Functional hierarchical composite structure

Abstract

A composite ring includes: a first region comprising a first polymer material; a second region comprising a second polymer material; and an interface region defining a compositional gradient between the first and second regions; wherein the wear resistance of the first region and the wear resistance of the second region are different. A composite bearing includes: a first layer comprising a first polymer material and a first filler; a second layer disposed on the first layer, comprising a second polymer material and a second filler; and an interface region defining a compositional gradient between the first and second layers; wherein the wear resistance of the first layer is greater than that of the second layer, and wherein the mechanical strength of the second layer is greater than that of the first layer.

Description

Technical Field

[0001] This disclosure generally relates to functionally graded composite structures (e.g., functionally graded composite rings), such as functionally graded composite bearings for reciprocating gas compressors or rotating machinery. Background Technology

[0002] Mechanical components such as wear rings, rod rings, piston rings, wear bands, support rings, bearings, or dynamic sealing rings are integral parts of mechanical systems such as reciprocating gas compressors or rotating machinery (e.g., gas or steam turbines, electric motors, pumps, generators, turbomachinery, rotary compressors, axial compressors, or centrifugal compressors). These mechanical components support the mechanical system by, for example, managing heat, assisting motion, enhancing system durability, reducing airflow, and enabling other components to perform their tasks more efficiently. Summary of the Invention

[0003] This specification describes functionally graded composite structures (e.g., rings, tubes, ring segments, or bearings) and methods that can be used to manufacture them. The functionally graded composite structures described herein can be used as part of mechanical systems such as reciprocating gas compressors or rotating machinery, such as gas turbines or steam turbines, electric motors, pumps, generators, turbomachinery, rotary compressors, axial compressors, or centrifugal compressors. The functionally graded composite structure comprises two or more polymer regions with different compositions and properties, defined by an interface region that defines a compositional gradient between the regions. For each region, its properties, such as strength, stiffness, wear resistance, creep resistance, or thermal conductivity, can be controlled, for example, by incorporating fillers that impart desired properties to that region into each polymer region. For example, in a composite ring, the ring regions subjected to wear during operation of the mechanical system can be formed of a composition that provides improved wear resistance, while other regions of the ring can provide thermal conductivity, mechanical stiffness, or strength, or other properties.

[0004] In one aspect, a composite ring includes: a first region comprising a first polymer material; a second region comprising a second polymer material; and an interface region defining a compositional gradient between the first and second regions; wherein the first region has different abrasion resistance than the second region.

[0005] An embodiment may include one or any combination of two or more of the following features.

[0006] The thermal conductivity of the first region is different from that of the second region.

[0007] The stiffness of the first region is different from that of the second region.

[0008] The mechanical strength of the first region is different from that of the second region.

[0009] The first region has a greater wear resistance than the second region. The second region has a greater thermal conductivity than the first region. The second region has a greater stiffness than the first region, and / or the second region has a greater mechanical strength than the first region.

[0010] The first polymer material and the second polymer material each independently include one or more of the following: polyetheretherketone, polyetherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, perfluoroalkoxyalkane, ultra-high molecular weight polyethylene, polybenzimidazole, polyamide-imide, polyphenylene sulfone, and fluoropolymers. The first polymer material and / or the second polymer material includes polytetrafluoroethylene. The first polymer material and / or the second polymer material includes one or more of the following: polyetherketone, polyetherketoneetherketoneketone, and polyetherketoneketone.

[0011] The component gradient is distributed along the radius of the ring. The surface of the first region defines the outer perimeter of the ring, and the surface of the second region defines the inner perimeter of the ring. The wear resistance of the first region is greater than that of the second region, or the wear resistance of the second region is greater than that of the first region.

[0012] The component gradient is distributed along a portion of the outer periphery of the ring.

[0013] The component gradient is distributed along a portion of the inner periphery of the ring.

[0014] A portion of the inner periphery of a first surface defining a ring in a first region, and a portion of the outer periphery of a second surface defining a ring in a second region. A portion of the inner periphery of a first surface defining a ring in a second region, and a portion of the outer periphery of a second surface defining a ring in a second region.

[0015] The composite ring includes one or more additional regions, each of which includes a polymer material, which independently includes one or more of the following: polyetheretherketone, polyetherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, perfluoroalkoxyalkane, ultra-high molecular weight polyethylene, polyamide-imide, polyphenylene sulfone, and fluoropolymers. One or more additional regions include polytetrafluoroethylene.

[0016] The first and / or second regions independently include fillers. The fillers include lubricants. The fillers include wear-resistant additives. The fillers include one or more of the following: molybdenum disulfide, tungsten disulfide, bronze, boron nitride, titanium dioxide, alumina. The fillers include carbon. The fillers include one or more of the following: carbon powder, carbon particles, carbon fibers, graphene, graphite, carbon nanotubes. The fillers include polymers. The fillers include one or more of the following: polytetrafluoroethylene, polyetheretherketone, polyphenylene sulfide, polyimide, polybenzimidazole. The fillers include glass. The fillers include one or more of the following: glass beads, glass fibers.

[0017] The ring is a wear ring, rod ring, piston band, wear band, or dynamic sealing ring.

[0018] In one aspect, a composite bearing includes: a first layer comprising a first polymer material and a first filler; a second layer disposed on the first layer, comprising a second polymer material and a second filler; and an interface region defining a component gradient between the first layer and the second layer; wherein the first layer has a greater wear resistance than the second layer, and wherein the second layer has a greater mechanical strength than the first layer.

[0019] An embodiment may include one or any combination of two or more of the following features.

[0020] The thermal conductivity of the first layer is different from that of the second layer.

[0021] The stiffness of the first layer is different from that of the second layer.

[0022] The mechanical strength of the first layer is different from that of the second layer.

