying the coating. Cleaning can include chemical cleaning using solvents and / or mechanical cleaning, such as ultrasonic cleaning.

[0043] Figure 3A An illustration of a top perspective view of a bearing 300 including a plurality of embodiments and formed from a blank or composite material 1000, 1001, 1002, 1003, 1004 of materials as described above. The bearing 300 may include a semi-annular band 302. The semi-annular band 302 may be formed from a blank as described above, which may be bent into an arc-like shape about a central axis 390. The bearing 300 and / or the semi-annular band 302 may have a first axial end 320 and a second axial end 322. The bearing 300 and / or the semi-annular band 302 may have an inner surface 330 and an outer surface 332. The bearing 300 and / or the semi-annular band 302 may have a first circumferential end 334 and a second circumferential end 336. An axial gap 338 may bridge the first circumferential end 334 and the second circumferential end 336. The inner surface 330 of the bearing 300 and / or the semi-annular band 302 may have a low friction layer that conforms to the shape of the semi-annular band 302, wherein the substrate forms the outer surface 332, and the low friction layer is formed of a material or composite material 1000, 1001, 1002, 1003, 1004 as described above. Alternatively or in addition, the outer surface 332 of the bearing 300 may have a low friction layer that conforms to the shape of the semi-annular band 302, wherein the substrate forms the inner surface 330, and the low friction layer is formed of a composite material 1000, 1001, 1002, 1003, 1004 as described above. In other embodiments, the low friction layer may be laminated to both surfaces of the bearing 300 and / or the semi-annular band 302.

[0044] In various embodiments, the bearing 300 may cover the rotating member 370. In various embodiments, due to the axial gap 338 between the first circumferential end 334 and the second circumferential end 336, the bearing 300 may cover the rotating member 370 around less than 360 degrees of the circumference of the rotating member 370. In various embodiments, the bearing 300 may cover the rotating member 370 around at least 90 degrees of the circumference of the rotating member 370, such as at least 120 degrees, such as at least 150 degrees, such as at least 180 degrees, such as at least 210 degrees, such as at least 240 degrees, such as at least 270 degrees, such as at least 300 degrees, such as at least 330 degrees. In various embodiments, the bearing 300 may be covered on the rotating member 370 around no more than 345 degrees, such as no more than 300 degrees, such as no more than 270 degrees, such as no more than 240 degrees, such as no more than 210 degrees, such as no more than 180 degrees, such as no more than 150 degrees, such as no more than 119 degrees of the circumference of the inner surface bearing member 104. In various embodiments, the bearing 300 may be covered on the rotating member 370 between approximately 180 degrees and 300 degrees of the circumference of the rotating member 370.

[0045] In various embodiments, the bearing 300 may have a plurality of spaced radially extending protrusions 308 (e.g., waves) that extend radially inward from the inner surface 330 of the bearing 300. In one embodiment, the protrusions 308 may abut the semi-annular band 302 around the entire circumference of the semi-annular band 302. The protrusions 308 may extend radially from the semi-annular band 302 and may be adapted to contact a mating component and provide increased stiffness in the direction they face. For example, Figure 3B An illustration of an end view of a bearing 300 within an assembly according to various embodiments and formed from a blank 1000, 1001, 1002, 1003, 1004 of a material or composite material as described above, wherein a protrusion 308 extends radially inwardly and contacts an inner rotating member 370 within a bore 385 of an outer member or housing 380 in the assembly 3000. As shown, the central axis 390 may be the central axis of the inner rotating member 370. The protrusion 308 may be formed from the composite material 1000, 1001, 1002, 1003, 1004 via stamping (e.g., pressing using a suitably shaped die, rotary wave forming, etc.). Reference is again made to Figure 3A, there may be a flat, circumferentially extending edge 310 of composite material at at least one axial end 320, 322 of the semi-annular band 302 of the bearing 300 above or below the projection 308. Each projection 308 may also be separated from its adjacent projection 308 by an unformed portion 309 of the semi-annular band 302 of the bearing 300, which may be formed in contact with the edge 310 and circumferentially spaced between the first pair of adjacent projections 308. The projection 308 may include an axially elongated ridge, which is a wave portion commonly used on conventional bearings. In another embodiment, the projection 308 may have a polygonal cross-section starting from the central axis 390.

[0046] The protrusion 308 may include at least one polygonal corner. For example, the protrusion 308 may include a triangular or quadrilateral shape extending from the semi-annular band 302. In yet another embodiment, at least one of the protrusions 408 may have an arcuate portion and a polygonal portion. In another embodiment, the protrusion 408 may have a semicircular cross-section starting from the central axis 390. In another embodiment, the protrusion 308 may have a variable cross-section starting from the central axis 390. In one embodiment, at least two of the protrusions 308 may have the same geometry or size as each other. In yet another embodiment, all of the protrusions 308 may have the same geometry or size as each other. In another embodiment, at least one of the protrusions 308 may have a different geometry or size from each other. In yet another embodiment, all of the protrusions 308 may have a different geometry or size from each other.

[0047] In various embodiments, the radially extending protrusion 308 (or the wave-shaped portion as described above) can be positioned at or adjacent to the axis along the X direction (substantially horizontal relative to the central axis 390 of the inner rotating member 370) while providing enhanced stiffness along the X direction, such as Figure 3B In addition, the radially extending protrusion 308 (or the wavy shape as described above) can be positioned at or adjacent to the axis along the Y direction (generally perpendicular to the central axis 390 of the inner rotating member 370), while limiting the movement of the rotating member 370 in the Y direction, such as Figure 3B is most clearly shown in .

[0048] like Figure 3A and 3B As shown, at least one of the protrusions 308 may have a circumferential width W defined between a pair of bases 315a, 315b. P , and radial height H P, and a circumferential ridge 313 extending in the radial direction, the ridge 313 rising to and descending from an apex 317 within the circumferential width and axially constrained by a pair of shoulders 311. The apex 317 of the at least one protrusion 308 may be rounded or squared, and the axial end of each ridge may terminate at the shoulder 311. In some embodiments, the shoulder 311 of the at least one protrusion 308 may be tapered.

