Jound foil bearing system with top foil insert member

Abstract

A foil bearing system includes a journal member having an internal groove and a foil arrangement. The foil arrangement includes at least one offset foil and a top foil insertion member. The at least one offset foil is received between the journal member and the shaft in a radial direction relative to the axis. The top foil insert member includes a top foil and a ridge insert. The top foil includes an arcuate portion disposed in a radial direction between the at least one offset foil and the shaft and extending in a circumferential direction about the axis. The top foil includes an end extending from an arcuate portion. A ridge insert is received within the interior groove, and the ridge insert is fixedly attached to an end of the top foil.

Description

Technical Field

[0001] This disclosure generally relates to bearing systems, and more specifically, to journal foil bearing systems with top foil insert members. Background Technology

[0002] Various bearing systems are configured to support the rotation of a shaft within a housing. For example, turbines (e.g., turbochargers, superchargers, and other compressor equipment) may include one or more air bearings. These bearings preferably support the efficient rotation of the shaft under a wide range of operating conditions and throughout its long service life.

[0003] Some devices include foil bearing systems (i.e., journal foil bearing systems, foil-air bearing systems, air foil journal bearings, etc.). These bearings comprise one or more foils radially disposed between the shaft and the housing, wherein, when stationary, the foil(s) apply an inwardly directed radial preload to the shaft. The bearing disengagement speed (lifting speed) is affected by the magnitude of the preload applied to the shaft. Furthermore, bearing wear is also affected by the magnitude of the applied preload. Additionally, the foil(s) preferably possess sufficient stiffness to provide acceptable rotational dynamics / shaft motion control across the entire operating speed range of the shaft.

[0004] However, customizing and controlling these factors remains challenging for traditional foil bearing systems. For example, controlling certain dimensions of bearing components can be difficult, potentially leading to unacceptable preload in the foil bearing. The manufacturing efficiency of these bearing systems may also be low for various reasons. For instance, forming, assembling, and / or controlling the dimensions of bearing components can require significant labor and / or energy. Furthermore, there may be a large number of parts, complex structures, etc. This can increase costs and make handling and assembly more difficult.

[0005] Therefore, there is a need for a foil bearing system that enables precise and selective control of bearing support load, foil bearing system disengagement speed, and / or other characteristics of the bearing system. Furthermore, there is a need for a foil bearing system that provides manufacturing and assembly efficiency. Other desirable features and characteristics of this disclosure will become apparent from the following detailed description of embodiments, taken in conjunction with the accompanying drawings and the discussion of the background art, and from the appended claims. Summary of the Invention

[0006] In one embodiment, a foil bearing system is disclosed, comprising a journal member having a bore and an internal groove within the bore. The foil bearing system also includes a shaft received within the bore. The foil bearing system further includes a foil arrangement supporting the shaft for rotation about an axis relative to the journal member. The internal groove extends substantially along the axis. The foil arrangement includes at least one bias foil and a top foil insert member. The at least one bias foil is received radially relative to the axis between the journal member and the shaft. The top foil insert member includes a top foil and a ridged insert. The top foil includes an arcuate portion radially disposed between the at least one bias foil and the shaft, and extending circumferentially about the axis. The top foil includes an end extending from the arcuate portion. The ridged insert is received within the internal groove and is securely attached to the end of the top foil.

[0007] In another embodiment, a method of manufacturing a foil bearing system is disclosed, the method comprising providing a journal member having a bore and an internal groove located within the bore. The method further comprises positioning a shaft within the bore. Furthermore, the method comprises using a foil arrangement to support the shaft, allowing it to rotate relative to the journal member about an axis, the internal groove extending substantially along the axis, the foil arrangement comprising at least one bias foil and a top foil insert member. The top foil insert member comprises a top foil and a ridged insert fixedly attached to the top foil. The method further comprises positioning at least one bias foil radially between the journal member and the shaft relative to the axis. Furthermore, the method comprises positioning an arcuate portion of the top foil radially between at least one bias foil and the shaft, the arcuate portion extending circumferentially about the axis, the top foil including an end extending from the arcuate portion. Furthermore, the method comprises positioning the ridged insert within the internal groove, the ridged insert being fixedly attached to the end of the top foil.