[0023] The first layer has a greater wear resistance than the second layer. The second layer has a greater thermal conductivity than the first layer. The second layer has a greater stiffness than the first layer, and / or the second layer has a greater mechanical strength than the first layer.

[0024] The first polymer material and the second polymer material each independently include one or more of the following: polyetheretherketone, polyetherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, perfluoroalkoxyalkane, ultra-high molecular weight polyethylene, polybenzimidazole, polyamide-imide, polyphenylene sulfone, and fluoropolymers. The first polymer material and / or the second polymer material includes polytetrafluoroethylene. The first polymer material and / or the second polymer material includes one or more of the following: polyetherketone, polyetherketoneetherketoneketone, and polyetherketoneketone.

[0025] The composite bearing includes one or more additional layers, each comprising a polymer material, which independently includes one or more of the following: polyetheretherketone, polyetherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, perfluoroalkoxyalkane, ultra-high molecular weight polyethylene, polyamide-imide, polyphenylene sulfone, polyester (aliphatic, aromatic, aliphatic-aromatic), and fluoropolymers. One or more additional layers include polytetrafluoroethylene.

[0026] The filler includes lubricants. The filler includes wear-resistant additives. The filler includes one or more of the following: molybdenum disulfide, tungsten disulfide, bronze, boron nitride, titanium dioxide, alumina. The filler includes carbon. The filler includes one or more of the following: carbon powder, carbon particles, carbon fibers, graphene, graphite, carbon nanotubes. The filler includes polymers. The filler includes one or more of the following: polytetrafluoroethylene, polyetheretherketone, polyphenylene sulfide, polyimide, polybenzimidazole. The filler includes glass. The filler includes one or more of the following: glass beads, glass fibers.

[0027] In one aspect, a method of manufacturing a composite preform includes: providing a first polymer powder to a first portion of a mold; providing a second polymer powder to a second portion of the mold; compressing the first polymer powder and the second polymer powder in the mold to produce a composite preform, the composite preform including: a first region comprising a first polymer material formed by compressing the first polymer powder; a second region comprising a second polymer material formed by compressing the second polymer powder; and an interface region defining a composition gradient between the first region and the second region; and separating the composite preform from the mold.

[0028] An embodiment may include one or any combination of two or more of the following features.

[0029] The method includes heating a mold while compressing a first polymer powder and a second polymer powder.

[0030] The method includes sintering the composite preform.

[0031] The method includes compressing the material in a mold while it is hot after sintering.

[0032] The method includes machining the composite blank. Machining the composite blank includes forming a ring from the blank. The ring is a wear ring, rod ring, piston band, wear band, or dynamic sealing ring.

[0033] In one aspect, a machine component includes a body configured to be coupled to a moving shaft. The body has: a first region comprising a first polymer material; a second region comprising a second polymer material; and two or more interface regions. At least one of the interface regions defines a composition gradient between the first and second regions. One or more physical properties of the first region differ from one or more corresponding physical properties of the second region.

[0034] An embodiment may include one or any combination of two or more of the following features.

[0035] At least one of the physical properties includes abrasion resistance.

[0036] At least one of the interface regions defines a component gradient in the circumferential direction.

[0037] Each of at least two of the interface regions defines a component gradient in the circumferential direction.

[0038] At least one of the interface regions defines a component gradient in the radial direction.

[0039] The main body includes a third region, which includes a third polymer material. At least one of the interface regions defines a component gradient between the second and third regions.

[0040] The main body includes a ring configured for coupling with a reciprocating rod.

[0041] The components include bearings, and the main body is the bearing pad.

[0042] Details of one or more embodiments of these systems and methods will be set forth in the accompanying drawings and the description below. Other features, objects, and advantages of these systems and methods will become more apparent from the specification, drawings, and claims. Attached Figure Description

[0043] Figure 1 This is a schematic diagram of a reciprocating gas compressor system.

[0044] Figure 2 This is a schematic diagram of a functionally graded composite ring.

[0045] Figures 3A-3B This is a schematic diagram of a functionally graded composite ring.

[0046] Figure 4 This is a schematic diagram of a multi-layered functional composite bearing.

[0047] Figure 5 This is a schematic diagram of a bearing assembly.

[0048] Figures 6A-6E This is a diagram illustrating the manufacturing method of a functionally graded composite structure.

[0049] Figure 7 This is a flowchart illustrating a manufacturing method for a functionally hierarchical composite structure. Detailed Implementation

[0050] This specification describes a functionally graded composite structure (e.g., a ring or bearing) and methods that can be used to manufacture such a structure. The functionally graded composite structure described herein can be used as part of a mechanical system (e.g., a reciprocating gas compressor). The functionally graded composite structure comprises two or more polymer regions with different components and / or properties, defined by an interface region that defines a component gradient between the regions. For each region, its properties, such as strength, stiffness, wear resistance, creep resistance, or thermal conductivity, can be controlled, for example, by incorporating a filler (e.g., an additive, a lubricant (e.g., a solid lubricant), or a reinforcing agent that imparts desired properties to that region. For example, in a composite ring, the ring region subjected to wear during operation of the mechanical system can be formed of a composition with high wear resistance, while other regions of the ring can provide the ring with higher thermal conductivity, mechanical stiffness, or strength, or other properties.

[0051] The presence of two or more regions with different compositions and properties in a composite structure can be economically advantageous. For example, expensive wear-resistant fillers can be incorporated only into one or more regions with wear-exposed surfaces, while cheaper fillers (e.g., fillers that impart thermal conductivity, mechanical strength, stiffness, or other properties) can be incorporated into one or more other regions of the composite structure.