[0049] like Figure 3A and 3B As shown, the protrusion 308 may have a radial height H P For the purposes of the embodiments described herein, the radial height H of the protrusion 308 is P is the distance from the peak 317 of the protrusion 308 to the unformed area 309 of the semi-annular band 302, such as Figure 3B According to some embodiments, the protrusion 308 may have a radial height H of at least about 0.1 mm, or at least about 0.2 mm, or at least about 0.3 mm, or at least about 0.4 mm, or even at least about 0.5 mm. P According to still other embodiments, the protrusion 308 may have a radial height H of no greater than about 10 mm, such as no greater than 8 mm, no greater than 6 mm, 5 mm, 3 mm, 1 mm, 0.9 mm, or even no greater than about 0.8 mm. P In various embodiments, the radial height H of the protrusion 308 is P It can be in the range of at least about 0.1 mm to not more than about 1.5 mm. It should be understood that the radial height H of the protrusion 308 P It should be further understood that the radial height H of the protrusion 308 is within a range between any of the minimum and maximum values ​​described above. P It can be any value between any of the minimum and maximum values ​​mentioned above. It can also be understood that the radial height H of the protrusion 308 is P It can vary along its circumference and between multiple bearings.

[0050] The protrusion 308 may have a circumferential width W P For the purposes of the embodiments described herein, the circumferential width W of the protrusion 308 is P is the distance from the edge of one unformed segment 309 adjacent to the protrusion 308 to the unformed segment 309 on the circumferentially opposite side of the protrusion 308, such as Figure 3A According to some embodiments, the protrusion 308 may have a circumferential width W of at least about 0.1 mm, or at least about 0.2 mm, or at least about 0.3 mm, or at least about 0.4 mm, or even at least about 0.5 mm. PAccording to still other embodiments, the protrusion 308 may have a circumferential width W of not greater than about 20 mm, such as not greater than about 15 mm, 10 mm, 5 mm, 1 mm, 0.9 mm, or even not greater than about 0.8 mm. P In various embodiments, the circumferential width W of the protrusion 308 is P It can be in the range of at least about 1 mm to no more than about 10 mm. It should be understood that the circumferential width W of the protrusion 308 P It should be further understood that the circumferential width W of the protrusion 308 is within a range between any of the minimum and maximum values ​​described above. P It can be any value between any of the minimum and maximum values ​​mentioned above. It can also be understood that the circumferential width W of the protrusion 308 is P The circumferential width W of the plurality of protrusions 308 around the semi-annular band 302 may vary along its circumference and may vary between multiple bearings. P The ratio can be: 1:1, 2:1, 3:1, 4:1 or 5:1.

[0051] like Figure 3A and 3B As shown, the bearing 300 may include at least one leaf spring element 340. In various embodiments, the radially extending protrusion 308 of the bearing 300 and the at least one leaf spring element 340 may be disposed around a portion of the circumference of the semi-annular band 302. In addition, the radially extending protrusion 308 and the at least one leaf spring element 340 may alternatively be arranged around a portion of the circumference of the semi-annular band 302 of the bearing 300. In various embodiments, the leaf spring element 340 may take the form of a cantilever finger formed in a cutout 303 of the semi-annular band 302. The at least one finger 340' may be disposed along a first side (i.e., at the proximal end) of the bearing 300 (i.e., at the proximal end) of the bearing 300. Figure 3A341 in the figure is shown as a dotted line 341 connected to the annular band 302 of the bearing 300. And it is continuously disconnected from the semi-annular band 302 along the remaining sides. At least one finger 340' may extend in the radial direction. In multiple embodiments, multiple fingers may extend at different positions around the partial circumference of the semi-annular band, including a portion close to or below the axis along the X direction (roughly horizontal with respect to the central axis 390 of the inner rotating member 370). In one embodiment, at least one elongated finger of the finger 340' may have a straight profile or an arcuate profile. The finger 340' may include at least one substantially straight edge and / or at least one substantially arcuate edge. In one embodiment, at least one finger of the finger 340' may have a polygonal profile. The finger 340' may include at least one polygonal shape. For example, the finger 340' may include a triangular or quadrilateral shape extending from the semi-annular band 302. In another embodiment, at least one finger 340' may have an arcuate portion and a polygonal portion. In one embodiment, at least two of the fingers 340' have the same geometry or size as one another. In yet another embodiment, all of the fingers 340' may have the same geometry or size as one another. In another embodiment, at least two of the fingers 340' may have different geometry or size than one another. In yet another embodiment, all of the fingers 340' may have different geometry or size than one another.

[0052] Each finger 340' may have a connecting portion 343 defining a radially innermost surface 342 and a radially outermost surface 344. The best fit line of the finger 340' may be inclined relative to the central axis 390. In certain embodiments, each finger 340' may also further include an end or distal end portion 346 extending radially inward from the radially innermost surface 342 opposite the proximal end 341. The end portion 346 may extend from the radially innermost surface 342 opposite the bridge portion 343. In one embodiment, the outer surface of the end portion 346 may terminate radially inward of the bridge portion 343.

[0053] like Figure 3A and 3B As shown, the finger 340' may have a radial height H F For the purposes of the embodiments described herein, the radial height H of the finger 340 ′ is F is the distance from the radially innermost surface 342 of the finger 340' to the unformed region 309 of the semi-annular band 302, such as Figure 3B According to some embodiments, the finger 340' may have a radial height H of at least about 0.1 mm, or at least about 0.2 mm, or at least about 0.3 mm, or at least about 0.4 mm, or even at least about 0.5 mm. FAccording to still other embodiments, the finger 340' may have a radial height H of no greater than about 10 mm, such as no greater than 8 mm, no greater than 6 mm, 5 mm, 3 mm, 1 mm, 0.9 mm, or even no greater than about 0.8 mm. F In various embodiments, the radial height H of the finger 340 ′ is F It can be in the range of at least about 0.1 mm to not more than about 1.5 mm. It should be understood that the radial height H of the finger 340 ′ F It should be further understood that the radial height H of the finger 340 ′ is within a range between any of the minimum and maximum values ​​described above. F It can be any value between any of the minimum and maximum values ​​mentioned above. It can also be understood that the radial height H of the finger 340' F It can vary along its circumference and between multiple bearings.