[0008] In another embodiment, a foil bearing system is disclosed. The foil bearing system includes a journal member having a bore and an internal groove within the bore. The foil bearing system also includes a shaft received within the bore and a foil arrangement supporting the shaft for rotation about an axis relative to the journal member. The internal groove extends substantially along the axis, and the foil arrangement includes at least one bias foil and a top foil insert member. The at least one bias foil is received radially relative to the axis between the journal member and the shaft. The top foil insert member includes a top foil and a ridged insert. The top foil includes an arcuate portion, a first end, and a second end. The arcuate portion extends between the first and second ends and is radially disposed between the at least one bias foil and the shaft, extending circumferentially about the axis. The first and second ends extend radially from the arcuate portion. The ridged insert includes a separator disposed between and separating the first and second ends, and the ridged insert includes an abutment member extending from the separator. The ridged insert is received within an internal groove, and the abutment member is configured to abut the inner surface of the groove. The ridged insert is fixedly attached to a first end of the top foil, and a second end is separate from the ridged insert. Attached Figure Description

[0009] The present disclosure will now be described in conjunction with the accompanying drawings, wherein like reference numerals denote like elements, and in the drawings:

[0010] Figure 1 This is a schematic diagram of an engine system with a turbine according to an exemplary embodiment of the present disclosure, the turbine including a foil bearing system;

[0011] Figure 2 According to the example embodiment Figure 1 An axial end view of a turbine, in which parts are hidden to show an example foil bearing system of the turbine;

[0012] Figure 3 yes Figure 2 Detailed end view of the foil bearing system;

[0013] Figure 4 yes Figure 2 A perspective view of the top foil insertion component of the foil bearing system;

[0014] Figure 5 This is a detailed end view of a foil bearing system according to an additional embodiment of the present disclosure;

[0015] Figure 6 This is a detailed end view of a foil bearing system according to an additional embodiment of the present disclosure; and

[0016] Figure 7 yes Figure 6 A perspective view of the ridge-shaped insert of the foil bearing system. Detailed Implementation

[0017] The following specific embodiments are merely exemplary in nature and are not intended to limit this disclosure or its application and use. Furthermore, this disclosure is not intended to be bound by any theory presented in the foregoing background or the following specific embodiments.

[0018] In a broader sense, the exemplary embodiments disclosed herein include an improved foil bearing system. This foil bearing system has a robust construction. Bearing characteristics (e.g., stiffness, dimensions, spring bias load, etc.) can be precisely controlled. The bearing system also includes features that improve manufacturing efficiency. The number of parts is relatively low. Furthermore, the bearing system is relatively compact. The manufacture and assembly of this journal foil bearing system can be performed efficiently, accurately, and repeatably. These and other advantages will be discussed herein.

[0019] In some embodiments, the foil bearing system includes at least one bias foil and a top foil insert member. The top foil insert member may include at least one top foil and a ridge insert that at least partially surrounds a shaft segment, the ridge insert supporting the at least one top foil. The at least one top foil may be securely attached to the ridge insert at one end. The ridge insert may include a separator that separates the attached end of the top foil from the other end. This provides several advantages. For example, the configuration of this top foil insert member provides robust support for one or more bias foils, shafts, etc. The pressure exerted by the top foil on the shaft is controlled according to the dimensions of the ridge insert. Therefore, these pre-constraints can be selected and controlled to customize the bearing system. During operation, the top foil compresses the spring foil and grows (extends) in the radial direction, thereby creating radial displacement of the spring foil and reducing the pressure transmitted to the shaft. The spring characteristics of the top foil can be precisely controlled according to one or more dimensions of the separator of the ridge insert.

[0020] Furthermore, the ridged insert can be accommodated in a groove formed in the journal member of the bearing housing. This groove can be easily and precisely manufactured. The abutment between the ridged insert and the inner surface of the groove securely holds the top foil insert member within the assembly.

[0021] Furthermore, the top foil insert member improves operability and offers several manufacturing and assembly advantages. The top foil insert member, with a top foil securely attached to the ridge insert, can be operated as a single unit, for example, to facilitate the positioning of the ridge insert within a recess in the bearing housing. This configuration also makes replacement and maintenance of the bearing system easier.