[0052] Figure 1 This is a schematic diagram of a reciprocating gas compressor system 100 including functionally graded compound rings 104 and 106. The gas compressor system 100 uses a crankshaft-assisted piston 102 to increase the gas pressure level. The gas compressor system 100 includes a frame 116, a cylinder 118, a connecting rod 110, a valve 114, an oil scraper 112, a stuffing box 108, a crosshead, a crankshaft, and bearings. The piston 102 compresses air, thereby transferring energy from the crankcase to the gas contained in the cylinder 118. Piston rings 104 and a slider are disposed between the piston 102 and the wall of the cylinder 118. Rod rings 106 are disposed around the circumference of the rod 110. Due to the continuous movement of the piston 102 and the rod 110 during machine operation, the piston rings 104, slider, and rod rings 106 are subjected to friction and are prone to wear and tear. The durability of the piston rings, slider, and rod rings determines the lifespan of this component.

[0053] In some examples, the functionally graded composite rings described herein may have wear-resistant materials on wear surfaces (e.g., friction-affected surfaces such as those contacting pistons or rods). The presence of wear-resistant materials on wear surfaces improves the ring's durability, thereby extending its lifespan and reducing the frequency of replacement. Another region of the functionally graded composite ring may include materials exhibiting a different property (e.g., thermal conductivity or high mechanical strength or stiffness). Thermally conductive materials can help dissipate heat generated at wear surfaces. High mechanical strength or stiffness materials can provide a robust structure for the composite ring. The ability to combine multiple materials, each with different properties, into a single composite ring allows for the cost-effective at attributing multiple properties to the composite ring.

[0054] Figure 2 This is a schematic diagram of a functional hierarchical composite ring 124 that can be used with mechanical systems, such as... Figure 1 The reciprocating gas compressor system 100 is shown. Figure 2 In the example, ring 124 has a circular cross-section. In some examples, the functionally hierarchical composite ring may have other cross-sectional shapes, such as rectangular, hexagonal, octagonal, or other shapes.

[0055] The functionally graded composite ring 124 can be, for example, a wear ring, rod ring, piston band, wear band, or dynamic sealing ring. The composite ring 124 includes a first polymer region 126 containing a first polymer material and a second polymer region 130 containing a second polymer material. The first polymer region 126 and the second polymer region 130 are concentric; the first polymer region 126 defines the outer periphery of the ring 124, and the second polymer region 130 defines the inner periphery of the ring. An interface region 128 defines a compositional gradient between the first polymer region 126 and the second polymer region 130, such that the compositional gradient is distributed along the radius of the ring. A compositional gradient refers to the change in material composition from one region to another within the same component. In the interface region 128, the ratio of the second polymer material to the first polymer material increases radially toward the inner periphery of the ring 124.

[0056] Between the first polymer region 126 and the second polymer region 130 of ring 124, the material properties differ. For example, the properties that may differ between the regions include abrasion resistance, thermal conductivity, strength, stiffness, or creep resistance. The properties of each polymer region depend on the material composition of that region, the fillers incorporated into the polymer material, the processing conditions during the manufacture of the polymer region, or a combination of the above. By forming the composite ring 124 into multiple polymer regions, each with different properties, the composite ring as a whole exhibits the properties of both polymer regions.

[0057] In the example, the first polymer material and the second polymer material each independently include one or more of the following: polyether ether ketone, polyether ketone, polyether ketone ketone, polyphenylene sulfide, polyimide (PI), perfluoroalkoxy alkane, ultra-high-molecular-weight polyethylene (UHMWPE), polybenzimidazole, polyamide-imide, polyphenylsulfone, and fluoropolymers such as polytetrafluoroethylene. In some cases, the first polymer material and / or the second polymer material may also include one or more of the following: polyetherketone, polyetherketone ether ketone ketone, polyester (aliphatic, aromatic, aliphatic-aromatic), polyetherketone ketone.

[0058] The material of each of the first polymer region 126 and the second polymer region 130 can be selected to impart desired properties to the respective polymer region, such as wear resistance, thermal conductivity, stiffness, mechanical strength, creep resistance, properties at high or low temperatures, resistance to certain chemicals (e.g., resistance to certain gaseous chemicals), or other properties, or combinations thereof. The first polymer region 126 and the second polymer region 130 can have different compositions so that each region has different properties. In some examples, the polymer material itself is selected to impart the desired properties. In some examples, one or more fillers can be added to the polymer material of the first polymer region 126 and / or the second polymer region 130 to impart the desired properties. The filler can be, for example: a solid lubricant or an additive that enhances the wear resistance of the polymer region; a filler that changes (e.g., increases) the thermal conductivity of the region; a filler that changes (e.g., increases) the stiffness of the region; a filler that changes (e.g., increases) the mechanical strength of the region; or any combination thereof. In some cases, the filler includes one or more of the following: molybdenum disulfide, tungsten disulfide, bronze, boron nitride, titanium dioxide, and alumina. In some cases, the filler comprises carbon, such as one or more of the following: carbon powder, carbon particles, carbon fibers, graphene, graphite, carbon nanotubes. In some examples, the filler comprises polymers, such as one or more of the following: polytetrafluoroethylene, polyetheretherketone, polyphenylene sulfide, polyimide, polybenzimidazole. In some cases, the filler comprises glass, such as one or more of the following: glass beads, glass fibers.

