Compressor assembly

Abstract

The utility model relates to a bearing for a compressor. Specifically, a compressor assembly is provided, comprising: an inner component comprising an axial end along a central axis; an outer member including an axial end portion; wherein at least one of the inner component or the outer component has a radial cut-out at an axial end thereof; and a bearing disposed between the inner member and the outer member and in the radial cutout in the axial end of the inner member or the outer member, the bearing comprising: a base; and a functional layer covering the substrate, where the bearing has a length L and an inner diameter ID, where the ratio of L / ID is less than 0.5, and where the axial end of the inner component or the outer component is an outer axial end of the compressor assembly.

Description

Technical Field

[0001] The present disclosure generally relates to bearings and, more particularly, to bearings for compressor assemblies. Background Art

[0002] Generally, bearings constrain relative motion to desired motion and reduce friction between moving parts. A particular type of bearing can be located in a radial clearance between an outer surface of an internal component (e.g., a shaft) and an inner surface of a bore of an external component (e.g., a housing) within an assembly. Exemplary assemblies can include compressor assemblies, such as, but not limited to, air-conditioning compressor assemblies for vehicles. Recently, the shafts of compressor assemblies have been modified to be longer than the housing bores in which they are disposed, resulting in misalignment and wear of at least one of the internal and external components under operating conditions. Accordingly, there has been a continuing need for improved bearings and assemblies that provide improved wear and alignment performance while maintaining a long life of the assembly. Summary of the Utility Model

[0003] In one aspect, the present utility model provides a compressor assembly, comprising: an internal component including an axial end along a central axis; an external component including an axial end; wherein at least one of the internal component or the external component has a radial notch at its axial end; and a bearing disposed between the internal component and the external component and in the radial notch in the axial end of the internal component or the external component, the bearing comprising: a substrate; and a functional layer covering the substrate, wherein the bearing has a length L and an inner diameter ID, wherein the ratio of L / ID is less than 0.5, and wherein the axial end of the internal component or the external component is an outer axial end of the compressor assembly. Brief Description of the Drawings

[0004] The present disclosure can be better understood by reference to the accompanying drawings, and many of the features and advantages thereof will become apparent to those skilled in the art.

[0005] Figure 1 including a method of producing a bearing according to one embodiment;

[0006] Figure 2A including a cross-sectional view of a composite material that can form a bearing according to one embodiment;

[0007] Figure 2B including a cross-sectional view of a composite material that can form a bearing according to one embodiment;

[0008] Figure 2C including a cross-sectional view of a composite material that can form a bearing according to one embodiment;

[0009] Figure 3A Perspective view of a cylindrical bearing according to one embodiment;

[0010] Figure 3B Perspective view of a flange bearing according to one embodiment; and

[0011] Figure 4 Cross-sectional view of the bearing in the assembly according to one embodiment.

[0012] Those skilled in the art should understand that the elements in the drawings are shown for simplicity and clarity and are not necessarily drawn to scale. For example, the dimensions of some elements in the drawings may be enlarged relative to other elements to help improve the understanding of the embodiments of the present utility model. The same reference numerals are used in different drawings to indicate similar or identical items. Detailed Description

[0013] The following description in conjunction with the drawings is provided to assist in understanding the teachings disclosed herein. The following discussion will focus on specific implementations and embodiments of the present teachings. This focused discussion is provided to assist in describing the teachings and should not be construed as a limitation on the scope or applicability of the teachings. However, other embodiments may be used based on the teachings disclosed in this application.

[0014] The terms "comprising", "containing", "including", "having" or any other variation thereof are intended to cover non-exclusive inclusion. For example, a method, article or component that includes a series of features need not be limited to those features but may include other features not expressly listed or inherent to such method, article or component. Further, unless expressly stated to the contrary, "or" refers to an inclusive or rather than an exclusive or. For example, condition A or B is satisfied by any of the following: A is true (or present) and B is false (or absent), A is false (or absent) and B is true (or present), and both A and B are true (or present).

[0015] In addition, the terms "a" or "an" are used to describe the elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the present utility model. This description should be understood to include one, at least one, or the singular also includes the plural, and vice versa, unless expressly stated otherwise. For example, when a single embodiment is described herein, more than one embodiment may be used in place of the single embodiment. Similarly, in cases where more than one embodiment is described herein, a single embodiment may be used in place of the more than one embodiment.

[0016] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this utility model belongs. The materials, methods, and examples are illustrative only and not restrictive. To the extent not described herein, many details regarding specific materials and processing acts are conventional and can be found in textbooks and other sources within the field of bearings and bearing assemblies.

[0017] Embodiments of the present utility model may include a compressor assembly that includes: an internal component that includes an axial end along a central axis; an external component that includes an axial end; wherein at least one of the internal component or the external component has a radial notch at its axial end; and a bearing that is disposed between the internal component and the external component and in the radial notch in the axial end of the internal component or the external component, the bearing including: a substrate; and a functional layer covering the substrate, wherein the bearing has a length L and an inner diameter ID, wherein the ratio of L / ID is less than 0.5, and wherein the axial end of the internal component or the external component is the outer axial end of the compressor assembly.

[0018] For purposes of illustration, Figure 1 includes a method of producing a bearing according to one embodiment. The forming method 100 may include a first step 102 of providing a base material, a second step 104 of coating the base material with a functional layer coating to form a composite material, and a third step 106 of shaping the composite material into a bearing.

[0019] Referring to the first step 12, the base material may be a substrate. In one embodiment, the substrate may at least partially comprise a rigid material. In one embodiment, the substrate may at least partially comprise a metal. According to certain embodiments, the metal may include iron, copper, titanium, tin, aluminum, their alloys, or may be another type of material. More specifically, the substrate may at least partially include steel, such as stainless steel, carbon steel, or spring steel. For example, the substrate may at least partially include 301 stainless steel. The 301 stainless steel may be annealed, 1 / 4 hard, 1 / 2 hard, 3 / 4 hard, or full hard. Additionally, the steel may include stainless steel containing chromium, nickel, or a combination thereof. A specific stainless steel is 301 stainless steel. The substrate may include a woven mesh or an expanded metal grid. Alternatively, the woven mesh may be a woven polymer mesh. In another embodiment, the substrate may not include a mesh or grid. The substrate may comprise a conductive material.