[0022] Figure 1 This is a schematic diagram of an example turbine, such as a turbocharger 100 included within engine system 101. Turbocharger 100 may include one or more features of this disclosure. It should be understood that in various embodiments of this disclosure, turbocharger 100 may be other turbomachinery, such as a supercharger, compressor equipment, electric motor-driven turbomachinery, etc. Furthermore, without departing from the scope of this disclosure, the turbines of this disclosure may be included in many systems other than engine systems.

[0023] The turbocharger 100 may include a housing 103 and a rotating assembly 102, the rotating assembly 102 being supported within the housing 103 by a bearing system 105 for rotation about an axis 104. The bearing system 105 may include and / or define at least one air journal foil bearing, as described below.

[0024] As shown in the illustrated embodiment, housing 103 may include turbine housing 106, compressor housing 107, and bearing housing 109. Bearing housing 109 may be disposed between turbine housing 106 and compressor housing 107.

[0025] Furthermore, the rotating assembly 102 may include a turbine impeller 111, a compressor impeller 113, and a shaft 115. The turbine impeller 111 is substantially located within a turbine housing 106. The compressor impeller 113 is substantially located within a compressor housing 107. The shaft 115 extends along the axis of rotation 104, passing through a bearing housing 109, to connect the turbine impeller 111 to the compressor impeller 113. Thus, the turbine impeller 111 and the compressor impeller 113 rotate together as a single unit about the axis 104.

[0026] The turbine housing 106 and turbine impeller 111 cooperate to form a turbine (i.e., turbine section, turbine stage), which is configured to circumferentially receive high-pressure and high-temperature exhaust gas flow 121 from an engine, such as from the exhaust manifold 123 of an internal combustion engine 125. Therefore, the turbine impeller 111 and other components of the rotating assembly 102 are driven to rotate about axis 104 by the high-pressure and high-temperature exhaust gas flow 121, which transforms into a low-pressure and low-temperature exhaust gas flow 127 and is released into the downstream exhaust pipe 126.

[0027] The compressor housing 107 and the compressor impeller 113 form a compressor (i.e., a compressor section, compressor stage). The compressor impeller 113 is driven to rotate by an exhaust-driven turbine impeller 111. The compressor impeller 113 is configured to compress incoming input air 131 (e.g., ambient air or pressurized air from a previous stage in a multi-stage compressor) into a pressurized airflow 133, which is ejected circumferentially from the compressor housing 107. The compressor housing 107 may have a shape (e.g., a vortex or other shape) configured to guide and pressurize the air ejected from the compressor impeller 113. Due to the compression process, the pressurized airflow is characterized by an increased temperature, higher than that of the input air 131.

[0028] The pressurized airflow 133 can be directed through an air cooler 135 (i.e., an intercooler), such as a convection-cooled turbocharged air cooler. The air cooler 135 can be configured to dissipate heat from the pressurized airflow 133, thereby increasing its density. The resulting cooled and pressurized output airflow 137 is directed into the intake manifold 139 of the internal combustion engine 125, or alternatively, into a subsequent stage, tandem compressor. The operation of this system can be controlled by an ECU 151 (engine control unit), which is connected to the rest of the system via a communication link 153.

[0029] The bearing system 105 provides robust performance. The bearing system 105 also offers manufacturing and other advantages, which will be discussed below. The bearing system 105 disclosed herein can be configured as... Figure 1 The turbocharger 100 shown is illustrated; however, those skilled in the art will understand that the bearing system 105 of this disclosure can be configured for other systems with rotating shafts (e.g., generators, steam engines, gas turbine engines, and other turbomachinery) without departing from the scope of this disclosure.

[0030] Now for reference Figure 2 and Figure 3 The bearing system 105 of this disclosure will be discussed in more detail with reference to exemplary embodiments. As shown, the bearing system 105 may be configured as a journal foil bearing system. The bearing system 105 typically includes a journal member 160 having a bore 162 for receiving a portion 164 of a shaft 115. The bearing system 105 may also typically include a foil arrangement 170 radially disposed between the journal member 160 and the portion 164 of the shaft 115. Thus, the foil arrangement 170 may support the shaft 115 to rotate about an axis 104 relative to the journal member 160, as will be discussed below. The foil arrangement 170 may be constructed in various ways (e.g., employing a bump-type foil spring, a leaf-type foil spring, etc.) without departing from the scope of this disclosure.

