Bearing, assembly, and method of making and using the same

Abstract

To provide a bearing that can improve the conductivity and can increase the corrosion resistance, and to provide their production and use in assemblies.SOLUTION: A bearing 100 includes a substrate layer 102 including an aluminum alloy including a thickness, TS, where TS≤0.6 mm; an adhesive layer 112; and a low friction material layer 110 overlying the adhesive layer, where the bearing includes an elongation at break, A50, of ≥23%.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] FIELD This disclosure relates generally to bearings and their manufacture and use in assemblies. [Background technology]

[0002] Bearings made from composite materials consisting of a substrate layer and a low-friction material layer covering are generally known. The substrate layer and the low-friction material layer are usually connected by lamination with a suitable adhesive. The composite materials can be used to form bearings used, for example, by the automotive industry for door, hood, and engine bay hinges, seats, steering columns, flywheels, balancer shaft bearings, or other vehicle components. Furthermore, bearings made from composite materials can also be used in non-automotive applications. There is a continuing need for improved bearings under a variety of conditions. [Brief description of the drawings]

[0003] The present disclosure can be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings. [Figure 1] FIG. 2 is a diagram of a layer structure of a bearing according to some embodiments. [Figure 2A] FIG. 2 is a diagram of a layer structure of a bearing according to some embodiments. [Figure 2B] FIG. 2 is a diagram of a layer structure of a bearing according to some embodiments. [Figure 3A] FIG. 1 illustrates a bearing according to some embodiments. [Figure 3B] FIG. 1 illustrates a bearing according to some embodiments. [Figure 3C] FIG. 1 illustrates a bearing according to some embodiments. [Figure 3D] FIG. 1 illustrates a bearing according to some embodiments. [Figure 3E] FIG. 1 illustrates a bearing according to some embodiments. [Figure 3F]FIG. 1 illustrates a bearing according to some embodiments. [Figure 4] FIG. 1 illustrates a bearing in an assembly according to some embodiments. [Diagram 5] FIG. 1 illustrates a bearing in an assembly according to some embodiments. [Figure 6] FIG. 1 illustrates a bearing in an assembly according to some embodiments. [Figure 7] FIG. 1 illustrates a bearing in an assembly according to some embodiments. [Figure 8] FIG. 1 illustrates a bearing in an assembly according to some embodiments. [Figure 9] 1 is a graph of sizing pin oversize versus bearing inner diameter versus wall thickness reduction relative to bearing material thickness compared to existing prior art bearings according to some embodiments. [Figure 10] 1 is a graph of bearing inner diameter versus achievable flange width of the bearing compared to existing prior art bearings according to some embodiments.

[0004] Those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present invention. Use of the same reference numbers in different figures indicates similar or identical items. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0005] The following description in combination with the drawings is provided to aid in understanding the teachings disclosed herein. The following description will focus on specific implementations and embodiments of the present teachings. This focus is provided to aid in explaining the present teachings and should not be construed as a limitation on the scope or applicability of the present teachings. However, other embodiments can be used based on the teachings disclosed in this application.

[0006] The terms "comprises," "comprising," "includes," "including," "has," "having," or any other variations thereof, are intended to include non-exclusive inclusions. For example, a method, article, or apparatus comprising a list of features is not necessarily limited to only those features, but may include other features not expressly listed or inherent in such method, article, or apparatus. Furthermore, unless expressly stated otherwise, "or" refers to an inclusive "or," not an exclusive "or." For example, a 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).

[0007] Additionally, the use of "a" or "an" is used to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include the singular form including one, at least one, or more than one, or vice versa, unless it is clear that something else is meant. For example, where a single embodiment is described herein, multiple embodiments can be used in place of the single embodiment. Similarly, where multiple embodiments are described herein, a single embodiment can be substituted for the multiple embodiments.

[0008] 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 invention belongs. The materials, methods, and examples are illustrative only and are not intended to be limiting. To the extent not described herein, many details regarding specific materials and processing operations are conventional and can be found in textbooks and other sources within the bearing or bearing assembly art.

[0009] 1 shows a cross-sectional view illustrating the various layers of a bearing, generally designated 100. The bearing 100 can include a substrate layer 102. The bearing 100 can include a low friction material layer 110. The bearing 100 can include an adhesive layer 112.