[0020] In multiple embodiments, the substrate can be spring steel. The spring steel substrate can be annealed, 1 / 4 hard, 1 / 2 hard, 3 / 4 hard, or fully hard. The spring steel substrate can have a tensile strength of no less than 600 MPa, such as no less than 700 MPa, such as no less than 750 MPa, such as no less than 800 MPa, such as no less than 900 MPa, or such as no less than 1000 MPa. The spring steel substrate can have a tensile strength of no greater than 1500 MPa or such as no greater than 1250 MPa.

[0021] Figure 2A Illustration of a composite material 200A that can be formed according to the first step 12 and the second step 14 of the forming method 10. For illustrative purposes, Figure 2A shows the layer-by-layer configuration of the composite material 200A after the second step 14. In multiple embodiments, the composite material 200A can include a substrate 202 (i.e., the matrix material provided in the first step 12) and a functional layer 204 (i.e., a low-friction coating applied in the second step 14). As Figure 2A shown, the functional layer 204 can be bonded to at least a portion of the substrate 202. In a specific embodiment, the functional layer 204 can be bonded to the surface of the substrate 202 to form a low-friction interface with another surface of another component. The functional layer 204 can be bonded to the radially inner surface of the substrate 202 to form a low-friction interface with another surface of another component. The functional layer 204 can be bonded to the radially outer surface of the substrate 202 to form a low-friction interface with another surface of another component.

[0022] In multiple embodiments, the functional layer 204 may comprise an elastic material. In multiple embodiments, the functional layer 204 may comprise a low-friction material. In multiple embodiments, the functional layer 204 may comprise a low-friction material that includes a polymer, the polymer including at least one of polyketone, polyaramide, polyimide, polyetherimide, polyphenylene sulfide, polyethersulfone, polysulfone, polyphenylsulfone, polyamideimide, ultra-high molecular weight polyethylene, fluoropolymer, polyamide, polybenzimidazole, or any combination thereof. In one example, the functional layer 204 includes polyketone, polyaramide, polyimide, polyetherimide, polyamideimide, polyphenylene sulfide, polyphenylene sulfone, fluoropolymer, polybenzimidazole, their derivatives, or combinations thereof. In one specific example, the functional layer 204 may comprise a polymer such as polyketone, thermoplastic polyimide, polyetherimide, polyphenylene sulfide, polyethersulfone, polysulfone, polyamideimide, their derivatives, or combinations thereof. In another example, the functional layer 204 may include polyketone such as polyetheretherketone (PEEK), polyetherketone, polyetherketoneketone, polyetherketoneetherketone, their derivatives, or combinations thereof. In an additional example, the functional layer 204 may include ultra-high molecular weight polyethylene. In an additional example, the functional layer 204 may comprise a fluoropolymer that includes at least one of fluorinated ethylene propylene (FEP), polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), perfluoroalkoxy (PFA), terpolymer of tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride (THV), polychlorotrifluoroethylene (PCTFE), ethylene tetrafluoroethylene copolymer (ETFE), ethylene chlorotrifluoroethylene copolymer (ECTFE), polyacetal, polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyimide (PI), polyetherimide, polyetheretherketone (PEEK), polyethylene (PE), polysulfone, polyamide (PA), polyphenylene ether, polyphenylene sulfide (PPS), polyurethane, polyester, liquid crystal polymer (LCP), or any combination thereof. According to a specific embodiment, a fluoropolymer may be used. As used herein, a "low-friction material" may be a material having a dry static coefficient of friction of less than 0.5, such as less than 0.4, less than 0.3, or even less than 0.2, measured against steel. A "high-friction material" may be a material having a dry static coefficient of friction of greater than 0.6, such as greater than 0.7, greater than 0.8, greater than 0.9, or even greater than 1.0, measured against steel. The functional layer 204 may be a non-conductive or low-conductive sliding material, for example, comprising a non-conductive or low-conductive material.

[0023] In multiple embodiments, the functional layer 204 may comprise a solid-based material. In multiple embodiments, the functional layer 204 may comprise a solid-based material that includes at least one of lithium soap, graphite, boron nitride, molybdenum disulfide, tungsten disulfide, polytetrafluoroethylene, carbon nitride, tungsten carbide, or diamond-like carbon, a metal (such as aluminum, zinc, copper, magnesium, tin, platinum, titanium, tungsten, lead, iron, bronze, steel, spring steel, stainless steel), a metal alloy (including the listed metals), an anodized metal (including the listed metals), or any combination thereof.

[0024] In multiple embodiments, the functional layer 204 may comprise a damping material. In multiple embodiments, the functional layer 204 may comprise a damping material that includes at least one of fluorinated ethylene propylene (FEP), polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), perfluoroalkoxy (PFA), a terpolymer of tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride (THV), polychlorotrifluoroethylene (PCTFE), ethylene tetrafluoroethylene copolymer (ETFE), ethylene chlorotrifluoroethylene copolymer (ECTFE), natural polyisoprene, synthetic polyisoprene, polybutadiene, chloroprene rubber, butyl rubber, styrene-butadiene rubber, nitrile rubber, ethylene propylene rubber, epichlorohydrin rubber, polyacrylate rubber, silicone rubber, fluorosilicone rubber, fluorinated elastomer, perfluoroelastomer, polyether block amide, chlorosulfonated polyethylene, ethyl vinyl acetate (EVA), polyacetal, polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyimide (PI), polyetherimide, polyetheretherketone (PEEK), polyethylene (PE), polysulfone, polyamide (PA), polyphenylene ether, polyphenylene sulfide (PPS), polyurethane, polyester, liquid crystal polymer (LCP), or any combination thereof. In multiple embodiments, the damping material may comprise a foam that includes at least one of EVA foam, low density polyethylene foam, nitrile rubber foam, polychloroprene foam, polyimide foam, polypropylene foam, polyurethane foam, polystyrene foam, polyvinyl chloride foam, silicone foam, foam rubber, polyurethane foam, XPS foam, epoxy foam, phenolic foam, or any combination thereof.