[0054] The finger 340' may have a circumferential width W F For the purposes of the embodiments described herein, the circumferential width W of the finger 340 ′ is F is the distance from the edge of one unformed segment 309 adjacent to the finger 340' to the unformed segment 309 on the circumferentially opposite side of the finger 340', such as Figure 3A According to some embodiments, the finger 340' may have a circumferential width W of at least about 0.1 mm, or at least about 0.2 mm, or at least about 0.3 mm, or at least about 0.4 mm, or even at least about 0.5 mm. F According to still other embodiments, the finger 340' may have a circumferential width W of not greater than about 20 mm, such as not greater than about 15 mm, 10 mm, 5 mm, 1 mm, 0.9 mm, or even not greater than about 0.8 mm. F In various embodiments, the circumferential width W of the finger 340 ′ is F It can be in the range of at least about 1 mm to no more than about 10 mm. It should be understood that the circumferential width W of the finger 340 ′ F It should be further understood that the circumferential width W of the finger 340 ′ may be within a range between any of the minimum and maximum values ​​noted above. F It can be any value between any of the minimum and maximum values ​​mentioned above. It can also be understood that the circumferential width W of the finger 340' F The circumferential width W of the plurality of fingers 340' around the semi-annular band 302 may vary along its circumference and may vary between multiple bearings. F The ratio can be 1:1, 2:1, 3:1, 4:1 or 5:1.

[0055] Figure 4AAn illustration of a side perspective view of a bearing 400 according to various embodiments and formed from a blank of a material or composite material 1000, 1001, 1002, 1003, 1004 as described above is depicted. The bearing 400 may include a semi-annular band 402. The semi-annular band 402 may be formed from a blank as described above, which may be bent into an arc-like shape about a central axis 490. In various embodiments, the bearing 400 may include a semi-annular band 402, 402' having a plurality of generally arcuate shapes. The bearing 400 and / or the semi-annular band 402 may have a first axial end 420 and a second axial end 422. The bearing 400 and / or the semi-annular band 402 may have an inner surface 430 and an outer surface 432. The inner surface 430 of the bearing 400 and / or the semi-annular band 402 may have a low friction layer that conforms to the shape of the semi-annular band 402, wherein the substrate forms the outer surface 432, and the low friction layer is formed of a material or composite material 1000, 1001, 1002, 1003, 1004 as described above. Alternatively or in addition, the outer surface 432 of the bearing 400 may have a low friction layer that conforms to the shape of the semi-annular band 402, wherein the substrate forms the inner surface 430, and the low friction layer is formed of a composite material 1000, 1001, 1002, 1003, 1004 as described above. In other embodiments, the low friction layer may be laminated to both surfaces of the bearing 400 and / or the semi-annular band 402.

[0056] The bearing 400 and / or the annular band 402 may include at least one leaf spring element 440. The at least one leaf spring element 440 may be adapted to contact a mating component. For example, Figure 4BAn illustration of an end view of a bearing 400 is depicted within an assembly and formed from a blank 1000, 1001, 1002, 1003, 1004 of a material or composite material as described above, wherein a plurality of leaf spring elements 440, 440' contact an internal rotating member 470 within a bore 485 of an outer member or housing 480 in the assembly 4000. As shown, the central axis 490 may be the central axis of the internal rotating member 470. In various embodiments, each leaf spring element 440, 440' may include an inner portion 410 and at least one outer portion 412. In various embodiments, each leaf spring element 440, 440' may include a plurality of outer portions 412a, 412b, 412a', 412b'. In various embodiments, each leaf spring element 440, 440' may include a plurality of bridging portions 421a, 421a', 421b, 421b'. The first leaf spring element 440 may include a first bridge portion 421a and a second bridge portion 421b. The second leaf spring element 440' may include a first bridge portion 421a' and a second bridge portion 421b'. In various embodiments, the first and second bridge portions 421a, 421b, 421a', 421b' may include axial cutouts 425a, 425b, 425a', 425b'. The axial cutouts 425a, 425b, 425a', 425b' may be adapted to couple the first and second leaf spring elements 440, 440' together in the Z direction (along the central axis 490). The axial cutouts 425a, 425b, 425a', 425b' may allow the first and second bridge portions 421a, 421b, 421a', 421b' to overlap each other and reduce the axial length of the bearing 400. In various embodiments, the bridge portions 421a, 421b, 421a', 421b' can be located at the first circumferential end 415, 415' and the second circumferential end 417, 417' of each leaf spring element 440, 440'. In various embodiments, the bridge portions 421a, 421b, 421a', 421b' can connect the inner portion 410, 410' with the plurality of outer portions 412a, 412b, 412a', 412b' of each leaf spring element 440, 440. In various embodiments, the bridging portion 421a, 421b, 421a', 421b' can be folded over so that the outer portion 412a, 412b, 412a', 412b' covers the inner portion 410, 410' of each leaf spring element 440, 440' to form at least one folded edge 411a, 411b, 411a', 411b'. In various embodiments, each leaf spring element 440, 440' may include two folded edges 411a, 411b, 411a', 411b'.In various embodiments, the folded edges 411a , 411b , 411a ′, 411b ′ may form axial engagement surfaces 419a , 419b , 419a ′, 419b ′ to axially couple each leaf spring element 440 , 440 ′ to form the bearing 400 .

[0057] like Figures 4A to 4B As shown, each leaf spring element 440, 440' may include an inner portion 410, 410' having a circumferential length CL IP , the circumference length CL IP Between the bridging portions 421a, 421b, 421a', 421b' of each leaf spring element 440, 440'. Figure 4B As shown, at least one of the first and second bridging portions 421a, 421b, 421a', 421b' can be positioned at or near an axis along the X direction (substantially horizontal relative to the central axis 490 of the inner rotating member 470), wherein the first and second bridging portions 421a, 421b, 421a', 421b' provide enhanced stiffness along the X direction. In various embodiments, further, in various embodiments, the inner portions 410, 410' of the plurality of leaf spring elements 440, 440' can be joined to extend along their circumferential lengths CL IP , CL IP 'Together covering the entire circumference of the rotating member 470.