[0031] Shaft segment 164 may have a circular cross-section. Shaft segment 164 may include an outer diameter surface 190 ( Figure 3 The outer diameter surface is smooth and oriented at axis 104 ( Figure 1 Centered on ), shaft segment 164 can be supported in... Figure 2 and Figure 3 Rotate counterclockwise from the viewpoint (as shown by arrow 200).

[0032] In some embodiments, the journal member 160 may be relative to the bearing housing 109 ( Figure 1 The journal member 160 is fixed (e.g., attached thereto) to the surrounding portion of the bearing housing 109. The journal member 160 may be integrally attached to another portion of the bearing housing 109. The journal member 160 may be an internal region of the bearing housing 109 through which the bore 162 extends. The bore 162 may have an inner radius surface 192 having a circular cross-section and a radius 172 (measured from axis 104 to the inner radius surface 192). The radius 172 may be slightly larger than the radius of the segment 164 of the shaft 115. Therefore, an annular gap 174 may be defined between the outer radius surface 190 of the shaft 115 and the inner radius surface 192 of the journal member 160. The gap 174 may receive a foil arrangement 170. The dimensions of the gap 174 may be determined based on the dimensions of the foil arrangement 170, the spring stiffness, and / or other characteristics provided by it.

[0033] The journal member 160 may also include an internal groove 176 (i.e., a first internal groove). The groove 176 may be elongated and may extend along the axis of rotation 104 of the shaft 115, and the groove 176 may be recessed into the inner diameter surface 192 of the bore 162. In some embodiments, the groove 176 may have a longitudinal axis 178 substantially parallel to the axis of rotation 104. Figure 1 ).

[0034] Figure 3 An example cross-sectional profile of the groove 176 (orthogonal to the groove axis 178) is shown. The cross-sectional profile may be defined by a plurality of inner surfaces, some of which may be smooth and flat. The cross-sectional profile may include at least three flat inner portions extending along the longitudinal axis 178. In some embodiments, the inner edges may be rounded. The cross-sectional profile may remain substantially constant along most of the length of the journal member 160. In some embodiments, the cross-sectional profile of the groove 176 may remain constant along the length of the journal member 160.

[0035] In some embodiments, the recess 176 may be defined by a substantially flat recessed surface 180, which may be disposed substantially parallel to the tangential plane of the inner radius surface 192. The recessed surface 180 may define a depth dimension 182 of the recess 176 (e.g., measured as the difference between the radii of the inner diameter surface 192 and the recessed surface 180). The recess 176 may also be defined by a substantially flat first side surface 184 and a substantially flat second side surface 186. The first side surface 184 and the second side surface 186 may extend substantially radially along the depth direction of the recess 176. The first side surface 184 may extend radially between the inner radius surface 192 and the recessed surface 180. The second side surface 186 may extend radially from the inner radius surface 192, and an inclined surface 163 may extend from the second side surface 186 to the recessed surface 180.

[0036] It should be understood that the groove 176 is very easy to manufacture. The groove 176 can be easily machined within the hole 162. For example, in some embodiments, the groove 176 can be machined using a broaching tool. This allows for a larger space and channel to form the hole 162. Furthermore, the flat surfaces 180, 184, 186, and 163 of the groove 176 can be formed relatively easily and can be machined to higher tolerances (for high-precision machining). Figure 2 As shown, journal member 160 may include one or more second recesses 210. As shown, there are two second recesses 210, and these second recesses may be angularly spaced from recess 176 about axis 104 (e.g., spaced approximately 120° apart). The second recesses 210 may have a different cross-sectional profile than recess 176. For example, the second recesses 210 may have a generally rectangular cross-sectional profile.