[0025] In multiple embodiments, the functional layer 204 may comprise a fabric. In multiple embodiments, the functional layer 204 may comprise a fabric that includes at least one of bronze, steel, aluminum, a polymer as polyketone; the polymer as polyketone, such as polyetheretherketone (PEEK), polyetherketone, polyetherketoneketone, polyetherketoneetherketone, their derivatives, or their combinations. In an additional example, the fabric may include ultra-high molecular weight polyethylene (UHMWPE). In an additional example, the low friction layer may include fluorinated ethylene propylene (FEP), polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), perfluoroalkoxy (PFA), a terpolymer of tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride (THV), polychlorotrifluoroethylene (PCTFE), ethylene tetrafluoroethylene copolymer (ETFE), ethylene chlorotrifluoroethylene copolymer (ECTFE), polyacetal, polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyimide (PI), polyetherimide, polyetheretherketone (PEEK), polyethylene (PE), polysulfone, polyamide (PA), polyoxymethylene (POM), polyamideimide (PAI), polyphenylene ether, polyphenylene sulfide (PPS), polyurethane, polyester, liquid crystal polymer (LCP); glass fiber, aramid fiber, carbon fiber, natural fiber (plant fiber, animal hair), or any combination thereof. In multiple embodiments, any of the above may be combined to form a fabric.

[0026] In multiple embodiments, the functional layer 204 may comprise a ceramic. In multiple embodiments, the functional layer 204 may comprise a ceramic that includes at least one of glass filler, silica, clay mica, alumina, kaolin, lithium soap, graphite, boron nitride, molybdenum disulfide, tungsten disulfide, polytetrafluoroethylene, carbon nitride, tungsten carbide, or diamond-like carbon. In multiple embodiments, any of the above may be combined to form a ceramic.

[0027] In multiple embodiments, the functional layer 204 may further comprise a filler that includes glass fiber, carbon fiber, silicon, PEEK, aromatic polyester, carbon particles, bronze, fluoropolymer, thermoplastic filler, alumina, polyamideimide (PAI), PPS, polyphenylene sulfone (PPSO2), LCP, aromatic polyester, molybdenum disulfide, tungsten disulfide, graphite, graphene, expanded graphite, boron nitride, talc, calcium fluoride, or any combination thereof. Additionally, the filler may include alumina, silica, titanium dioxide, calcium fluoride, boron nitride, mica, wollastonite, silicon carbide, silicon nitride, zirconia, carbon black, pigment, or any combination thereof. The filler may be in the form of beads, fibers, powders, meshes, or any combination thereof. The filler may be at least 1 wt%, such as at least 5 wt%, or even 10 wt% based on the total weight of the functional layer.

[0028] The substrate 202 may have a thickness Ts between about 10 microns and about 1500 microns, such as between about 50 microns and about 1000 microns, such as between about 100 microns and about 750 microns, such as between about 350 microns and about 650 microns. In various embodiments, the substrate 202 may have a thickness Ts between about 700 microns and 800 microns. In various embodiments, the substrate 202 may have a thickness Ts between about 950 microns and 1050 microns. In various embodiments, the substrate 202 may have a thickness Ts greater than 500 microns. It should also be understood that the thickness Ts of the substrate 202 may be any value between any of the above minimum and maximum values. The thickness of the substrate 202 may be uniform, i.e., the thickness at a first location of the substrate 202 may be equal to the thickness at a second location along it. The thickness of the substrate 202 may be non-uniform, i.e., the thickness at a first location of the substrate 202 may be different from the thickness at a second location along it.

[0029] In one embodiment, the functional layer 204 may have a thickness T between about 1 micron and about 1500 microns SL , such as between about 10 microns and about 1000 microns, such as between about 30 microns and about 500 microns, such as between about 40 microns and about 250 microns. In various embodiments, the functional layer 204 may have a thickness T between about 1 micron and 1000 microns SL . It should also be understood that the thickness T of the functional layer 204 SL may be any value between any of the above minimum and maximum values. The thickness of the functional layer 204 may be uniform, i.e., the thickness at a first location of the functional layer 204 may be equal to the thickness at a second location along it. The thickness of the functional layer 204 may be non-uniform, i.e., the thickness at a first location of the functional layer 204 may be different from the thickness at a second location along it. It can be understood that different functional layers 204 may have different thicknesses. The functional layer 204 may cover one major surface of the illustrated substrate 202, or cover both major surfaces. The substrate 202 may be at least partially encapsulated by the functional layer 204. That is, the functional layer 204 may cover at least a portion of the substrate 202. In various embodiments, the functional layer 204 may encapsulate the substrate 202 such that at least one of the radially inner surface and the radially outer surface of the substrate 202 may be located within the functional layer 202. The axial surfaces of the substrate 202 may be exposed from the functional layer 204. The encapsulation step may be performed by calendering or laminating through holes in the sheet. The sheet may be formed into the substrate 202 having a radially inner surface and a radially outer surface.

[0030] Figure 2B Illustration of an alternative embodiment of a composite material that may be formed according to the first step 12 and the second step 14 of the forming method 10. For purposes of illustration, Figure 2BShows the layer-by-layer configuration of the composite material 200B after the second step 14. According to this specific embodiment, the composite material 200B can be similar to Figure 2A the composite material 200A, except that the composite material 200B can also include at least one adhesive layer 206 and a functional layer 204 (i.e., the low-friction coating applied in the second step 14), and the adhesive layer can bond the functional layer 204 to the substrate 202 (i.e., the matrix material provided in the first step 12). In another alternative embodiment, the substrate 202, which is a solid component, a woven mesh, or an expanded metal grid, can be embedded between at least one adhesive layer 206 included between the functional layer 204 and the substrate 202.