[0058] In various embodiments, Figure 3B and 4A As shown, the bearings 300, 400 may have an outer radius OR, from the central axis 390, 490 to the outer surface 332, 432, and OR may be ≧5mm, such as ≧1mm, ≧5mm, ≧10mm, ≧15mm or ≧20mm. OR may be ≦45mm, such as ≦40mm, such as ≦35mm, such as ≦30mm, ≦20mm, ≦15mm, ≦10mm or ≦5mm. In multiple embodiments, the outer radius OR of the bearings 300, 400 may be in the range of at least about 1mm to not more than about 10mm. It should be understood that the outer radius OR of the bearings 300, 400 may be in the range between any of the minimum and maximum values ​​described above. It should be further understood that the outer radius OR of the bearings 300, 400 may be any value between any of the minimum and maximum values ​​described above. It will also be appreciated that the outer radius OR of a bearing 300, 400 may vary along its circumference and may vary between multiple bearings. The ratio of the outer radius OR across multiple bearings 300, 400 may be 1:1, 2:1, 3:1, 4:1 or 5:1.

[0059] In various embodiments, Figure 3B and 4AAs shown, the bearings 300, 400 may have an inner radius IR from the central axis 390, 490 to the inner surface 330, 430, and the IR may be ≧1mm, such as ≧5mm, ≧7.5mm, ≧10mm, ≧15mm or ≧20mm. The inner radius IR may be ≦20mm, such as ≦15mm, ≦10mm, ≦7.5mm, ≦5mm or ≦1mm. In multiple embodiments, the inner radius IR of the bearings 300, 400 may be in the range of at least about 1mm to not more than about 10mm. It should be understood that the inner radius IR of the bearings 300, 400 may be in the range between any of the minimum and maximum values ​​described above. It should be further understood that the inner radius IR of the bearings 300, 400 may be any value between any of the minimum and maximum values ​​described above. It can also be understood that the inner radius IR of the bearings 300, 400 may vary along its circumference and may vary across multiple bearings. The ratio of the inner radius IR across the plurality of bearings 300 , 400 may be 1:1, 2:1, 3:1, 4:1, or 5:1.

[0060] In various embodiments, Figure 3A and 4A As shown, the bearings 300, 400 may have a length L measured between the first axial end 320, 420 and the second end 322, 422. The length L may be ≧1mm, such as ≧5mm, ≧7.5mm, ≧10mm, ≧15mm or ≧20mm. The length L may be ≦20mm, such as ≦15mm, ≦10mm, ≦7.5mm, ≦5mm or ≦1mm. In multiple embodiments, the length L of the bearings 300, 400 may be in the range of at least about 1mm to not more than about 10mm. It should be understood that the length L of the bearings 300, 400 may be in the range between any of the minimum and maximum values ​​described above. It should be further understood that the length L of the bearings 300, 400 may be any value between any of the minimum and maximum values ​​described above. It can also be understood that the length L of the bearings 300, 400 may vary along their circumference and may vary across multiple bearings. The ratio of the length L across the plurality of bearings 300 , 400 may be 1:1, 2:1, 3:1, 4:1, or 5:1.

[0061] In one particular aspect, the bearing 300, 400 as described herein can provide a higher degree of stiffness in the X direction (generally horizontal with respect to the central axis 390, 490 of the inner rotating member 370, 470) while providing a lower degree of stiffness in the Y direction (generally vertical with respect to the central axis 390, 490 of the inner rotating member 370, 470). In this regard, the assembly can support high side loads while allowing normal loads on the bearing 300, 400 to better bias the inner rotating member 370, 470. In one embodiment, at least one leaf spring element 340, 440 of the bearing 300, 400 can provide a biasing force in the Y direction, which is generally vertical with respect to the central axis 390, 490 of the rotating member 370, 470, wherein the bearing 300, 400 can have a first stiffness S1 in the Y direction and a second stiffness S2 in the X direction generally horizontal with respect to the central axis 390, 490 of the rotating member 370, 470, wherein S2 ≥ S1. In one embodiment, S2≥1.1S1, such as S2≥1.2S1, S2≥1.5S1, S2≥2S1, S2≥3S1 or S2≥10S1.

[0062] In one particular aspect, the bearing 300, 400 as described herein can provide a first elasticity ratio S1 in the Y direction. The first elasticity ratio S1 can be the elasticity ratio when a force in the range of 1 to 50 N is applied to the bearing 300, 400 against the rotating member 370, 470. The first elasticity ratio S1 in the Y direction can be between 10 and 500 N / mm.

[0063] In one particular aspect, the bearing 300, 400 as described herein can provide a second elasticity ratio S2 in the Y direction. The second elasticity ratio S2 can be the elasticity ratio when a force in the range of 400 to 800 N is applied to the bearing 300, 400 against the rotating member 370, 470. The second elasticity ratio S2 in the Y direction can be between 100 and 10,000 N / mm.

[0064] As described above, the bearing according to the embodiments of the present invention can be used in the assembly. For example and according to a plurality of embodiments, the assembly can be a steering assembly for a vehicle. The steering assembly can include an electric motor. The electric motor can include a stator and a rotor, an input shaft, an output shaft, and a gearbox, the input shaft being operably connected to the rotor and adapted to rotate therewith, the output shaft being associated with a steering column, the gearbox being adapted to transfer torque from the input shaft to the output shaft, in response to a torque measurement in the output shaft generated by a torque sensor, as described in detail below. As the measured torque increases, the motor can apply an increased torque to the output shaft, thereby applying an auxiliary torque that helps to steer the vehicle. A steering assembly such as this can use a worm and worm gearbox to transfer torque from the input shaft to the output shaft (the worm is usually provided on the input shaft and the gear is provided on the output shaft) or a steering column. An example of this can be a power steering system.