[0059] The wear resistance of the first polymer region 126 and the second polymer region 130 can differ, for example, such that a region with greater wear resistance is formed on the wear surface of the composite ring 124. The wear surface of a component (e.g., a composite ring) is a surface subjected to wear, for example, a surface subjected to wear caused by friction generated by the movement of elements such as rods or pistons. Wear resistance is the ability of a material to withstand exposure to wear without damage. For example, the wear resistance of the second polymer region 130 can be greater than that of the first polymer region 126. This configuration, where the second inner polymer region 130 has greater wear resistance, is useful when the composite ring 124 is a rod ring. The rod ring is disposed around the rod, and a seal is formed between the rod and the inner surface of the ring; making the inner surface of the rod ring the wear surface. In some cases, the wear resistance of the first polymer region 126 can be greater than that of the second polymer region 130. This configuration, where the first outer polymer region 126 has greater wear resistance, is useful when the composite ring 124 is a piston ring. The piston ring is arranged around the piston and forms contact between the piston ring and the cylinder wall of the system. When the piston moves up and down, friction occurs between the cylinder wall and the outer surface of the piston ring, making the outer surface of the piston ring a wear surface.

[0060] When one polymer region of the composite ring 124 is a wear-resistant region, another polymer region can be designed to impart other properties to the composite ring 124, such as stiffness, thermal conductivity, mechanical strength, or creep resistance, or combinations thereof. The resulting composite ring 124 has a wear-resistant surface and simultaneously possesses one or more of these other properties. For example, for a rod ring, a second inner polymer region is a wear-resistant material to provide a wear-resistant inner surface, and a first outer polymer region can be a thermally conductive material to dissipate heat generated by friction on the wear surface. The second region has greater wear resistance than the first region, and the first region has greater thermal conductivity than the second region. Optionally or additionally, the first region can be a hard or mechanically strong region to provide a robust physical structure for the ring, such that the stiffness or mechanical strength of the first region is greater than that of the second region. Wear-resistant fillers (e.g., solid lubricants or additives) can be expensive. By introducing wear-resistant material only as part of the entire composite ring 124, material costs can be reduced.

[0061] Fillers that enhance the wear resistance of the reinforced areas may include solid lubricants or wear-resistant additives. Solid lubricants are additives that help improve the wear resistance of the composite material by reducing friction between the composite and the contact surfaces. Solid lubricants themselves are not necessarily wear-resistant, but they contribute to improving the wear resistance of the entire system by reducing friction. Some common examples are polytetrafluoroethylene (PTFE), graphite, boron nitride, and molybdenum disulfide. Wear-resistant additives such as carbon and carbon fibers, glass fibers, alumina, some minerals, and ceramics are harder and naturally wear-resistant materials, and these materials directly contribute to the wear resistance of the composite. The regions of composite ring 124 that include lubricants or wear-resistant additives have greater wear resistance than other regions of composite ring 124. Lubricants may include PTFE, graphite, graphene, molybdenum disulfide (MoS2), boron nitride, tungsten disulfide, or combinations thereof. Fillers may include wear-resistant additives such as alumina, glass, bronze, short carbon fibers, carbon particles or powder, titanium dioxide (TiO2), other ceramics, or combinations thereof. The filler that enhances the thermal conductivity of the region helps dissipate heat from one region of the ring to another. The region of composite ring 124 including the thermally conductive filler has a higher thermal conductivity than other regions of composite ring 124. Fillers used to enhance thermal conductivity may include, for example, molybdenum disulfide, tungsten disulfide, bronze, boron nitride, titanium dioxide or alumina, carbon, carbon powder, carbon particles, carbon fibers, graphene, graphite, carbon nanotubes, or combinations thereof. Fillers that enhance the stiffness or mechanical strength of the region may include, for example, glass or carbon, such as carbon powder, carbon particles, carbon fibers, graphene, graphite, carbon nanotubes, glass beads, or glass fibers, or combinations thereof. Each polymer region 126, 130 may individually include any of the above materials or combinations thereof. The region of composite ring 124 including the filler for stiffness or mechanical strength has a higher stiffness or mechanical strength than other regions of composite ring 124.

[0062] In the examples, the wear-resistant, low-friction region comprises 40-70% PTFE, 20-30% carbon, and 5-20% graphite by weight. In the examples, the wear-resistant, low-friction region comprises 40-70% PTFE, 10-30% glass, and 5-15% MoS2 by weight. In the examples, the wear-resistant, low-friction region comprises 50-70% PEEK, 10-30% PTFE, and 5-20% graphite by weight. In the examples, the wear-resistant, low-friction region comprises 40-70% PEEK, 5-20% carbon fiber, 10-20% PTFE, and 5-15% graphite by weight. In the example, the wear-resistant, low-friction region comprises 40-60% PTFE, 40-60% bronze, and 0-15% glass by weight. In an example where the composite ring comprises a wear-resistant region with a self-lubricating wear surface and a hard, high-mechanical-strength region, the wear-resistant region comprises 50-70% PEEK, 10-30% PTFE, and 5-20% graphite by weight, and the high-mechanical-strength region comprises 70% PEEK and 30% carbon fiber or glass fiber by weight.

[0063] In some examples, small amounts of fillers such as graphene, alumina, or TiO2 may be added (e.g., between 0.5% and 5% by mass) to further enhance the wear resistance of this area. Boron nitride can be used as an alternative to graphite or MoS2. Bronze can be used with, for example, PTFE and glass to improve thermal conductivity.

[0064] In some examples, the functionally graded composite ring 124 includes one or more additional polymer regions, such as three, four, or more than four polymer regions. Each additional polymer region is concentric with and arranged between the first polymer region 126 and the second polymer region 130, such that the first polymer region 126 still defines the outer periphery of the ring 124 and the second polymer region 130 still defines the inner periphery of the ring 124. Each additional polymer region includes a polymer material, which may be the same as or different from the polymer material of regions 126 and 130, respectively. The polymer material of each additional polymer region may include one or more of the following: polyetheretherketone, polyetherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, perfluoroalkoxyalkane, ultra-high molecular weight polyethylene, polyamide-imide, polyphenylene sulfone, fluoropolymers such as PTFE, and combinations thereof. Each additional polymer region may include one or more fillers.