[0031] The adhesive layer 206 can contain any known adhesive material commonly used in the bearing field, including but not limited to fluoropolymers, epoxy resins, polyimide resins, polyether / polyamide copolymers, ethylene vinyl acetate, ethylene tetrafluoroethylene (ETFE), ETFE copolymers, perfluoroalkoxy (PFA), or any combination thereof. Additionally, the adhesive can include at least one functional group selected from -C=O, -C-O-R, -COH, -COOH, -COOR, -CF 2 =CF-OR, or any combination thereof, where R is a cyclic or straight-chain organic group containing 1 to 20 carbon atoms. Additionally, the adhesive can include a copolymer. In one embodiment, the hot-melt adhesive can have a melting temperature not higher than 250 °C, such as not higher than 220 °C. In another embodiment, the adhesive can decompose at a temperature higher than 200 °C, such as higher than 220 °C. In a further embodiment, the melting temperature of the hot-melt adhesive can be higher than 250 °C or even higher than 300 °C. The adhesive layer 206 can have a thickness of about 1 micron to 50 microns, such as about 7 microns to 15 microns. In one embodiment, the hot-melt adhesive can have a melting temperature not higher than 250 °C, such as not higher than 220 °C.

[0032] The adhesive layer 206 can have a thickness T between about 1 micron and about 80 microns AL , such as between about 10 microns and about 50 microns, such as between about 20 microns and about 40 microns. In multiple embodiments, the adhesive layer 206 can have a thickness T between about 3 microns and 20 microns AL . In multiple embodiments, the adhesive layer 206 can have a thickness T between about 10 microns and 60 microns AL . It should also be understood that the thickness T of the adhesive layer 206 ALIt can be any value between any of the above minimum and maximum values. The thickness of the adhesive layer 206 can be uniform, i.e., the thickness at a first position of the adhesive layer 206 can be equal to the thickness at a second position along it. The thickness of the adhesive layer 206 can be non-uniform, i.e., the thickness at a first position of the adhesive layer 206 can be different from the thickness at a second position along it.

[0033] Figure 2C Illustration of an alternative embodiment of a composite material that can be formed according to the first step 12 and the second step 14 of the forming method 10. For illustrative purposes, Figure 2C shows the layer-by-layer configuration of the composite material 200C after the second step 14. According to this specific embodiment, the composite material 200C can be similar to Figure 2B the composite material 200B, except that the composite material 200C can further include at least one anti-corrosion layer 210, 212, and 214 and a corrosion-resistant coating 220, and the corrosion-resistant coating can include a tackifier layer 222 and an epoxy resin layer 224, which can be bonded to the substrate 202 (i.e., the matrix material provided in the first step 12) and the functional layer 204 (i.e., the low-friction coating applied in the second step 14).

[0034] The substrate 202 can be coated with anti-corrosion layers 210 and 212 to prevent the composite material 200C from being corroded before processing. Additionally, an anti-corrosion layer 214 can be applied on the layer 210. Each of the layers 210, 212, and 214 can have a thickness of about 1 micron to 50 microns, such as about 7 microns to 15 microns. The layers 210 and 212 can include phosphates of zinc, iron, manganese, or any combination thereof, or a nanoceramic layer. In addition, the layers 210 and 212 can include functional silanes, nanoscale silane primers, hydrolyzed silanes, organosilane tackifiers, solvent / water-based silane primers, chlorinated polyolefins, passivated surfaces, phosphates of aluminum, zinc, iron, manganese, or any combination thereof, nanoceramic layers, commercially available zinc (mechanical / plated) or zinc-nickel coatings, or any combination thereof. The layer 214 can include functional silanes, nanoscale silane primers, hydrolyzed silanes, organosilane tackifiers, solvent / water-based silane primers. The anti-corrosion layers 210, 212, and 214 can be removed or retained during processing.

[0035] The composite material 200C may further include a corrosion-resistant coating 220. The corrosion-resistant coating 220 may have a thickness of about 1 micron to 50 microns, such as about 5 microns to 20 microns, and such as about 7 microns to 15 microns. The corrosion-resistant coating 220 may include a corrosion-preventive layer 222 and an epoxy resin sealing layer 224. The adhesion promoter layer 222 may include phosphates of zinc, iron, manganese, tin, or any combination thereof, or a nanoceramic layer. The adhesion promoter layer 222 may include functional silanes, nanoscale silane underlayers, hydrolyzed silanes, organosilane adhesion promoters, solvent / water-based silane primers, chlorinated polyolefins, passivated surfaces, aluminum, commercially available zinc (mechanical / plated), or zinc-nickel coatings, or any combination thereof. The epoxy resin sealing layer 224 may be a thermally cured epoxy resin, a UV-cured epoxy resin, an IR-cured epoxy resin, an electron beam-cured epoxy resin, a radiation-cured epoxy resin, or an air-cured epoxy resin. In addition, the epoxy resin sealing layer 224 may include polyglycidyl ethers, diglycidyl ethers, bisphenol A, bisphenol F, ethylene oxide, oxirane, oxethylene, 1,2-epoxypropane, 2-methyloxirane, 9,10-epoxy-9,10-dihydroanthracene, or any combination thereof. The epoxy resin layer 224 may further include a hardener. The hardener may include amines, acid anhydrides, phenolic novolak hardeners such as phenolic novolak poly[N-(4-hydroxyphenyl)maleimide] (PHPMI), resole, aliphatic amine compounds, polycarbonic anhydrides, polyacrylates, isocyanates, encapsulated polyisocyanates, boron trifluoride amine complexes, chromium-based hardeners, polyamides, or any combination thereof. Generally, the acid anhydride may conform to the formula R-C=O-O-C=O-R’, where R may be C as described above X H Y X Z A U 。 Amines may include aliphatic amines such as monoethylamine, diethylenetriamine, triethylenetetramine, etc., alicyclic amines, aromatic amines such as cyclic aliphatic amines, alicyclic amines, amidoamines, polyamides, dicyandiamide, imidazole derivatives, etc., or any combination thereof.

[0036] In one embodiment, at Figure 1Under step 14, as described above, any layer on the composite materials 200A, 200B, 200C can be individually set in a roller and peeled off therefrom, and bonded together under pressure, at an elevated temperature (hot or cold pressing or roll pressing), by an adhesive or by any combination thereof. As described above, any layers of the composite material 200A can be laminated together such that they at least partially overlap each other. As described above, any layers on the composite materials 200A, 200B, 200C can be applied together using coating techniques (such as, for example, physical or vapor deposition, spraying, electroplating, powder coating) or by other chemical or electrochemical techniques. In a specific embodiment, the functional layer 204 can be applied by a roll-to-roll coating method, including, for example, extrusion coating. The functional layer 204 can be heated to a molten or semi-molten state and extruded onto the main surface of the substrate 202 through a slot die. In another embodiment, the functional layer 204 can be cast or molded.