[0010] The substrate layer 102 can be a metal support layer. The metal support layer can include a metal or metal alloy, such as steel, including carbon steel, spring steel, and the like, iron, aluminum, zinc, copper, magnesium, or any combination thereof. In certain embodiments, the substrate layer 102 can be a metal (including a metal alloy), such as aluminum. In more particular embodiments, the substrate layer 102 can be an aluminum 3003 alloy. In some embodiments, the substrate layer 103 can have the following composition: 96.8-99 wt.% aluminum, 0.05-0.20 wt.% copper, 0-0.70 wt.% iron, 1-1.5 wt.% manganese, 0-0.6 wt.% silicon, and 0-0.1 wt.% zinc. The substrate layer 102 can have a thickness Ts of about 1 micron to about 1000 microns, such as about 50 microns to about 500 microns, such as about 100 microns to about 250 microns, such as about 75 microns to about 150 microns. In some embodiments, the substrate layer 102 can have a thickness Ts of about 100 microns to 500 microns. In some embodiments, the substrate layer 102 can have a thickness Ts of about 350 microns to 450 microns. It will be further appreciated that the thickness Ts of the substrate layer 102 can be any value between any of the minimum and maximum values ​​listed above. For example, the thickness Ts of the substrate layer 102 can be 380 microns.

[0011] The low friction material layer 110 can be applied to the substrate layer 102. The low friction material layer 110 can include a polymer. In an exemplary embodiment, the low friction material layer 110 can include a fluoropolymer. Examples of polymers that can be used for the low friction material layer 110 include polytetrafluoroethylene (PTFE), fluorinated ethylene-propylene (FEP), polyvinylidene fluoride (PVDF), polychlorotrifluoroethylene (PCTFE), ethylene chlorotrifluoroethylene (ECTFE), perfluoroalkoxy polymers, polyacetal, polybutylene terephthalate, polyimide, polyetherimide, polyetheretherketone (PEEK), polyethylene, polysulfone, polyamide, polyphenylene oxide, polyphenylene sulfide (PPS), polyurethane, polyester, or any combination thereof. Additionally, the low friction material layer 110 can include fillers, such as friction reducing fillers. Examples of fillers that can be used in the low friction material layer 110 further include fillers including glass fiber, carbon fiber, silicon, graphite, PEEK, molybdenum disulfide, aromatic polyester, carbon particles, bronze, fluoropolymers, thermoplastic fillers, silicon carbide, aluminum oxide, polyamideimide (PAI), PPS, polyphenylene sulfone (PPSO2), liquid crystal polymer (LCP), aromatic polyester (Econol), and mineral particles such as wollastonite and barium sulfate, or any combination thereof. The fillers can be in the form of beads, fibers, powder, mesh, or any combination thereof. The low friction material layer 110 has a thickness Ts of about 1 micron to about 500 microns, such as about 10 microns to about 250 microns, such as about 30 microns to about 150 microns, such as about 40 microns to about 100 microns. L In some embodiments, the low friction material layer 110 can have a thickness Ts between about 50 microns and 330 microns. L The low friction material layer 110 may have a thickness Ts L It will be further understood that the thickness Ts of the low friction material layer 110 can be any value between any of the minimum and maximum values ​​listed above. Lcan be 100 microns.

[0012] The low friction material layer 110 can be applied to the substrate layer 102 by an adhesive layer 112. The adhesive layer 112 can be disposed between the low friction material layer 110 and the substrate layer 102. In another alternative embodiment shown in FIG. 2, a woven mesh or expanded metal grid 120 can be embedded between the two adhesive layers 112A and 112B. The adhesive layer 112 can be a hot melt adhesive. Examples of adhesives that can be used for the adhesive layer 112 include fluoropolymers, epoxy resins, polyimide resins, polyether / polyamide copolymers, ethylene vinyl acetate, ethylene tetrafluoroethylene (ETFE), ETFE copolymers, perfluoroalkoxy (PFA), or any combination thereof. Furthermore, the adhesive layer 112 can include at least one functional group selected from -C=O, -COR, -COH, -COOH, -COOR, -CF2=CF-OR, or any combination thereof, where R is a cyclic or linear organic group containing 1 to 20 carbon atoms. In certain embodiments, the adhesive layer 112 can be a fluoropolymer adhesive. Additionally, the adhesive layer 112 can include a copolymer. In embodiments, the hot melt adhesive can have a melting point of about 250° C. or less, such as about 220° C. or less. In other embodiments, the adhesive layer 112 may break down above about 200° C., such as above about 220° C. In further embodiments, the melting point of the hot melt adhesive can be greater than 250° C. or even greater than 300° C. The adhesive layer 112 has a thickness T of about 1 micron to 100 microns, such as about 10 microns to 50 microns. AL For example, the adhesive layer 112 may have a thickness T AL can be 27.5 microns.