[0065] In some examples, the functionally graded composite ring 124 has an inner diameter d ranging from 1 inch to 5.5 inches.i And has a radial thickness t ranging from 0.3 inches to 0.7 inches. In some examples, the functionally graded composite ring 124 has an outer diameter d ranging from 1 inch to 36 inches. o It has a radial thickness t ranging from 0.15 inches to 1 inch. In some composite rings, about one-third of the radial thickness undergoes wear, and the radial thickness of the wear-resistant region can be between about one-third and one-half of the ring's total radial thickness.

[0066] Figure 3A This is a schematic diagram of a functional hierarchical composite ring 324 that can be used with mechanical systems, such as... Figure 1 The reciprocating gas compressor system 100 is shown. The functionally graded composite ring 324 can be, for example, a wear ring, rod ring, piston band, wear band, or dynamic sealing ring. The composite ring 324 includes a first polymer region 302 formed of a first polymer material and a second polymer region 304 formed of a second polymer material. Each of the first and second polymer regions may independently include one or more fillers to impart desired properties to that region, such as wear resistance, thermal conductivity, mechanical strength, stiffness, creep resistance, or other properties. The first and second polymer regions are arranged radially around the composite ring 324 such that each polymer region occupies a portion of the radial extent of the ring. The inner surface 306 and outer surface 308 of the first polymer region 302 define a first portion of the inner and outer circumferences of the ring 324, respectively. The inner surface 310 and outer surface 312 of the second polymer region 304 define a second portion of the inner and outer circumferences of the ring 324, respectively. Interface regions 314 each define a component gradient between the first polymer region 302 and the second polymer region 304, such that the component gradient is distributed along a portion of the inner and outer periphery of the ring.

[0067] In some examples, each radially arranged polymer region of the composite ring comprises multiple radially arranged partitions. (Reference) Figure 3BThe composite ring 324' includes a first polymer region containing a first polymer material, wherein the first polymer region includes four partitions 326a to 326d. Each of partitions 326a-326d has the same composition, and each partition includes the same first polymer material and the same one or more fillers. The composite ring 324' includes a second polymer region containing a second polymer material, wherein the second region includes four partitions 142a-142d. Each of partitions 142a-142d has the same composition, and each partition includes the same second polymer material and the same one or more fillers. The four partitions 142a-142d of the second polymer region are arranged radially alternately with the four partitions 326a-326d of the first polymer region. Each partition 326a-326d of the first polymer region includes an inner surface 328a-328d and an outer surface 330a-330d, which together define a first portion of the inner and outer circumferences of the ring 324', respectively. Each partition 142a-142d of the second polymer region includes inner surfaces 332a-332d and outer surfaces 334a-334d, which together define a second portion of the inner and outer peripheries of the ring 324', respectively. The interface region 314' between each pair of adjacent partitions defines a component gradient between the first and second polymer regions (e.g., between corresponding partitions of the first and second polymer regions).

[0068] The first polymer material and the second polymer material of the first polymer region and the second polymer region of the composite rings 324 and 324' can be any of the materials listed above for use with... Figure 2 The composite ring 124 comprises a first polymer region and a second polymer region of polymer material. The first polymer region and / or the second polymer region may each independently include one or more fillers to impart properties such as abrasion resistance, thermal conductivity, mechanical strength, stiffness, or creep resistance to the respective region. The fillers may be those referenced above. Figure 2 The fillers described. In the examples, one region of the composite rings 324, 324' is a wear-resistant, low-friction region comprising 60% PEEK, 30% PTFE, and 10% graphite by weight. In the examples, another region of the composite rings 324, 324' is a region of increased thermal conductivity comprising 60% PEEK, 15% carbon fiber, 20% graphite, and 5% graphene by weight. In some examples, the wear-resistant region occupies at least 70% of the total radial extent of the rings 324, 324'.

[0069] In some examples, each polymer region of rings 324, 324' includes more than four partitions or fewer than four partitions. In some examples, rings 324, 324' include three or more radially arranged polymer regions, wherein each region includes one or more partitions.

[0070] In some examples, the dimensions of the functional hierarchical composite rings 324 and 324' in Figure 3 are the same as those of the reference rings. Figure 2 The described composite rings are similar in size.

[0071] Figure 4 This is a schematic diagram of a functionally graded composite bearing 152 that can be used with mechanical systems such as rotating machinery. The functionally graded composite bearing 152 has a multi-layer structure, comprising a first layer 154 formed of a first polymer material, a second layer 156 formed of a second polymer material, and a third layer 158 formed of a third polymer material. The polymer material can be as described above. Figure 2 The polymer materials described. Each layer may include fillers (e.g., those referenced above). Figure 2 The fillers described herein impart certain properties to the layer, such as wear resistance, thermal conductivity, stiffness, mechanical strength, or creep resistance. A first layer 154 is disposed on a second layer 156, and a second layer 156 is disposed on a third layer 158. Interface regions 160 and 162 define compositional gradients between the first layer 154 and the second layer 156, and between the second layer 156 and the third layer 158, respectively. In the example, the first layer 154 is a wear-resistant layer comprising PEEK and 0-15% by mass PTFE, 0-15% by mass graphite, and 0-10% by mass carbon fiber; and the second layer 156 and the third layer 158 provide mechanical strength and stiffness for the bearing and comprise PEEK and 30% by mass carbon fiber, while the first layer 154 comprises PEEK and 10% by mass PTFE, 10% by mass graphite, and 10% by mass carbon fiber. The functional graded composite bearing 152 may be an all-plastic bearing comprising one or more layers of bearing-grade polymer and one or more layers of strength backing polymer.

[0072] Figure 5 This is a schematic diagram of bearing assembly 502, which includes bearing 504 and such Figure 4 The bearing pad 506 shown is for use, for example, with mechanical systems such as rotating machinery. The bearing assembly 502 also includes an inner pad 508 arranged around the inner surface of the bearing.