[0037] In one embodiment, the functional layer 204 or any layer can be bonded to the substrate 202 using a molten adhesive layer 206 to form a laminate. In one embodiment, any intermediate layer or protruding layer on the material or composite materials 200A, 200B, 200C can form a laminate. The laminated material can be cut into strips or blanks that can form bearings. The cutting of the laminated material can include using a die, a press, a stamping machine, a saw, or can be machined in different ways. Cutting the laminate can produce a cut edge including an exposed portion of the substrate 202.

[0038] In other embodiments, under Figure 1 Under step 14, as described above, any layer on the composite materials 200A, 200B, 200C can be applied by coating techniques (such as, for example, physical or vapor deposition, spraying, electroplating, powder coating) or by other chemical or electrochemical techniques. In a specific embodiment, the functional layer 204 can be applied by a roll-to-roll coating method, including, for example, extrusion coating. The functional layer 204 can be heated to a molten or semi-molten state and extruded onto the main surface of the substrate 202 through a slot die. In another embodiment, the functional layer 204 can be cast or molded.

[0039] Now refer to as Figure 1The third step 16 of the shaping method 10 shown, according to certain embodiments, forms the composite materials 200A, 200B, 200C into a bearing. In one embodiment, a blank of the laminate can be formed into a bearing via molding or stamping (e.g., pressing using a mold of appropriate shape, rotary swaging, etc.). In one embodiment, forming into a bearing can include a cutting operation. In one embodiment, the cutting operation can include using stamping, pressing, punching, sawing, deep drawing, or can be machined in a different manner. In multiple embodiments, the cutting operation can form an outer peripheral surface on the bearing. The cutting operation can define a cutting direction starting from a first major surface to a second major surface opposite the first major surface to form an outer peripheral surface or an edge. Alternatively, the cutting operation can define a cutting direction starting from the second major surface to the first major surface to form an outer peripheral surface or an edge.

[0040] After forming the bearing, the bearing can be cleaned to remove any lubricants and oils used during the forming and shaping processes. Additionally, cleaning can prepare the exposed surface of the substrate for applying a coating. Cleaning can include chemical cleaning using a solvent and / or mechanical cleaning, such as ultrasonic cleaning.

[0041] Figure 3A A cylindrical bearing 300A is shown, which includes an embodiment formed from a blank of the materials or composite materials 200A, 200B, 200C as described above. Figure 3B A flanged bearing 300B is shown, which includes an embodiment formed from a blank of the materials or composite materials 200A, 200B, 200C as described above. In multiple embodiments, the bearings 300A, 300B can be plain bearings. In multiple embodiments, the bearings 300A, 300B can be sliding bearings. The bearings 300A, 300B include a generally cylindrical sidewall 302. The generally cylindrical sidewall 302 can be formed from the blank as described above and includes a substrate (e.g., spring steel), which can be bent into an annular (substantially ring-shaped) shape around a central axis 399, thereby forming a hole 350. The central axis 399 can extend longitudinally along the length of the bearing. The hole 350 can travel along the axial length of the bearings 300A, 300B and is adapted to be coupled to another component of an assembly. The hole 350 can be parallel or planar to the central axis 399. The formation of the hole 350 can include forming a formed hole in a sheet by perforation or stamping. Manufacturing the geometry into a sheet can be achieved by molding, shaping, or deep drawing corrugations, balls, or cones to form a sheet profile. The generally cylindrical sidewall 302 can also include a functional layer consistent with the shape of the generally cylindrical sidewall 302, such as a functional layer formed from a blank of the composite materials 200A, 200B, 200C as described above.

[0042] As Figures 3A to 3BAs shown, in multiple embodiments, bearings 300A, 300B may have a first outer radial end or edge 307 and a second outer radial end or edge 309. In multiple embodiments, a generally cylindrical sidewall 302 may form an annular shape having a first axial end or edge 303 and a second axial end or edge 305. The ends of the generally cylindrical sidewall 302 may not meet (e.g., may be formed as split bearings), leaving an axial crack 311 adjacent to the circumference of the generally cylindrical sidewall 302. In other embodiments, the generally cylindrical sidewall 302 may be curved such that the ends overlap each other. In still other embodiments, the generally cylindrical sidewall 302 may be a continuous, unbroken ring. Bearings 300A, 300B and / or the generally cylindrical sidewall 302 may have an inner surface 330 and an outer surface 332. The inner surface 330 of bearings 300A, 300B and / or the generally cylindrical sidewall 302 may have a functional layer that conforms to the shape of the generally cylindrical sidewall 302, where a substrate forms the outer surface 332, such as formed by composite materials 200A, 200B, 200C as described above. Alternatively or in addition, the outer surface 332 of bearings 300A, 300B may have a functional layer that conforms to the shape of the generally cylindrical sidewall 302, where a substrate forms the inner surface 330, such as formed by composite materials 200A, 200B, 200C as described above. In other embodiments, the functional layer may be deposited on both surfaces of bearings 300A, 300B and / or the generally cylindrical sidewall 302.

[0043] As Figures 3A to 3B shown, in multiple embodiments, bearings 300A, 300B may have a non-planar shape. In multiple embodiments, as Figure 3A shown, bearing 300A may have a generally cylindrical annular shape. In multiple embodiments, as Figure 3A shown, bearing 300B may have a generally L-shaped annular shape. In other words, bearing 300B may have an L-bearing cross-section extending radially and axially, as Figure 3B shown. Other annular shapes of the bearing are possible. In multiple embodiments, the L-shaped bearing 300B may be achieved by a deep drawing method involving stamping a formed cylindrical bearing 300A. In multiple embodiments, to form the L-bearing cross-section, bearing 300B may include a radially extending flange 340. The radially extending flange 340 may extend from at least one of the first axial end 303 or the second axial end 305. The radially extending flange 340 may extend from the first radial end or edge 307 to the second radial end or edge 309.