[0013] FIG. 2A shows a cross-sectional view showing various layers of a bearing generally designated 150. According to this particular embodiment, the bearing 150 can be similar to the bearing 100 of FIG. 1, except that the bearing 150 can also include at least one corrosion protection layer 104, 106. The substrate layer 102 can be coated with the corrosion protection layers 104 and 106 to prevent corrosion of the substrate layer prior to treatment. Additionally, a temporary corrosion protection layer 108 can be applied over the layer 104. Each of the layers 104, 106, and 108 can have a thickness between about 1 micron and about 50 microns, such as between about 7 microns and about 15 microns. The layers 104 and 106 can include phosphates of zinc, iron, manganese, or any combination thereof. Additionally, the layers can be nano-ceramic layers. Additionally, layers 104 and 106 can include functional silanes, nanoscale silane-based primers, hydrolyzed silanes, organosilane adhesion promoters, solvent / water-based silane primers, chlorinated polyolefins, passivated surfaces, commercial zinc (mechanical / galvanic) or zinc-nickel coatings, or any combination thereof. Layer 108 can include functional silanes, nanoscale silane-based primers, hydrolyzed silanes, organosilane adhesion promoters, solvent / water-based silane primers. The temporary corrosion protection layers 104, 106, and 108 can be removed or retained during processing.

[0014] A corrosion resistant coating 114 can be applied to the surface of the substrate layer 102 opposite the low friction material layer 110. The corrosion resistant coating 114 can have a thickness between about 1 micron and about 50 microns, such as between about 5 microns and about 20 microns, such as between about 7 microns and about 15 microns. The corrosion resistant coating 114 can include an adhesion promoter layer 116 and an epoxy layer 118. The adhesion promoter layer 116 can include phosphates of zinc, iron, manganese, tin, or any combination thereof. Additionally, the adhesion promoter layer 116 can be a nano-ceramic layer. The adhesion promoter layer 116 can include functional silanes, nano-scale silane-based layers, hydrolyzed silanes, organosilane adhesion promoters, solvent / water-based silane primers, chlorinated polyolefins, passivated surfaces, commercial zinc (mechanical / galvanic) or zinc-nickel coatings, or any combination thereof.

[0015] The epoxy layer 118 can be a thermally cured epoxy, a UV cured epoxy, an IR cured epoxy, an e-beam cured epoxy, a radiation cured epoxy, or an air cured epoxy. Additionally, the epoxy resin can include polyglycidyl ether, diglycidyl ether, bisphenol A, bisphenol F, oxirane, oxacyclopropane, ethylene oxide, 1,2-epoxypropane, 2-methyloxirane, 9,10-epoxy-9,10-dihydroanthracene, or any combination thereof. The epoxy resin can include synthetic resin modified epoxies based on phenolic resins, urea resins, melamine resins, benzoguanamine with formaldehyde, or any combination thereof. By way of example, the epoxy can include monoepoxides, bisepoxides, linear trisepoxides, branched trisepoxides, or any combination thereof, and can include C X H Y X Z A U is a halogen atom X optionally replacing a hydrogen atom Zand optionally with atoms of nitrogen, phosphorus, boron, etc., where B is one of carbon, nitrogen, oxygen, phosphorus, boron, sulfur, etc.