[0037] The foil arrangement 170 may include at least one bias foil 202. Figure 3 ) and top foil insert component 211 ( Figure 3 and Figure 4 One or more bias foils 202 may provide a spring biasing force to shaft segment 164 (e.g., by providing a radially oriented biasing force thereto). A top foil insert member 211 may cover shaft segment 164 and support bending of one or more bias foils 202. The top foil insert member 211 may also be partially received within an inner recess 176. Furthermore, portions of one or more bias foils 202 may be received within the inner recess 176, while other portions may be received within one or more second recesses 210. Figure 2 and Figure 3The diagram shows the foil arrangement 170 in a stationary state with the shaft 115 stationary. A portion of the foil arrangement 170 is in contact with the shaft 115 to support it. However, once the shaft 115 rotates fast enough, the working fluid (e.g., air) may push against the foil arrangement 170 and cause it to bend elastically away from the shaft 115 to support its rotation.

[0038] The bias foil 202 (i.e., spring foil, spring foil arrangement, etc.) may include at least one flexible and elastic sheet or foil extending arcuately within the gap 174. Multiple sheets or foils may be arranged end-to-end around axis 104. Figure 2 As shown, there may be three bias foils 202 that are equidistant from each other around axis 104. Figure 3 A portion of an exemplary bias foil 202 is shown. As illustrated, the bias foil 202 may include an arcuate portion 208 extending in a circumferential direction, which is radially disposed between the journal member 160 and the shaft segment 164. The bias foil 202 may also include an end portion 206 extending radially away from the arcuate portion 208 and away from the axis 104. The end portion 207 of the end portion 206 may be further bent (turned) outward (flipped) in a tangential direction relative to the circle centered on the axis 104. Figure 3 The bias foil 202 shown has an end portion 206 that extends radially outward to be received in an inner recess 176. An end portion 207 may oppose a side surface 186 of the recess 176. During operation, the end portion 207 may abut against surface 186 to limit rotation of the bias foil 202. Figure 2 As shown, the ends 206 of the other bias foils 202 can be similarly accommodated in the second groove 210.

[0039] It should be understood that the bias foil 202 can be configured in various shapes, sizes, and specifications, and have different surface features, materials, and / or other arrangements to provide ideal bearing performance. In some embodiments, the arcuate portion 208 may be ripple-shaped, corrugated, wave-shaped, or other patterns to affect the flexibility and elasticity of the foil arrangement 170.

[0040] According to the example embodiment, the top foil insert member 211 is as follows: Figures 2-4 As shown in the figure. In some embodiments, the top foil insert member 211 may typically include at least one top foil 212 and a ridge insert 250.

[0041] In some embodiments, a single arc-shaped boundary top foil 212 may be present in the foil arrangement 170. The top foil 212 may be a sheet of material extending about axis 104. The top foil 212 may be partially annular, having a first end 214, a second end 216, and an intermediate portion 218 extending circumferentially between the first end 214 and the second end 216. The intermediate portion 218 may be circular and may follow a substantially circular path. The intermediate portion 218 may be radially disposed between one or more bias foils 202 and the outer radius surface 190 of the shaft segment 164. The bias foil 202 may abut against the outer radial side 213 of the top foil 212. The inner radial side 215 of the top foil 212 may (stack) cover and abut against the outer radius surface 190 of the shaft segment 164. The first end 214 and the second end 216 may protrude radially and may be received within a groove 176 of the journal member 160.

[0042] The ridge insert 250 may be elongated, with its straight longitudinal axis extending along longitudinal axis 178. The ridge insert 250 may be rigid and robust. In some embodiments, the ridge insert 250 may be made of metal. In additional embodiments, the ridge insert 250 may be made of polymeric or composite materials. The ridge insert 250 may be formed by extrusion molding, forging, machining, or other methods.

[0043] Without departing from the scope of this disclosure, the ridge insert 250 may have various shapes, sizes, specifications, etc. In some embodiments, the ridge insert 250 may have multiple smooth, flat surfaces and sides. The cross-section of the ridge insert 250 orthogonal to the axis of rotation 104 and the longitudinal axis 178 may be inverted L-shaped or V-shaped. This cross-section may remain substantially constant along most of the length of the ridge insert 250 (i.e., along axis 178). Therefore, the ridge insert 250 may include a radially extending partition 254 and an abutment member 256 extending laterally (e.g., tangentially) from the partition 254. The partition 254 may include a first side surface 261 and a second side surface 262. The first side surface 261 and the second side surface 262 may be substantially flat and may be parallel to each other, oriented in opposite tangential directions, and far apart from each other. The separator 254 may also define an inner radial edge 264 of the ridge insert 250, which extends along and is radially spaced from the outer diameter surface 190 of the shaft segment 164. The abutment member 256 may extend perpendicularly to the separator 254 and may terminate at the abutment surface 257.