[0073] In some examples, the bearing pad 506 of the bearing assembly 502 is a polymer liner pad, and each polymer liner pad includes, for example... Figure 4The polymer sheet, like that of the multilayer polymer bearing 152, is bonded to a metal backing. This configuration can help reduce the rate of interfacial debonding between the polymer and metal materials, thus helping to prevent failure. In some examples, the inner pad 508 is also a polymer pad.

[0074] Figures 6A-6E This is a schematic diagram of a manufacturing method for a functionally hierarchical composite structure. (Reference) Figure 6A A first polymer powder 192 is provided to a portion 197 (shown in cross-section) of a cylindrical mold 190. The mold is a frame that can be filled with raw materials such as polymers, glass, metals, or ceramics. The shape of the mold approximates the shape of the desired final part. A second polymer powder 194 is provided to a portion 198 of the mold 190. The two polymer powders 192, 194 are separated by a temporary separator 196 disposed between each portion 197, 198 of the mold 190. To form a structure comprising a polymer with fillers or additives, the fillers or additives are mixed with the polymer powders prior to molding, and the mixed powders are placed into the mold 190.

[0075] refer to Figure 6B Once each section of the mold 190 is filled with powders 192 and 194, the temporary separator 196 is removed. The removal of the temporary separator 196 brings the powders 192 and 194 into contact, resulting in limited mixing between the powders, which will create a component gradient in the interfacial region of the resulting composite structure.

[0076] refer to Figures 6C-6D The first polymer powder 192 and the second polymer powder 194 are compressed in a mold 190 by applying force 208 using a press 206. The compressed powders generate a composite preform 218 (e.g., ...). Figure 6D (As shown). The composite preform 218 includes a first region 220 formed by compressing a first polymer powder 192, a second region 222 formed by compressing a second polymer powder 194, and an interface region 224 defining a component gradient between the first region 220 and the second region 222. In some cases, the mold 190 is heated during the compression process, which facilitates a uniform distribution of powder in each region.

[0077] The filling of the mold can also be achieved by the automatic feeding system in the powder bed melt additive manufacturing system through the simultaneous co-deposition (or coaxial, concentric deposition) of powder, thereby eliminating the need for temporary separators.

[0078] In the examples, to form a billet from PTFE powder, a pressure of 4000-8000 psi is applied to the first end of the die for 4-10 minutes at ambient temperature. In the examples, to form a billet from PEEK powder, a pressure of 8000-10000 psi is applied for 4-10 minutes at ambient temperature. In some examples, to create the geometry of the supply shape (e.g., a 6-8 inch long billet), the die is inverted relative to the press, and pressure is applied from the other end of the die, for example, to homogenize the effect of the applied pressure along the length of the billet.

[0079] refer to Figure 6E In the example shown, the composite preform 218 is separated from the mold 190. The preform 218 is heat-treated (e.g., sintered) to form a solid, compacted supply shape 232. For example, a preform formed from compressed PTFE powder is removed from the mold and, for example, sintered at a temperature of 675°F–700°F for 4–10 hours, depending on the size of the preform. In some examples, heat treatment such as sintering is performed while the preform is still in the mold. For example, a preform formed from compressed PEEK powder is sintered in the mold at a temperature of 730°F–770°F for 8–12 hours. Pressure is applied to the hot mold (e.g., thermoforming) while the sintered material is hot and molten. This additional pressure application improves the melting and quality of the material. In one example of the thermoforming process, a first polymer powder 192 and a second polymer powder 194 are first formed in a press at room temperature and then sent for sintering. At the end of sintering, when the material heats up and melts, the mold is moved back to the press to compress the material in the mold.

[0080] Refer again Figure 6E The supply shape 232 is machined into a composite ring or composite bearing having the desired size and shape. The finished component may be, for example, a ring 124 comprising a first polymer region 126 and a second polymer region 130. A similar process may be used for blanks formed from other polymer materials (e.g., PPS, UHMWPE, PI, and / or combinations thereof), wherein the sintering temperature is higher than the melting temperature of the material.

[0081] The functional hierarchical composite structures described herein can also be manufactured using other technologies, such as injection molding, casting, 3D printing, laser cutting and texturing, extrusion, micromachining, co-forming, re-flow, electron beam melting, and / or other suitable technologies.

[0082] refer to Figure 7A method for manufacturing a composite ring or composite bearing includes providing a first polymer powder (178) to a first portion of a mold and a second polymer powder (180) to a second portion of the mold. The polymer powder may be, for example, polyetheretherketone, polyphenylene sulfide, polyimide, perfluoroalkoxyalkane, ultra-high molecular weight polyethylene, polybenzimidazole, polyamide-imide, polyphenylene sulfone, fluoropolymers such as PTFE, polyetherketone, polyetherketone-ketone-ketone, or polyetherketone-ketone. One or more fillers or additives may be mixed with the polymer powder prior to molding, and the mixed polymer powder may be provided to the mold. The filler may be, for example, molybdenum disulfide, tungsten disulfide, bronze, boron nitride, titanium dioxide, alumina, carbon powder, carbon particles, carbon fiber, graphene, graphite, carbon nanotubes, PTFE, polyetheretherketone, polyphenylene sulfide, polyimide, polybenzimidazole, glass beads, glass fiber, or combinations thereof.

[0083] A composite preform is generated by applying force to compress a first polymer powder and a second polymer powder in a mold (182). In some examples, the mold is heated during the compression process.

[0084] The composite preform is separated from the mold (184) and sintered (186). In some examples, the composite preform is sintered simultaneously in the mold. The sintered composite preform is machined to form a functionally graded composite ring or composite bearing (188).