[0065] FIG. 5A to FIG. 5B Bearings according to embodiments herein are shown for use with an exemplary steering assembly 5000 according to various embodiments. Figure 5A A side cross-sectional view of a bearing according to embodiments herein for use with a steering assembly 5000 according to one embodiment is included. Figure 5B A plan cross-sectional view of a bearing according to an embodiment herein for an exemplary steering assembly 5000 according to one embodiment is included. In various embodiments, the steering assembly 500 may be a power-assisted steering assembly and may include an anti-knock device. Figure 5A, the steering assembly 5000 may include a housing 510. The steering assembly 500 may further include a motor 512 for applying torque to an output shaft 514, which is operably connected to a steering column shaft. The motor 512 may include a stator and a rotor (not shown). The motor 512 may be mounted on one side of the housing 510. One end of an input shaft 516 (or an internal rotating member as described above) extends through a first opening into an inner cavity 519 of the housing 510 and may be supported by a first bearing element 520. The motor 512 is operably connected to the input shaft 516 or (or internal rotating member) and is adapted to rotate the input shaft 516. The input shaft 516 may be connected to a rotor within the motor 512 adjacent to the first bearing element 520. The other end of the input shaft 516 passes through a second opening on the housing 510 opposite to the first opening and may be supported by a second bearing element 522. The first bearing element 520 and the second bearing element 522 may support the input shaft 516 within the cavity 519 of the housing 510 and may contact the housing 510 at one side of the cavity 519. The first bearing element 520 and the second bearing element 522 may be disposed between the rotating member (the input shaft 516) and the housing 510. The input shaft 516 may include a worm 530 between the two bearing elements 520, 522, the worm being adapted to contact and engage a worm wheel 540, which is operably connected to the output shaft 514 of the steering assembly 5000. The engagement between the worm 530 and the worm wheel 540 may be performed by using teeth 532, 542 disposed on each, respectively. The worm 530 may be adapted to be rotated by the motor 512 (together with the inner shaft 516, i.e., the rotating member), the motor rotating the worm wheel 540 based on the engagement of the teeth 532 of the worm 530 with the teeth 542 of the worm wheel 540. In use, the output from the torque sensor 550, which is adapted to measure torque in the output shaft 514 (or a steering shaft operatively connected thereto), may in turn be transmitted to an electronic control unit (ECU) 555 to generate a motor drive signal which controls the torque produced by the motor 512. The motor 512 then transmits the torque to the input shaft 516 and the output shaft 514 via the motor rotor to provide assistance to aid the driver of the vehicle.

[0066] The first bearing element 520 can be fixed to the housing 510 and serve as a pivot point about which the input shaft 516 can tilt, such as Figure 5B516. When the shaft 516 passes through the first bearing element 520, it prevents substantially all radial movement of the shaft 516. The first bearing element 520 may include any component commonly used in the field of bearings. By way of non-limiting example, the first bearing element 520 may include a ball bearing or roller bearing seat having an inner bearing race that mates with the input shaft 516 and an outer bearing race spaced about the inner race, with the bearing provided therebetween. The ball bearing is exemplary and any well-known bearing assembly may be used, as long as the tolerance and load requirements set by the designer for the first bearing element 520 are met.

[0067] The second bearing element 522 may include multiple components. The second bearing element 522 may include a shaft 550. The shaft 550 may support a bearing according to embodiments disclosed herein. Figure 5A As shown, shaft 500 may support bearing 500A, which is FIG. 3A to FIG. 3B As shown and described in more detail in . Alternatively, Figure 5B As shown, shaft 500 can support bearing 500B, which is FIG. 4A to FIG. 4B 500B. The bearings 500A, 500B in the second bearing element 522 may surround and support an input shaft 516 similar to the rotating member described above. A shaft 550 may be used to press the bearings 500A, 500B against the input shaft 516. The shaft 550 may be operably coupled to the housing 510 and may be used to press the bearings 500A, 500B against the input shaft 516. Further, the bearings 500A, 500B may be used to bias the teeth 532 of the worm 530 into engagement with the teeth 542 of the worm wheel 540 and allow them to remain in engagement (i.e., there is a correct gap between the tooth surfaces on either side of the engagement of the teeth 532 of the worm and the teeth 542 of the worm wheel) for a range of worm wheel 540 size and position variations (due to manufacturing tolerances), temperature, and tooth wear. The magnitude of the force depends on the degree of configuration of the bearings 500A, 500B.

[0068] For a range of torque values ​​measured at the worm gear 540 (e.g., up to 4 N-m in one application), it may be desirable to maintain this meshed state to prevent the gears from rattling when driven. In various exemplary embodiments, it may be desirable to apply a force in the range of 1-50 N to the worm 530 radially relative to the worm gear 540 to maintain the torque of the worm gear 540 in the range of 0.5-50 N-m.

[0069] The steering assembly components disclosed herein may be made of metal, polymer, or a combination thereof. The metal may be a single metal, such as aluminum, or a metal alloy, such as steel, aluminum alloy, brass, etc. The polymer may be a thermoplastic polymer. The thermoplastic polymer may be a polyamide thermoplastic. In addition, the thermoplastic may be polyoxymethylene (POM). In addition, the thermoplastic polymer may be a polyethylene thermoplastic, such as high-density polyethylene (HDPE). The steering assembly components may be made of die-cast metal or injection-molded plastic using molding or drawing techniques.

[0070] According to various embodiments herein, bearings are provided that can provide improved torque and tolerance performance, which can eliminate additional components, reduce installation and manufacturing time, and provide easier use of the assembly while eliminating or reducing noise, harshness and vibration. More specifically, according to embodiments herein, bearings can provide better tolerance and torque performance, which improves contact and engagement of worms and worm wheels in anti-vibration devices and steering assemblies, reduces rattle / noise and improves steering assembly and vehicle performance. This can reduce and / or compensate for component wear and provide more stable assembly and vehicle performance over its life cycle.

[0071] The subject matter disclosed above should be understood as exemplary rather than restrictive, and we hope that the appended claims cover all such modifications, improvements and other embodiments that fall within the essential scope of the present invention. Therefore, to the maximum extent permitted by law, the scope of the present invention is defined by the broadest permissible interpretation of the appended claims and their equivalents, and is not restricted or limited by the above-mentioned specific embodiments.