[0044] A separator 254 may be disposed between a first end 214 and a second end 216 of a top foil 212. The first end 214 of the top foil 212 may be flatly stacked on and abutting a first side surface 261 of the separator 254, and / or the second end 216 of the top foil 212 may be flatly stacked on and abutting a second side surface 262 of the separator 254. Therefore, the separator 254 allows the first end 214 and the second end 216 to be at least spaced apart by a distance (e.g., a tangential distance 290), equal to the thickness of the separator 254. Ends 214 and 216 may be biased toward each other in the tangential and / or circumferential directions; however, the separator 254 may overcome this biasing force to push the first end 214 and the second end 216 away from each other. This load from the separator 254 may cause the top foil 212 to have an arcuate boundary within the foil arrangement 170.

[0045] Furthermore, the first end 214 of the top foil 212 can be fixedly attached to the partition 254 of the ridge insert 250. The first end 214 may be fixedly attached in a variety of ways (e.g., welding, soldering, adhesive attachment, press fitting, crimping, etc.).

[0046] For example, such as Figure 4 As shown, the first end 214 can be fixedly attached by welding to form a plurality of weldments 291 along the separator 254. The weldments 291 can be equidistantly spaced along axis 178 to integrally attach the top foil 212 to the ridge insert 250. As will be discussed, this configuration of the top foil insert member 211 (where the top foil 212 and the ridge insert 250 are fixedly attached) facilitates handling, manufacturing, etc.

[0047] like Figure 3 and Figure 4 As shown, at low rotational speeds of shaft segment 164, the second end 216 of the top foil 212 can cover the second side surface 262. However, the second end 216 can be detachably supported on the second side surface 262. During operation, the second side surface 262 and the second end 216 can move circumferentially away from each other, as... Figure 4 As shown by the dashed line in the figure. As the speed of shaft segment 164 decreases, the top foil 212 can elastically recover, causing the second end 216 to come to rest and return to cover the second side surface 262.

[0048] The ridge insert 250 can be received within the internal recess 176. The separator 254, the first end 214, and / or the second end 216 can be at least partially received within the recess 176. The abutment member 256 can extend tangentially within the recess 176 such that the abutment surface 257 is positioned (very) close to (immediately adjacent to) the first side surface 184. Furthermore, the inclined surface 163 can be (very) close to the rounded leading edge 209 of the ridge insert 250. The outer radius surface 201 of the ridge insert 250 can be opposite the flat recessed surface 180 of the recess 176. This engagement allows the ridge insert 250 to be manually inserted into the recess 176. The engagement of the ridge insert 250 within the recess 176 allows the ridge insert 250 to undergo some displacement therein, for example, during rotation of the shaft segment 164. However, the ridge insert 250 may abut against the inner surface of the groove 176 to restrict the movement of the top foil insert member 211 relative to the journal member 160 (e.g., restrict rotation).

[0049] It should be understood that, such as Figure 2 and Figure 3 As shown, the ridge insert 250 can fit individually within the recess 176. In other words, the ridge insert 250 can fit unidirectionally within the recess 176 (i.e., the adjacent member 256 extends toward the side surface 184). If the ridge insert 250 is inverted, for example during assembly, with the adjacent member 256 extending toward the other side surface 186, then obviously the ridge insert 250 cannot fit within the recess 176. Therefore, the asymmetry of the ridge insert 250 and the recess 176, and the unidirectional fit provided, can be convenient during the assembly of the foil bearing system 105.