[0016] The epoxy resin can further include a curing agent. The curing agent can include amines, acid anhydrides, phenol novolac hardeners such as phenol novolac poly[N-(4-hydroxyphenyl)maleimide] (PHPMI), resole phenol formaldehyde, fatty amine compounds, polycarboxylic acid anhydrides, polyacrylates, isocyanates, encapsulated polyisocyanates, boron trifluoride amine complexes, chromium-based hardeners, polyamides, or any combination thereof. In general, the acid anhydrides can conform to the formula RC=OOC=O-R', where R is C, as described above. X H Y X Z A U The amines can include aliphatic amines such as monoethylamine, diethylenetriamine, triethylenetetraamine, cycloaliphatic amines, cycloaliphatic amines, aromatic amines such as amidoamines, polyamides, dicyandiamide, imidazole derivatives, or any combination thereof. In general, the amines can be primary, secondary, or tertiary amines conforming to the formula R1R2R3N, where R is C, as described above. X H Y X Z A U It can be said that:

[0017] In one embodiment, the epoxy layer 118 can include fillers to improve electrical conductivity, such as metal fillers such as carbon fillers, carbon fibers, carbon particles, graphite, bronze, aluminum, and other metallic materials and alloys thereof, metal oxide fillers, metal coated carbon fillers, metal coated polymer fillers, or any combination thereof. The conductive fillers can allow electrical current to pass through the epoxy coating and can increase the electrical conductivity of the coated bearing compared to a coated bearing without the conductive fillers.

[0018] In one embodiment, the epoxy layer can increase the corrosion resistance of the bearing. For example, an epoxy layer, such as epoxy layer 118, can substantially prevent corrosive elements, such as water, salt, and the like, from contacting the substrate layer, thereby inhibiting chemical corrosion of the substrate layer. Additionally, the epoxy layer can inhibit galvanic corrosion of the housing or substrate layer by preventing contact between dissimilar metals. For example, placing an aluminum bearing without an epoxy layer in a magnesium housing can cause the magnesium to oxidize. However, an epoxy layer, such as epoxy layer 118, can prevent the aluminum substrate from contacting the magnesium housing, inhibiting corrosion due to galvanic reactions.

[0019] FIG. 2B shows a cross-sectional view showing the various layers of a bearing generally designated 175. According to this particular embodiment, the bearing 175 can be similar to the bearing 100 of FIG. 2A, except that the bearing 175 can also include a woven mesh or expanded metal grid 120 embedded between the two adhesive layers 112A and 112B. In an embodiment, the low friction material layer 110 can include a woven mesh or expanded metal grid. The woven mesh or expanded metal grid can include a metal or metal alloy, such as aluminum, steel, stainless steel, bronze, etc. Alternatively, the woven mesh can be a woven polymer mesh. In an alternative embodiment, the low friction material layer may not include a mesh or grid. In some embodiments, the substrate layer 102 may be encapsulated in the low friction material layer 110 by calendaring or laminating through openings in the sheet. The sheet may be formed into the substrate layer 102 having a radial inner and outer surface. The low friction material layer 110 can encapsulate the base layer 102 such that at least one of the radially inner and outer surfaces of the base layer 102 can be located within the low friction material layer 110 .

[0020] In some embodiments, as shown in Figures 1-2B, the bearing 100 can have a thickness T, where T can be ≧0.1 mm, for example, ≧0.25 mm, ≧0.5 mm, ≧1 mm, ≧1.5 mm, ≧2 mm, or ≧2.5 mm. In another aspect, T can be ≦2.0 mm, ≦1.5 mm, ≦1 mm, ≦0.5 mm, ≦0.25 mm, or ≦0.1 mm. It will be appreciated that the bearing 100 can have a thickness T that can be within a range between any of the minimum and maximum values ​​listed above. It will be further appreciated that the bearing 100 can have a thickness T that can be any value between any of the minimum and maximum values ​​listed above. For example, the bearing 100 can have a thickness T that can be 0.5 mm.

[0021] Turning to a method of forming a bearing (hereinafter generally designated 100, but which may include any of the components of bearings 150, 175 described above), a low friction material layer 110 can be adhered to a substrate layer 102 using a melt adhesive 112 to form a laminate sheet. The laminate sheet can be cut into strips or blanks that can be formed into bearings. Cutting the laminate sheet can form cut edges that include exposed portions of the substrate layer. The blank can be formed into a bearing 100, such as by rolling and flanging the laminate to form a semi-finished bearing of the desired shape.