[0044] In multiple embodiments, bearings 300A, 300B may have an overall outer radius OR from the central axis 399 to the outer radial end 309, and OR may be ≥ 0.5 mm, such as ≥ 1 mm, ≥ 5 mm, ≥ 10 mm, ≥ 15 mm, or ≥ 20 mm. OR may be ≤ 60 mm, such as ≤ 30 mm, ≤ 20 mm, ≤ 15 mm, ≤ 10 mm, or ≤ 5 mm. It should be understood that the OR of bearings 300A, 300B may be within the range between any of the above minimum and maximum values. It should also be understood that the OR of bearings 300A, 300B may be any value between any of the above minimum and maximum values. It can also be understood that the OR of bearings 300A, 300B may vary along its circumference. It can also be understood that the OR of bearings 300A, 300B may vary along its circumference and may vary between multiple bearings.

[0045] In multiple embodiments, bearings 300A, 300B may have an overall inner radius IR from the central axis 399 to the first inner radial end 307, and IR may be ≥ 1 mm, such as ≥ 5 mm, ≥ 7.5 mm, ≥ 10 mm, ≥ 15 mm, or ≥ 20 mm. IR may be ≤ 50 mm, such as ≤ 15 mm, ≤ 10 mm, ≤ 7.5 mm, ≤ 5 mm, or ≤ 1 mm. It should be understood that the IR of bearings 300A, 300B may be within the range between any of the above minimum and maximum values. It should also be understood that the IR of bearings 300A, 300B may be any value between any of the above minimum and maximum values. It can also be understood that the IR of bearings 300A, 300B may vary along its circumference. It can also be understood that the IR of bearings 300A, 300B may vary along its circumference and may vary between multiple bearings.

[0046] In multiple embodiments, as Figure 3A shown, bearings 300A, 300B may have an overall length L from the first axial end 303 to the second axial end 305, and L may be ≥ 0.5 mm, ≥ 0.75 mm, ≥ 1 mm, ≥ 2 mm, ≥ 5 mm, or ≥ 10 mm. L may be ≤ 500 mm, such as ≤ 250 mm, ≤ 100 mm, ≤ 50 mm, or ≤ 25 mm. It should be understood that the L of bearings 300A, 300B may be within the range between any of the above minimum and maximum values. It should also be understood that the L of bearings 300A, 300B may be any value between any of the above minimum and maximum values. It can also be understood that the L of bearings 300A, 300B may vary along its circumference. It can also be understood that the L of bearings 300A, 300B may vary along its circumference and may vary between multiple bearings.

[0047] In multiple embodiments, as Figure 3AAs shown, the bearings 300A, 300B may have a ratio L / IR between their total length L and their inner radius IR, and the L / IR may be less than 5, such as less than 2.5, such as less than 2, such as less than 1, such as less than 0.75, such as less than 0.5, such as less than 0.25, such as less than 0.2, such as less than 0.15, such as less than 0.1, such as less than 0.5 or such as less than 0.1. It should be understood that the L / IR of the bearings 300A, 300B may be within the range between any of the above minimum and maximum values. It should also be understood that the L / IR of the bearings 300A, 300B can be any value between any of the above minimum and maximum values.

[0048] In multiple embodiments, the bearings 300A, 300B may have a specific thickness T B . For the purposes of the embodiments described herein, the thickness T of the bearings 300A, 300B B is the distance from the inner surface 330 to the outer surface 332. It should be understood that the thickness T of the bearings 300A, 300B B may be substantially similar to or the same as the thickness of the materials or composites 200A, 200B, 200C as Figures 2A to 2C shown. According to certain embodiments, the thickness T of the bearings 300A, 300B B may be at least about 0.1 mm, or at least about 0.2 mm, or at least about 0.5 mm, or at least about 0.8 mm or even at least about 1.5 mm. According to other embodiments, the T of the bearings 300A, 300B B may not be greater than about 2 mm, such as not greater than about 1.5 mm or even not greater than about 1.0 mm. It should be understood that the thickness T of the bearings 300A, 300B B may be within the range between any of the above minimum and maximum values. It should also be understood that the thickness T of the bearings 300A, 300B B can be any value between any of the above minimum and maximum values. It can also be understood that the thickness T of the bearings 300A, 300B B may vary along its circumference. It can also be understood that the thickness T of the bearings 300A, 300B B may vary along its circumference and may vary between multiple bearings.

[0049] In operation, the bearings 300A, 300B may be adjacent to opposing components. In operation, the bearings 300A, 300B may be located between two opposing (mating) components. For example, it may be located in an annular space between an internal component (such as a shaft) and a hole in an external component (such as a housing). Figure 4Shows a cross-sectional view through an embodiment of a component 475 that includes a bearing 400. In a plurality of embodiments, the component 475 can be a compressor. In a plurality of embodiments, the component 475 can be a compressor disposed within a vehicle. In a plurality of embodiments, the component 475 can be an air conditioning rotary compressor. The component 475 incorporates, for example Figure 3A the bearing 300A shown. Thus, Figure 4 includes features similar to those shown in Figure 3A and are so labeled. For a description of these elements, reference is made to the previous description of Figure 3A . The component 475 includes a housing 402 or an external component. The housing 402 can have a hole 404 formed therein that receives a shaft 406 or an internal component. The size of the hole 404 can vary because the diameters of the shaft 306 and the hole 304 can vary within manufacturing tolerances.

[0050] In a plurality of embodiments, at least one of the external component 402 or the internal component 406 can include a rigid material. According to certain embodiments, the rigid material can include a metal, which includes iron, copper, titanium, tin, aluminum, their alloys, or can be another type of material. More specifically, the substrate can at least partially include steel, such as stainless steel, carbon steel, or spring steel. For example, the substrate can at least partially include 301 stainless steel. 301 stainless steel can be annealed, 1 / 4 hard, 1 / 2 hard, 3 / 4 hard, or fully hard. Additionally, the steel can include stainless steel containing chromium, nickel, or a combination thereof. A specific stainless steel is 301 stainless steel.