[0072] In addition, in the above detailed description, various features may be grouped together or described in a single embodiment for the purpose of simplifying the disclosure. The disclosure should not be interpreted as embodying such an intention: the embodiments protected by the claims require more features than those explicitly listed in each claim. Rather, as reflected in the following claims, the subject matter of the invention may involve less than all the features of any of the embodiments disclosed by the present invention. Therefore, the following claims are incorporated into the detailed description, with each claim independently defining a separately claimed subject matter.

[0073] Many different aspects and embodiments are possible. Some of those aspects and embodiments are described below. After reading this specification, those skilled in the art will understand that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments can be based on any one or more embodiments listed below.

[0074] Embodiment 1: A bearing for being arranged between a housing and a rotating member, the bearing comprising: at least one leaf spring element, which provides a biasing force in the Y direction; wherein the bearing has a first stiffness S1 in the Y direction and a second stiffness S2 in the X direction perpendicular to the Y direction, wherein S2 ≥ S1, and wherein the bearing comprises a metal substrate and a low friction layer, which is covered on at least one surface of the substrate and is suitable for contacting the rotating member.

[0075] Embodiment 2: A bearing for being arranged between a housing and a rotating member, the bearing comprising: at least one leaf spring element, which provides a biasing force in the Y direction; wherein the bearing has a first stiffness S1 in the Y direction and a second stiffness S2 in the X direction perpendicular to the Y direction, wherein S2 ≥ S1, and wherein the bearing further comprises 1) a plurality of leaf spring elements and a plurality of radially extending protrusions; or 2) a plurality of leaf spring elements, comprising a radial inner portion, a radial outer portion and a bridging portion connecting the radial inner portion and the radial outer portion, wherein the bridging portion is located at a circumferential end of at least one leaf spring element, wherein the inner radial portion and the outer radial portion are folded so that the outer portion covers the inner portion.

[0076] Embodiment 3: The assembly comprises: a housing; a rotating member; and a bearing arranged between the housing and the rotating member, the bearing comprising: at least one leaf spring element providing a biasing force in the Y direction; wherein the bearing has a first stiffness S1 in the Y direction and a second stiffness S2 in the X direction perpendicular to the Y direction, wherein S2 ≥ S1, and wherein the bearing comprises a metal substrate and a low friction layer covering at least one surface of the substrate and adapted to contact the rotating member.

[0077] Embodiment 4: The bearing and assembly according to any of the preceding embodiments, wherein S2 ≥ 1.1S1, such as S2 ≥ 1.2S1, S2 ≥ 1.5S1, S2 ≥ 2S1 or S2 ≥ 3S1.

[0078] Embodiment 5: A bearing or assembly according to any of the preceding embodiments, wherein the bearing comprises a first elasticity ratio SR1 and a second elasticity ratio SR2, wherein the first elasticity ratio has a range of 10 to 500 in the Y direction and the second elasticity ratio has a range of 100 to 10,000.

[0079] Embodiment 6: The bearing or assembly of any of the preceding embodiments, wherein the bearing further comprises a semi-annular band comprising a plurality of radially extending protrusions and at least one leaf spring element is disposed around a portion of the circumference of the semi-annular band.

[0080] Embodiment 7: The bearing or assembly of Embodiment 6, wherein the radially extending protrusion includes a wave portion positioned at or adjacent the axis along the X direction, wherein the wave portion provides enhanced stiffness along the X direction.

[0081] Embodiment 8: A bearing or assembly according to Embodiment 6, wherein the radially extending protrusion includes a wave portion positioned at or adjacent to the axis along the X direction, wherein the radially extending protrusion limits movement of the rotating component in the Y direction.

[0082] Embodiment 9: The bearing or assembly of any one of Embodiments 7 to 8, wherein the wave portion is integral with the semi-annular band such that the wave portion abuts the semi-annular band around the entire perimeter of the semi-annular band.

[0083] Embodiment 10: A bearing or assembly according to any one of embodiments 6 to 9, wherein at least one leaf spring element includes a radially extending finger, wherein the radially extending finger is cantilevered, wherein the radially extending finger includes a proximal end and a distal end, wherein the proximal end is connected to the semi-annular band and the distal end is opposite to the proximal end.

[0084] Embodiment 11: The bearing or assembly of any of Embodiments 6 to 10, wherein the semi-annular band covers at least 180° and no more than 300° of the circumference of the rotating component.

[0085] Embodiment 12: A bearing or component according to any one of embodiments 1 to 5, wherein at least one leaf spring element comprises a radial inner portion, a radial outer portion and a bridging portion connecting the radial inner portion and the radial outer portion, wherein the bridging portion is located at a circumferential end of at least one leaf spring element, wherein the inner radial portion and the outer radial portion are folded so that the outer portion covers the inner portion.

[0086] Embodiment 13: The bearing or assembly of Embodiment 12, wherein the at least one leaf spring element comprises a first leaf spring element and a second leaf spring element, and wherein the first leaf spring element and the second leaf spring element are connected to collectively cover the entire circumference of the rotating member.

[0087] Embodiment 14: A bearing or assembly according to Embodiment 12, wherein each of the first leaf spring element and the second leaf spring element includes a first bridging portion and a second bridging portion, wherein the first bridging portion and the second bridging portion of each of the first leaf spring element and the second leaf spring element are positioned at or adjacent to the axis along the X direction, wherein the first bridging portion and the second bridging portion provide enhanced stiffness along the X direction.

[0088] Embodiment 15: A bearing or assembly according to embodiment 14, wherein the first bridging portion and the second bridging portion include complementary axial cuts, which are suitable for connecting the first leaf spring element and the second leaf spring element together in the Z direction so that the first bridging portion and the second bridging portion overlap each other, wherein the axial cuts reduce the axial length of the bearing.

[0089] Embodiment 16: The assembly of Embodiment 3, wherein the rotating member comprises a worm including a plurality of teeth.

[0090] Embodiment 17: The assembly of Embodiment 16, further comprising a worm gear comprising a plurality of teeth adapted to mesh with the teeth of the worm.

[0091] Embodiment 18: The bearing or assembly of any of the preceding embodiments, wherein the low friction layer comprises a polymer.