[0050] As mentioned above, Figure 2 and Figure 3 The foil arrangement 170 shown represents the case where the shaft 115 is stationary. The arc-shaped boundary top foil 212 can provide a selected radial preload to the shaft 115. As the shaft 115 begins to rotate (e.g., counterclockwise along arrow 200), air pressure may cause the second end 216 (i.e., the front end of the top foil 212) to lift off the second side surface 262, while the first end 214 remains stacked on the first side surface 261. As the angular velocity of the shaft 115 increases further, the top foil 212 can overcome the biasing force of the bias foil 202 and expand radially outward, disengaging from the shaft 115, causing the air film to support the shaft's rotation. As the shaft 115 decelerates, the bias foil 202 and the top foil 212 can elastically return to their original positions. Figure 2 The state shown in the image.

[0051] Now for reference Figure 5A foil bearing system 1105 is shown according to an additional example embodiment. Unless otherwise specified, the foil bearing system 1105 can be substantially similar to... Figures 2-4 The implementation examples are similar. And... Figures 2-4 The features corresponding to those features are represented by the corresponding figure labels that are increased by 1000.

[0052] In some embodiments, a first end 1214 of the top foil 1212 may be adhesively attached to a first surface 1261 of the ridge insert 1250. An adhesive 1205 may be included between the first end 1214 and the first surface 1261 to securely attach the top foil 1212 to the ridge insert 1250.

[0053] Furthermore, the abutment member 1256 may include a flipped edge 1255 and a middle portion 1279. The middle portion 1279 may extend tangentially between the separator 1254 and the flipped edge 1255. As the middle portion 1279 extends away from the separator 1254, the abutment member 1256 may extend radially inward at the flipped edge 1255. The flipped edge 1255 may extend a predetermined radial distance 1295 from the outer radial edge of the first end 1214. This distance 1295 may be controlled to provide sufficient support to the side surface 1184 during operation of the ridge insert 1250.

[0054] Now for reference Figure 6 and Figure 7 The accompanying illustration shows a foil bearing system 2105 according to an additional example embodiment. Unless otherwise specified, the foil bearing system 2105 can be substantially similar to... Figures 2-4 The implementation examples are similar. And... Figures 2-4 The features corresponding to those features are represented by the corresponding figure labels with an increase of 2000.

[0055] The ridged insert 2250 may include an opening 2280. The opening 2280 may be a radially extending slot in the separator 2254. Figure 6 The opening 2280 separates the first side 2282 of the separator 2254 from its second side 2284. The opening 2280 accommodates a first end portion 2214 of the top foil 2212, which is securely attached to the ridge insert 2250. In some embodiments, the first side 2282 and / or the second side 2284 may be plastically deformed against the first end portion 2214, thereby crimping the first end portion 2214 within the opening 2280. In some embodiments, the thickness 2271 of the first end portion 2214 may be slightly greater than the width 2273 of the opening 2280, and the first end portion 2214 may be frictionally or press-fitted within the opening 2280.

[0056] Embodiments of foil bearing systems offer various advantages. These embodiments facilitate the assembly of foil bearing systems. Furthermore, as described above, the various embodiments of this disclosure allow for improved control over bearing loads and increased precision. These systems also improve manufacturing efficiency.

[0057] While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that many variations exist. It should also be understood that one or more exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or construction of this disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing exemplary embodiments of this disclosure. It should be understood that various changes may be made to the function and arrangement of the elements described in the exemplary embodiments without departing from the scope of this disclosure as set forth in the appended claims.

Claims

1. A foil bearing system, comprising: A journal member having a hole and an internal groove located within the hole; A shaft, which is received within the hole; A foil arrangement that supports the shaft to rotate about an axis relative to the journal member, the internal groove extending substantially along the axis, the foil arrangement including at least one bias foil and a top foil insert member; The at least one bias foil is accommodated radially relative to the axis between the journal member and the shaft; The top foil insertion member includes a top foil and a ridged insert; The top foil includes an arcuate portion disposed radially between the at least one biased foil and the axis, and extending circumferentially about the axis. The top foil includes an end extending from the arcuate portion; and The ridged insert is received within the internal groove and is fixedly attached to the end of the top foil.

2. The foil bearing system according to claim 1, characterized in that, The ridge-shaped insert is fixedly attached to the end by a weld.

3. The foil bearing system according to any of the preceding claims, characterized in that, The ridge-shaped insert includes an opening, and the end portion is received within the opening.

4. The foil bearing system according to any of the preceding claims, characterized in that, The ridge-shaped insert is adhesively attached to the end.