[0051] In a plurality of embodiments, the external component 402 can have an axial end 402a. In a plurality of embodiments, the internal component 406 can have an axial end 406a. In a plurality of embodiments, the axial ends 402a, 406a of at least one of the external component 402 or the internal component 406 can be the outer axial ends of the component 475. In a plurality of embodiments, a radial cut 405 can be present at the axial ends 402a, 406a of at least one of the internal component 406 or the external component 402. In a plurality of embodiments, the cut 405 can receive the bearing 400 within the component 475 such that the bearing 400 is embedded within the cut 405. As shown in Figure 4 , in a plurality of exemplary embodiments, the bearing 400 can be fixed relative to the housing 402 by frictional engagement with the space within the cut 405 and / or by frictional engagement at the contact area between the generally cylindrical sidewall of the bearing 400 and / or the outer surface 416 of the internal component 406. In one embodiment, a functional layer on the bearing 400 can reduce the torque required during use of the bearing 400 within the component 475 while maintaining a desired torque range.

[0052] In various embodiments, the bearing 400 can reduce the annular gap within the bore 404, so there can be no large radial gap between the components 402, 406 in the assembly 475, thereby reducing vibration. In various embodiments, the radial gap between the bearing 400 and at least one of the inner or outer members 402, 406 can be ≤50 μm, such as ≤25 μm, ≤20 μm, ≤15 μm, ≤10 μm, ≤7.5 μm, ≤5 μm or ≤1 μm. It should be understood that the radial gap between the bearing 400 and at least one of the inner or outer members 402, 406 can be within the range between any of the minimum and maximum values ​​described above. It should also be understood that the radial gap between the bearing 400 and at least one of the inner or outer members 402, 406 can be any value between any of the minimum and maximum values ​​described above. It can also be understood that the radial gap between the bearing 400 and at least one of the inner or outer members 402, 406 can vary along its circumference. It will also be appreciated that the radial clearance between the bearing 400 and at least one of the inner or outer members 402 , 406 may vary along its circumference and may vary between multiple bearings.

[0053] The use of bearing 400 can allow hole 404 to accommodate lubricants. In multiple embodiments, the lubricant can include at least one of greases including at least one of lithium soap, lithium disulfide, graphite, mineral or vegetable oils, silicone greases, fluorinated ether-based greases, apisone, food grade greases, petrochemical greases, or can be different types. In at least one embodiment, the lubricant can include oils including Class I to Class III+ oils, paraffinic oils, naphthenic oils, aromatic oils, bio-lubricants, castor oil, canola oil, sunflower oil, rapeseed oil, tall oil, lanolin, synthetic oils, polyalphaolefins, synthetic esters, polyalkylene glycols, phosphate esters, alkylated naphthalenes, silicates, ionic fluids, polyalkylated cyclopentanes, petrochemical base oils, combinations thereof, or can be different types. In at least one embodiment, the lubricant can include a solid-based lubricant including at least one of lithium soap, graphite, boron nitride, molybdenum disulfide, tungsten disulfide, combinations thereof, or can be different types.

[0054] In various embodiments, such as Figure 4 As shown, the bearing 400 may have an overall length L thereof and an overall length L of the outer member 402. OC The ratio between them, and L / L OC It may be less than 1 / 2, such as less than 1 / 3, such as less than 1 / 4, such as less than 1 / 6, such as less than 1 / 8, such as less than 1 / 10, such as less than 1 / 15, such as less than 1 / 25, such as less than 1 / 50, such as less than 1 / 75 or such as less than 1 / 100. It should be understood that L / L OCwithin a range that can be between any of the above - mentioned minimum and maximum values. It should also be understood that L / L OC can be any value between any of the above - mentioned minimum and maximum values.

[0055] Applications of the embodiments include, for example, components of a compressor, which are used in applications such as but not limited to vehicle components. Additionally, the use of the bearing or the component can provide increased benefits in several applications, such as but not limited to doors, hoods, tailgates, and engine compartment hinges, seats, steering columns, flywheels, drive shaft assemblies, driveline applications (such as belt tensioners), or other types of applications. According to specific embodiments herein, the bearing can improve the alignment of internal and external components. Additionally, the bearing according to the embodiments herein can reduce noise / vibration, reduce wear of the bearing surface and mating components, support lubricant introduction, reduce drag torque, and reduce complex component parts and assembly time, thereby increasing the lifespan, improving the visual appearance, and improving the effectiveness and performance of the component, the bearing, and its other parts.

[0056] Embodiment

[0057] Journal bearing tests are conducted on the bearing according to the embodiments herein. The bearing is placed in a short journal bearing test (i.e., wear test 1), where the shaft has an outer diameter of 19.03 mm, a shaft hardness of HRC 52, and a shaft roughness of 0.13. The shaft rotates at a speed of 6 m / s, and a load is applied in two stages of 11.6 MPa and 19.3 MPa. The 11.6 MPa stage runs for 43 hours, and the 19.3 MPa stage runs for 120 hours. Importantly, the bearing according to the embodiments herein shows that the wear of its functional layer is only 36 μm. Additionally, when the load increases, the drag torque on the shaft decreases conversely, providing good evidence that the bearing can ensure steady - state operation.

[0058] Many different aspects and embodiments are possible. Some of these aspects and embodiments are described below. After reading this specification, those skilled in the art will recognize that those aspects and embodiments are merely illustrative and do not limit the scope of the present utility model. Embodiments can be based on any one or more of the embodiments listed below.

[0059] Embodiment 1: A compressor assembly, comprising: an internal component including an axial end along a central axis; an external component including an axial end; wherein at least one of the internal component or the external component has a radial notch at its axial end; and a bearing disposed between the internal component and the external component and in the radial notch of the axial end of the internal component or the external component, the bearing comprising: a base; and a functional layer covering the base, wherein the bearing has a length L and an inner diameter ID, wherein the ratio of L / ID is less than 0.5, and wherein the axial end of the internal component or the external component is the outer axial end of the compressor assembly.

[0060] Embodiment 2: The compressor assembly according to Embodiment 1, wherein the base comprises a rigid material.

[0061] Embodiment 3: The compressor assembly according to Embodiment 1, wherein the base comprises a metal.