[0092] Embodiment 19: The bearing or assembly of Embodiment 18, wherein the low friction layer comprises polyketone, polyaramid, polyimide, polyetherimide, polyamideimide, polyphenylene sulfide, polyphenylene sulfone, fluoropolymer, polybenzimidazole, derivatives thereof, or combinations thereof.

[0093] Embodiment 20: The bearing or assembly of any of the preceding embodiments, wherein the substrate comprises a metal or an alloy thereof.

[0094] Embodiment 21: A bearing or assembly according to Embodiment 20, wherein the substrate comprises stainless steel or spring steel.

[0095] Embodiment 22: A bearing or assembly according to any one of Embodiments 2 to 21, wherein the assembly comprises an anti-knock assembly for a steering assembly.

[0096] Note that not all of the features described above are required, a portion of a particular feature may not be required, and one or more features may be provided in addition to the features described. Furthermore, the order in which the features are described is not necessarily the order in which the features are installed.

[0097] For the sake of clarity, certain features described herein in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, for the sake of brevity, various features described in the context of a single embodiment may also be provided separately or in any sub-combination.

[0098] Benefits, other advantages, and solutions to problems have been described above with reference to specific embodiments. However, benefits, advantages, solutions to problems, and any features that may make any benefit, advantage, or solution present or more significant should not be construed as critical, required, or essential features of any or all claims.

[0099] The description and illustration of the embodiments described herein are intended to provide a general understanding of the structure of various embodiments. The description and illustration are not intended to be used as a detailed and comprehensive description of all elements and features of the device and system using the structure or method described herein. A separate embodiment may also be provided in a combined manner in a single embodiment, and conversely, the various features described in the context of a single embodiment for simplicity may also be provided individually or in any sub-combination. In addition, references to values ​​expressed in ranges include each value and all values ​​within the range, including the range end values ​​cited. Only after reading this specification, many other embodiments will be apparent to the technician. Other embodiments may be utilized and obtained through the present disclosure, so that structural replacement, logical replacement or any change may be performed without departing from the scope of the present disclosure. Therefore, the present disclosure should be considered illustrative and not restrictive.

Claims

1. A bearing, the bearing being used to be arranged between a housing and a rotating member, the bearing comprising: at least one leaf spring element providing a biasing force in the Y direction; wherein the bearing has a first stiffness S1 in the Y direction and a second stiffness S2 in the X direction perpendicular to the Y direction, wherein S2 ≥ S1, and wherein the bearing comprises a metal substrate and a low friction layer, the low friction layer covering at least one surface of the substrate and adapted to contact the rotating member, The bearing comprises a plurality of spaced radially extending projections extending radially inwardly from an inner surface of the bearing, wherein the at least one leaf spring element comprises a first leaf spring element and a second leaf spring element, wherein each of the first leaf spring element and the second leaf spring element comprises a first bridge portion and a second bridge portion, and The first bridge portion and the second bridge portion comprise complementary axial cutouts adapted to couple the first leaf spring element and the second leaf spring element together in the Z direction such that the first bridge portion and the second bridge portion overlap each other.

2. The bearing according to claim 1, wherein S2≥1.1S1, S2≥1.2S1, S2≥1.5S1, S2≥2S1, S2≥3S1 or S2≥10S1. 3 . The bearing according to claim 1 , wherein the bearing comprises a first elasticity ratio SR1 having a range of 10 to 500 N / mm and a second elasticity ratio SR2 having a range of 100 to 10,000 N / mm in the Y direction.

4. The bearing of claim 1, wherein the bearing further comprises a semi-annular band including the plurality of spaced radially extending projections, and wherein the at least one leaf spring element is disposed about a portion of the circumference of the semi-annular band.

5. The bearing of claim 4, wherein the radially extending protrusion includes a wave portion located at or adjacent to the axis along the X direction, wherein the wave portion provides enhanced stiffness along the X direction.

6. The bearing according to claim 4, wherein the radially extending protrusion includes a wave portion, the wave portion is positioned at or adjacent to the axis along the Y direction, wherein the radially extending protrusion restricts movement of the rotating member in the Y direction.

7. The bearing of claim 5, wherein the wave portion is integral with the semi-annular band such that the wave portion abuts the semi-annular band around the entire periphery of the semi-annular band.

8. The bearing of claim 4, wherein the at least one leaf spring element comprises a radially extending finger, wherein the radially extending finger is cantilevered, wherein the radially extending finger comprises a proximal end and a distal end, wherein the proximal end is connected to the semi-annular band, and the distal end is opposite the proximal end.

9. The bearing of claim 4, wherein the semi-annular band covers at least 180° and no more than 300° of the circumference of the rotating member.

10. The bearing according to claim 1, wherein the at least one leaf spring element comprises a radial inner portion, a radial outer portion, and a bridge portion connecting the radial inner portion and the radial outer portion, wherein the bridge portion is located at a circumferential end of the at least one leaf spring element, wherein the inner radial portion and the outer radial portion are folded so that the outer portion covers the inner portion.

11. The bearing according to claim 10, wherein the first leaf spring element and the second leaf spring element are connected to jointly cover an entire circumference of the rotating member.

12. The bearing according to claim 11, wherein the first bridging portion and the second bridging portion of each of the first leaf spring element and the second leaf spring element are positioned at or adjacent to the axis along the X direction, wherein the first bridging portion and the second bridging portion provide enhanced stiffness along the X direction.

13. The bearing of claim 12, wherein the axial cutout reduces the axial length of the bearing.

14. A bearing, the bearing being used to be arranged between a housing and a rotating member, the bearing comprising: at least one leaf spring element providing a biasing force in the Y direction; wherein the bearing has a first stiffness S1 in the Y direction and a second stiffness S2 in the X direction perpendicular to the Y direction, wherein S2 ≥ S1, and wherein the bearing further comprises: 1) a plurality of leaf spring elements and a plurality of radially extending protrusions; or 2) A plurality of leaf spring elements, the plurality of leaf spring elements comprising a radial inner portion, a radial outer portion and a bridging portion connecting the radial inner portion and the radial outer portion, wherein the bridging portion is located at a circumferential end of the at least one leaf spring element, wherein the inner radial portion and the outer radial portion are folded so that the outer portion covers the inner portion, wherein the at least one leaf spring element comprises a first leaf spring element and a second leaf spring element, wherein each of the first leaf spring element and the second leaf spring element comprises a first bridging portion and a second bridging portion, wherein the first bridging portion and the second bridging portion comprise complementary axial cuts, the axial cuts being suitable for coupling the first leaf spring element and the second leaf spring element together in the Z direction so that the first bridging portion and the second bridging portion overlap each other.