5. The foil bearing system according to any of the preceding claims, characterized in that, The ridge-shaped insert includes a separator; The top foil includes the first end and the second end; and The separator is disposed between the end and the other end to separate the end and the other end, and the end is fixedly attached to the separator.

6. The foil bearing system according to claim 5, characterized in that, The other end is separated from the separator.

7. The foil bearing system according to claim 5 or 6, characterized in that, At least one of the ends and the other end extends radially relative to the axis.

8. The foil bearing system according to claim 7, characterized in that, Both the end and the other end extend radially relative to the axis.

9. The foil bearing system according to claim 5, 6, 7 or 8, characterized in that, The internal groove is defined by an inner surface; and The ridge-shaped insert includes an abutting member extending from the separator, the abutting member being configured to abut against the inner surface.

10. The foil bearing system according to claim 9, characterized in that, The adjacent abutment member extends laterally away from the separator.

11. The foil bearing system according to claim 10, characterized in that, The adjacent abutment member includes a flipped edge member; and The abutment member includes a middle portion extending laterally between the separator and the flipped edge member; and The flipped edge member is configured to abut against the inner surface.

12. The foil bearing system according to any of the preceding claims, characterized in that, The internal groove extends along the longitudinal axis of the groove; and The ridge-shaped insert is elongated and extends along the longitudinal axis of the groove, and engages unidirectionally with the inner groove.

13. A method for manufacturing a foil bearing system, comprising: A journal member is provided, the journal member having a hole and an internal groove located within the hole; The shaft is placed inside the hole; The shaft is supported by a foil arrangement that allows it to rotate about an axis relative to the journal member. The internal groove extends substantially along the axis. The foil arrangement includes at least one bias foil and a top foil insert member, the top foil insert member including a top foil and a ridged insert fixedly attached to the top foil. The at least one bias foil is disposed radially relative to the axis between the journal member and the shaft; An arcuate portion of the top foil is disposed in the radial direction between the at least one bias foil and the axis, the arcuate portion extending in the circumferential direction about the axis, and the top foil including an end extending from the arcuate portion; as well as The ridge-shaped insert is disposed within the internal groove and is fixedly attached to the end of the top foil.

14. The method according to claim 13, characterized in that... It also includes welding the ridge insert to the end of the top foil.

15. The method according to any one of claims 13 to 14, characterized in that... It also includes adhesively attaching the ridge insert to the end of the top foil.

16. The method according to any one of claims 13 to 15, characterized in that, The ridge-shaped insert includes an opening, and the end portion is received within the opening.

17. The method according to any one of claims 13 to 16, characterized in that, The ridge-shaped insert includes a separator; The top foil includes the first end and the second end; and It also includes housing the separator between the end and the other end to separate the end from the other end, the end being fixedly attached to the separator.

18. The method according to claim 17, characterized in that, The other end is separated from the separator.

19. The method according to any one of claims 13 to 18, characterized in that, The internal groove extends along the longitudinal axis of the groove; and It also includes inserting the ridge-shaped insert into the inner groove in a unidirectional engagement manner along the longitudinal axis of the groove.

20. A foil bearing system, comprising: A journal member having a hole and an internal groove located within the hole; A shaft, which is received within the hole; A foil arrangement that supports the shaft so that it rotates about an axis relative to the journal member, the internal groove extending substantially along the axis, the foil arrangement including at least one bias foil and a top foil insert member; The at least one bias foil is accommodated radially relative to the axis between the journal member and the shaft; The top foil insertion member includes a top foil and a ridged insert; The top foil includes an arcuate portion, a first end, and a second end. The arcuate portion extends between the first end and the second end. The arcuate portion is disposed in the radial direction between the at least one biased foil and the axis, and extends in the circumferential direction about the axis. The first end and the second end extend radially from the arcuate portion. The ridge insert includes a separator disposed between the first end and the other end, separating the first end and the other end, the ridge insert including an abutment member extending from the separator, the ridge insert being received within the internal groove, wherein the abutment member is configured to abut against the inner surface of the groove, the ridge insert being fixedly attached to the first end of the top foil, and the second end being separate from the ridge insert.

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