[0062] Embodiment 4: The compressor assembly according to Embodiment 1, wherein the functional layer comprises an elastic material.

[0063] Embodiment 5: The compressor assembly according to Embodiment 1, wherein the functional layer comprises a polymer.

[0064] Embodiment 6: The compressor assembly according to Embodiment 1, wherein the functional layer comprises at least one of PEEK or PI.

[0065] Embodiment 7: The compressor assembly according to Embodiment 1, wherein the external component has a length L OC and an L / L ratio less than 1 / 8 OC ratio.

[0066] Embodiment 8: The compressor assembly according to Embodiment 1, wherein the external component comprises a rigid material.

[0067] Embodiment 9: The compressor assembly according to Embodiment 1, wherein the external component comprises a metal.

[0068] Embodiment 10: The compressor assembly according to Embodiment 1, wherein the internal component comprises a rigid material.

[0069] Embodiment 11: The compressor assembly according to Embodiment 1, wherein the internal component comprises a metal.

[0070] Embodiment 12: The compressor assembly according to Embodiment 1, wherein the bearing further comprises an adhesive layer disposed between the base and the functional layer.

[0071] Embodiment 13: The compressor assembly according to Embodiment 12, wherein the adhesive layer comprises a polymer.

[0072] Embodiment 14: The compressor assembly according to Embodiment 1, wherein the substrate has a thickness greater than 500 microns.

[0073] Embodiment 15: The compressor assembly according to Embodiment 1, wherein the functional layer has a thickness between 0.01 mm and 1 mm.

[0074] Embodiment 16: The compressor assembly according to Embodiment 1, wherein the bearing includes an axial crack.

[0075] Embodiment 17: The compressor assembly according to Embodiment 1, wherein the bearing has an inner radius between 4 mm and 60 mm.

[0076] Embodiment 18: The compressor assembly according to Embodiment 1, wherein the radial clearance between the internal component and the external component is not greater than 20 μm.

[0077] Embodiment 19: The compressor assembly according to Embodiment 1, wherein the compressor is disposed within a vehicle.

[0078] Embodiment 20: The compressor assembly according to Embodiment 1, wherein the compressor is an A / C rotary compressor.

[0079] Embodiment 21: The compressor assembly according to Embodiment 1, wherein under Wear Test 1, after 36 million revolutions, the bearing has a wear less than 50% of the thickness of the functional layer.

[0080] Note that not all of the above-described features are necessary, the areas of specific features may not be necessary, and one or more features may be provided in addition to those described. Further, the order in which the features are described is not necessarily the order in which the features are installed.

[0081] For clarity, certain features described herein in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, for brevity, the various features described in the context of a single embodiment may also be provided separately or in any sub-combination.

[0082] The above has described benefits, other advantages, and solutions to problems with respect to specific embodiments. However, these benefits, advantages, solutions to problems, and any features that may cause any benefit, advantage, or solution to occur or become more pronounced should not be construed as critical, essential, or necessary features of any or all claims.

[0083] The description and illustration of the embodiments described herein are intended to provide a general understanding of the structure of various embodiments. Description and illustration are not intended to be used as a detailed and comprehensive description of all elements and features of the components and systems using the structure or method described herein. Separate embodiments may also be provided in combination in a single embodiment, and on the contrary, for the sake of brevity, the various features described in the context of a single embodiment may also be provided individually or in any sub-combination. In addition, reference to the values ​​described in the range includes each value within the range. Many other embodiments are apparent to those skilled in the art only after they have read this specification. Other embodiments may be used and derived from the present disclosure, so that structural substitution, logical substitution or any change may be performed without departing from the scope of the present disclosure. Therefore, the present disclosure should be considered to be illustrative and not restrictive.

Claims

1. A compressor assembly, comprising: an inner component including an axial end portion along a central axis; an outer member, the outer member comprising an axial end; wherein at least one of the inner member or the outer member has a radial cutout at its axial end; and a bearing disposed between the inner component and the outer component and in the radial cutout in the axial end of the inner component or the outer component, the bearing comprising: substrate; and A functional layer covers the substrate, wherein the bearing has a length L and an inner diameter ID, wherein the ratio L / ID is less than 0.5, and wherein the axial end of the inner component or the outer component is an outer axial end of the compressor assembly.

2. The compressor assembly according to claim 1, characterized in that The substrate comprises a rigid material.

3. The compressor assembly according to claim 1, characterized in that The substrate comprises metal.

4. The compressor assembly according to claim 1, characterized in that The functional layer comprises an elastic material.

5. The compressor assembly according to claim 1, characterized in that The functional layer comprises a polymer.

6. The compressor assembly according to claim 1, characterized in that The functional layer includes at least one of PEEK or PI.

7. The compressor assembly according to claim 1, characterized in that The outer member has a length L OC and L / L less than 1 / 8 OC ratio.

8. The compressor assembly according to claim 1, characterized in that The outer member comprises a rigid material.

9. The compressor assembly according to claim 1, characterized in that The outer member comprises metal.

10. The compressor assembly of claim 1, wherein The inner component comprises a rigid material.

11. The compressor assembly according to claim 1, characterized in that The internal component comprises metal.

12. The compressor assembly of claim 1, wherein The bearing also includes an adhesive layer disposed between the substrate and the functional layer.

13. The compressor assembly according to claim 12, characterized in that The adhesive layer includes a polymer.

14. The compressor assembly of claim 1, wherein The substrate has a thickness greater than 500 microns.

15. The compressor assembly of claim 1, wherein The functional layer has a thickness between 0.01 mm and 1 mm.

16. The compressor assembly of claim 1, wherein The bearing includes an axial split.

17. The compressor assembly of claim 1, wherein The bearing has an inner radius between 4 mm and 60 mm.

18. The compressor assembly of claim 1, wherein A radial gap between the inner component and the outer component is no greater than 20 μm.

19. The compressor assembly of claim 1, wherein The compressor is disposed in a vehicle.

20. The compressor assembly of claim 1, wherein The compressor is an A / C rotary compressor.

21. The compressor assembly of claim 1, wherein Under wear test 1, after 36 million revolutions, the bearing had a wear of less than 50% of the thickness of the functional layer.

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