15. The bearing according to claim 14, wherein S2≥1.1S1, S2≥1.2S1, S2≥1.5S1, S2≥2S1, S2≥3S1 or S2≥10S1. 16 . The bearing according to claim 14 , wherein the bearing comprises a first elasticity ratio SR1 having a range of 10 to 500 N / mm and a second elasticity ratio SR2 having a range of 100 to 10,000 N / mm in the Y direction.

17. The bearing of claim 14, wherein the bearing further comprises a semi-annular band including the plurality of radially extending projections and the at least one leaf spring element is disposed around a portion of the circumference of the semi-annular band.

18. The bearing of claim 17, wherein the radially extending protrusion includes a wave portion located at or adjacent to the axis along the X direction, wherein the wave portion provides enhanced stiffness along the X direction.

19. The bearing of claim 17, wherein the radially extending protrusion includes a wave portion positioned at or adjacent to an axis along the Y direction, wherein the radially extending protrusion restricts movement of the rotating member in the Y direction.

20. The bearing of claim 18, wherein the wave portion is integral with the semi-annular band such that the wave portion abuts the semi-annular band around the entire periphery of the semi-annular band.

21. The bearing of claim 17, wherein the at least one leaf spring element comprises a radially extending finger, wherein the radially extending finger is cantilevered, wherein the radially extending finger comprises a proximal end and a distal end, wherein the proximal end is connected to the semi-annular band, and wherein the distal end is opposite to the proximal end.

22. The bearing of claim 17, wherein the semi-annular band covers at least 180° and no more than 300° of the circumference of the rotating member.

23. The bearing according to claim 14, wherein the at least one leaf spring element comprises a radial inner portion, a radial outer portion, and a bridging portion connecting the radial inner portion and the radial outer portion, wherein the bridging portion is located at a circumferential end of the at least one leaf spring element, wherein the inner radial portion and the outer radial portion are folded so that the outer portion covers the inner portion.

24. The bearing according to claim 23, wherein the first leaf spring element and the second leaf spring element are connected to jointly cover the entire circumference of the rotating member.

25. The bearing of claim 24, wherein the first bridging portion and the second bridging portion of each of the first leaf spring element and the second leaf spring element are positioned at or adjacent to an axis along the X direction, wherein the first bridging portion and the second bridging portion provide enhanced stiffness along the X direction.

26. The bearing of claim 25, wherein the axial cutout reduces the axial length of the bearing.

27. An assembly, comprising: case; Rotating components; as well as A bearing, the bearing being disposed between the housing and the rotating member, the bearing comprising: at least one leaf spring element, the at least one leaf spring element providing a biasing force in the Y direction; wherein the bearing has a first stiffness S1 in the Y direction and a second stiffness S2 in the X direction perpendicular to the Y direction, wherein S2 ≥ S1, and wherein the bearing comprises a metal substrate and a low friction layer, the low friction layer covering at least one surface of the substrate and adapted to contact the rotating member; and a plurality of spaced radially extending projections extending radially inwardly from an inner surface of the bearing, wherein the at least one leaf spring element comprises a first leaf spring element and a second leaf spring element, wherein each of the first leaf spring element and the second leaf spring element comprises a first bridge portion and a second bridge portion, and The first bridge portion and the second bridge portion comprise complementary axial cutouts adapted to couple the first leaf spring element and the second leaf spring element together in the Z direction such that the first bridge portion and the second bridge portion overlap each other.

28. The assembly of claim 27, wherein S2≥1.1S1, S2≥1.2S1, S2≥1.5S1, S2≥2S1, S2≥3S1 or S2≥10S1.

29. The assembly of claim 27, wherein the bearing comprises a first elasticity ratio SR1 having a range of 10 to 500 N / mm and a second elasticity ratio SR2 having a range of 100 to 10,000 N / mm in the Y direction.

30. The assembly of claim 27 wherein the bearing further comprises a semi-annular band including the plurality of spaced radially extending projections and wherein the at least one leaf spring element is disposed about a portion of the circumference of the semi-annular band.

31. The assembly of claim 30, wherein the radially extending protrusion includes a wave portion located at or adjacent to the axis along the X direction, wherein the wave portion provides enhanced stiffness along the X direction.

32. The assembly of claim 30, wherein the radially extending protrusion includes a wave portion positioned at or adjacent to an axis along the Y direction, wherein the radially extending protrusion limits movement of the rotating member in the Y direction.

33. The assembly of claim 31, wherein the undulating portion is integral with the semi-annular band such that the undulating portion abuts the semi-annular band around the entire periphery of the semi-annular band.

34. A component according to claim 30, wherein the at least one leaf spring element includes a radially extending finger, wherein the radially extending finger is cantilevered, wherein the radially extending finger includes a proximal end and a distal end, the proximal end is connected to the semi-annular band, and the distal end is opposite to the proximal end.

35. The assembly of claim 30, wherein the semi-annular band covers at least 180° and no more than 300b of the circumference of the rotating member.

36. A component according to claim 27, wherein the at least one leaf spring element includes a radial inner portion, a radial outer portion, and a bridging portion connecting the radial inner portion and the radial outer portion, wherein the bridging portion is located at the circumferential end of the at least one leaf spring element, wherein the inner radial portion and the outer radial portion are folded so that the outer portion covers the inner portion.

37. The assembly of claim 36, wherein the first leaf spring element and the second leaf spring element are connected to together cover the entire circumference of the rotating member.

38. An assembly according to claim 37, wherein the first bridging portion and the second bridging portion of each of the first leaf spring element and the second leaf spring element are positioned at or adjacent to the axis along the X direction, wherein the first bridging portion and the second bridging portion provide enhanced stiffness along the X direction.

39. The assembly of claim 38, wherein the axial cutout reduces the axial length of the bearing.

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