[0085] While this specification contains numerous specific implementation details, these details should not be construed as limiting the scope of the claims, but merely as descriptions of features that may be specific to particular embodiments. Certain features described in the context of individual embodiments may also be implemented in combination in a single embodiment. Accordingly, various features described in the context of a single embodiment may also be implemented individually or in any suitable sub-combination in multiple embodiments. Furthermore, although the features foregoing description may be described as functioning in certain combinations, and even initially constructed in this manner, in some cases one or more features from the claimed combination may be removed, and the claimed combination may be directed to sub-combinations or variations thereof.

[0086] Specific embodiments of the subject matter have been described. Those skilled in the art will understand that other embodiments, variations, and combinations of the described embodiments also fall within the scope of the appended claims. Although operations are described in a specific order in the drawings or claims, this should not be construed as requiring that such operations be performed in the specific order shown or sequentially, or requiring that all shown operations be performed (some operations may be considered optional) to achieve the desired result.

[0087] Therefore, the exemplary embodiments described above do not limit or restrict this disclosure. Other changes, substitutions, and modifications are possible without departing from the spirit and scope of this disclosure.

[0088] Several embodiments of these systems and methods have been described. However, it should be understood that various modifications can be made without departing from the spirit and scope of this disclosure. Therefore, other implementations also fall within the scope of the appended claims.

Claims

1. A composite ring, the composite ring comprising: A first region, the first region comprising a first polymer material; A second region, the second region comprising a second polymer material; as well as An interface region defining a component gradient between the first region and the second region, wherein the interface region is formed by compressing the first polymer material and the second polymer material in a cylindrical mold to produce the composite ring; The wear resistance of the first region is different from that of the second region.

2. The composite ring according to claim 1, wherein, The thermal conductivity of the first region is different from that of the second region.

3. The composite ring according to any one of the preceding claims, wherein, The stiffness of the first region is different from that of the second region.

4. The composite ring according to claim 1, wherein, The mechanical strength of the first region is different from that of the second region.

5. The composite ring according to claim 1, wherein, The wear resistance of the first region is greater than that of the second region.

6. The composite ring according to claim 5, wherein, The thermal conductivity of the second region is greater than that of the first region.

7. The composite ring according to claim 5 or 6, wherein, The stiffness of the second region is greater than that of the first region, and / or the mechanical strength of the second region is greater than that of the first region.

8. The composite ring according to claim 1, wherein, The first polymer material and the second polymer material each independently include one or more of the following: polyetheretherketone, polyetherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, perfluoroalkoxyalkane, ultra-high molecular weight polyethylene, polybenzimidazole, polyamide-imide, polyphenylene sulfone, polyester, and fluoropolymers.

9. The composite ring according to claim 8, wherein, The first polymer material and / or the second polymer material include polytetrafluoroethylene.

10. The composite ring according to claim 8 or 9, wherein, The first polymer material and / or the second polymer material includes one or more of the following: polyetherketone, polyetherketone etherketone ketone, polyetherketone ketone.

11. The composite ring according to claim 1, wherein, The component gradient is distributed along the radius of the composite ring.

12. The composite ring according to claim 11, wherein, The surface of the first region defines the outer periphery of the composite ring, and the surface of the second region defines the inner periphery of the composite ring.

13. The composite ring according to claim 12, wherein, The wear resistance of the first region is greater than that of the second region.

14. The composite ring according to claim 12, wherein, The wear resistance of the second region is greater than that of the first region.

15. The composite ring according to claim 1, wherein, The component gradient is distributed along a portion of the outer periphery of the composite ring.

16. The composite ring according to claim 1, wherein, The component gradient is distributed along a portion of the inner circumference of the composite ring.

17. The composite ring according to claim 1, wherein, The first surface of the first region defines a portion of the inner periphery of the composite ring, and the second surface of the first region defines a portion of the outer periphery of the composite ring.

18. The composite ring according to claim 17, wherein, The first surface of the second region defines a portion of the inner periphery of the composite ring, and the second surface of the second region defines a portion of the outer periphery of the composite ring.

19. The composite ring according to claim 1, wherein the composite ring comprises one or more additional regions, each additional region comprising a polymer material, the polymer material independently comprising one or more of the following: polyetheretherketone, polyetherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, perfluoroalkoxyalkane, ultra-high molecular weight polyethylene, polyamide-imide, polyphenylene sulfone, and fluoropolymers.

20. The composite ring according to claim 19, wherein, One or more of the additional regions comprise polytetrafluoroethylene.

21. The composite ring according to claim 1, wherein, The first region and / or the second region independently include filler.

22. The composite ring according to claim 21, wherein, The filler includes a solid lubricant.

23. The composite ring according to claim 21 or 22, wherein, The filler includes wear-resistant additives.

24. The composite ring according to claim 21, wherein, The filler includes one or more of the following: molybdenum disulfide, tungsten disulfide, bronze, boron nitride, titanium dioxide, and aluminum oxide.

25. The composite ring according to claim 21, wherein, The filler includes carbon.

26. The composite ring according to claim 25, wherein, The filler includes one or more of the following: carbon powder, carbon particles, carbon fiber, graphene, graphite, and carbon nanotubes.

27. The composite ring according to claim 21, wherein, The filler comprises a polymer.

28. The composite ring according to claim 27, wherein, The filler includes one or more of the following: polytetrafluoroethylene, polyetheretherketone, polyphenylene sulfide, polyimide, and polybenzimidazole.

29. The composite ring according to claim 21, wherein, The filler includes glass.

30. The composite ring according to claim 21, wherein, The filler includes one or more of the following: glass beads, glass fibers.

31. The composite ring according to claim 1, wherein, The composite ring is a wear ring, rod ring, piston band, wear band, or dynamic sealing ring.

32. A composite bearing, the composite bearing comprising: The first layer includes a first polymer material and a first filler; The second layer is disposed on the first layer, and the second layer includes a second polymer material and a second filler. as well as An interface region defining a component gradient between the first layer and the second layer, wherein the interface region is formed by compressing the first polymer material and the second polymer material in a cylindrical mold to produce a composite ring; Wherein, the wear resistance of the first layer is greater than that of the second layer, and the mechanical strength of the second layer is greater than that of the first layer.

33. The composite bearing according to claim 32, wherein, The thermal conductivity of the first layer is different from that of the second layer.

34. The composite bearing according to claim 32 or 33, wherein, The stiffness of the first layer is different from that of the second layer.

35. The composite bearing according to claim 33, wherein, The thermal conductivity of the second layer is greater than that of the first layer.

36. The composite bearing according to claim 35, wherein, The stiffness of the second layer is greater than that of the first layer.

37. The composite bearing according to claim 32, wherein, The first polymer material and the second polymer material each independently include one or more of the following: polyetheretherketone, polyetherketone, polyetherketoneketone, polyphenylene sulfide, polyimide, perfluoroalkoxyalkane, ultra-high molecular weight polyethylene, polybenzimidazole, polyamide-imide, polyphenylene sulfone, and fluoropolymers.

38. The composite bearing according to claim 37, wherein, The first polymer material and / or the second polymer material include polytetrafluoroethylene.

39. The composite bearing according to claim 37 or 38, wherein, The first polymer material and / or the second polymer material includes one or more of the following: polyetherketone, polyetherketone etherketone ketone, polyetherketone ketone.

40. The composite bearing of claim 32, wherein the composite bearing comprises one or more additional layers, each additional layer comprising a polymer material, the polymer material independently comprising one or more of the following: polyetheretherketone, polyphenylene sulfide, polyimide, perfluoroalkoxyalkane, ultra-high molecular weight polyethylene, polyamide-imide, polyphenylene sulfone, and fluoropolymers.

41. The composite bearing according to claim 40, wherein, One or more of the additional layers comprise polytetrafluoroethylene.

42. The composite bearing according to claim 32, wherein, The first packing and the second packing include a lubricant.

43. The composite bearing according to claim 32, wherein, The first filler and the second filler include wear-resistant additives.

44. The composite bearing according to claim 32, wherein, The first packing and the second packing include one or more of the following: molybdenum disulfide, tungsten disulfide, bronze, boron nitride, titanium dioxide, and alumina.

45. The composite bearing according to claim 32, wherein, The first packing and the second packing comprise carbon.

46. ​​The composite bearing according to claim 45, wherein, The first filler and the second filler include one or more of the following: carbon powder, carbon particles, carbon fiber, graphene, graphite, and carbon nanotubes.

47. The composite bearing according to claim 32, wherein, The first filler and the second filler comprise polymers.

48. The composite bearing according to claim 47, wherein, The first filler and the second filler include one or more of the following: polytetrafluoroethylene, polyether ether ketone, polyphenylene sulfide, polyimide, and polybenzimidazole.

49. The composite bearing according to claim 32, wherein, The first packing and the second packing comprise glass.

50. The composite bearing according to claim 48, wherein, The first filler and the second filler include one or more of the following: glass beads, glass fibers.

51. A method for manufacturing a compression-molded composite preform, the method comprising: A first polymer powder is supplied to the first part of the mold; A second polymer powder is provided to the second part of the mold; The first polymer powder and the second polymer powder are compressed in the mold to produce a composite preform, the composite preform comprising: A first region, the first region comprising a first polymer material formed by compressing the first polymer powder; A second region, the second region comprising a second polymer material formed by compressing the second polymer powder; and An interface region defining a component gradient between the first region and the second region, wherein the interface region is formed by compressing a mixture of the first polymer material and the second polymer material in the mold; and The composite blank is separated from the mold.

52. The method according to claim 51, wherein the method comprises: The mold is heated while compressing the first polymer powder and the second polymer powder.

53. The method according to claim 51 or 52, wherein the method comprises: The composite blank is sintered.

54. The method according to claim 53, further comprising: After sintering, the material is compressed in the mold while it is still hot.

55. The method according to claim 51 or 52, wherein the method comprises: The composite blank is then machined.

56. The method according to claim 55, wherein, Machining the composite blank includes forming a ring from the composite blank.

57. The method according to claim 56, wherein, The ring is a wear ring, rod ring, piston band, wear band, or dynamic sealing ring.

58. A machine component, the machine component comprising: A main body configured to be coupled to a moving axis, the main body comprising A first region, the first region comprising a first polymer material; A second region, the second region comprising a second polymer material; and Two or more interface regions, wherein at least one of the interface regions defines a composition gradient between the first region and the second region, wherein the interface regions are formed by compressing the first polymer material and the second polymer material in a cylindrical mold to produce a composite ring; Wherein, one or more physical properties of the first region are different from one or more corresponding physical properties of the second region.

59. The machine component according to claim 58, wherein, At least one of the physical properties is wear resistance.

60. The machine component according to claim 58 or 59, wherein, At least one of the two or more interface regions defines a component gradient in the circumferential direction.

61. The machine component according to claim 58 or 59, wherein, Each of at least two of the interface regions defines a component gradient in the circumferential direction.

62. The machine component according to claim 58 or 59, wherein, At least one of the interface regions defines a component gradient in the radial direction.

63. The machine component according to claim 58 or 59, wherein, The body includes a third region comprising a third polymer material, wherein at least one of the two or more interface regions defines a component gradient between the second region and the third region.

64. The machine component according to claim 58 or 59, wherein, The body includes a ring configured for coupling with a reciprocating rod.

65. The machine component according to claim 58 or 59, wherein, The component includes a bearing, wherein the body includes a bearing pad.

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