[0022] For illustrative purposes, Figures 3A-3F show several bearing 100 shapes that can be formed from a blank. Figure 3A shows a cylindrical bearing 100 that can be formed by rolling. Figure 3B shows a flanged bearing 100 that can be formed by rolling and flanging. Figure 3C shows a flanged bearing 100 with a tapered cylindrical section that can be formed by rolling a tapered section and flanging the ends. Figure 3D shows a flanged bearing 100 mounted in a housing with a shaft pin attached via the flanged bearing 100. Figure 3E shows a double flanged bearing 100 mounted in a housing with a shaft pin attached via the double flanged bearing 100. Figure 3F shows an L-shaped bearing 100 that can be formed using a stamping and cold deep drawing process rather than rolling and flanging.

[0023] 3A-3B, in some particular embodiments, the bearing can be a plain bearing 100. In some embodiments, the bearing 100 can be a slide bearing. The bearing 100 can extend axially relative to a central axis 500. The central axis 500 can be longitudinal down the length of the bearing 100. The bearing 100 can include a sidewall 14 forming an annular shape having a first axial end or edge 3 and a second axial end or edge 5. The bearing can have an outer radial end or edge 7 and an inner radial end or edge 6. In some embodiments, the bearing 100 can have a non-planar shape. The bearing 100 can have a substantially L-shaped annular shape. In other words, the bearing 100 can have an L-shaped bearing cross-section extending radially and axially, as shown in FIG. 3B. Other annular shapes of the bearing are possible. In some embodiments, the bearing 100 shown in FIG. 3A can be manufactured by rolling an appropriately sized piece of bearing composite, which may initially exist as a flat piece of material. The ends of the rolled material piece can be joined at the axial gap 30 running axially down the bearing sidewall 14. Axial gaps 30 running in any non-linear manner and / or at an angle to the axis of symmetry 500 of the bearing 100 are also possible. In some particular embodiments, the axial gap 30 may be welded or otherwise joined by other means to form the bearing 100. In some embodiments, the axial gap 30 may be left unbonded to facilitate assembly of the bearing 100. Still referring to FIG. 3A, the bearing 100 can include a hole 50. The hole 50 can extend down the axial length of the bearing 100 and be adapted to be joined to another component of the assembly. The hole 50 can be parallel or planar to the central axis 500. Forming the hole 50 can include forming the hole in a sheet by drilling or punching. Fabrication of geometric shapes into the sheet may be accomplished by coining, forming, or deep drawing waves, spheres, or cones to form the sheet profile.In some embodiments, the L-shaped bearing 100 can be achieved by a deep drawing process that involves stamping a shaped bearing 100 (as shown in FIG. 3B).

[0024] 3B, the bearing 100 may include a radial bearing portion 10. The radial bearing portion 10 may be in the form of an axially extending base region 12. The radial bearing portion 10 may extend from a first axial end 3 to a second axial end 5. The radial bearing portion 10 may be on a side wall 14 of the bearing 100. The bearing 100 may further include an axial bearing portion 20. The axial bearing portion 20 may be on a side wall 14 of the bearing 100. An axial gap 30 may extend axially down the axial bearing portion 20. The axial bearing portion 20 may be in the form of a radial flange 22. The axial bearing portion 20 or radial flange 22 may extend from a central shaft 500 at an outer radial end or edge 7. In some embodiments, the bore 50 may radially separate the axial bearing portion 20 by providing an inner radial end or edge 6 that defines an edge of the bore 50 within the bearing 100. In some embodiments, the outer radial end 7 may form an outer radius OR of the bearing 100 as measured radially from the central axis 500. In some embodiments, the inner radial end 6 may form an inner radius IR of the bearing 100 as measured radially from the central axis 500. In other words, the radial flange 22W may RF The radial width of the radial flange 22 may be a distance from the difference between the distance of the outer radius OR and the inner radius IR. In some embodiments, the radial flange 22 may include an axial split 26. The axial split 26 may provide a gap. In certain embodiments, the axial split 26 may include the radial flange 22 in continuity with an axial gap 30 in the sidewall 14.

[0025] In some embodiments, as shown in FIG. 3B, the radial flange 22 has a thickness T of about 1 micron to about 3500 microns, such as about 100 microns to about 2000 microns, such as about 250 microns to about 1000 microns, such as about 450 microns to about 800 microns. RF The radial flange 22 may have a thickness T which may range between any of the minimum and maximum values ​​listed above. RF It will be further understood that the radial flange 22 can have a thickness T which can be any value between any of the minimum and maximum values ​​listed above. RF It will be further appreciated that the

[0026] In some embodiments, as shown in Figures 3A-3B, the bearing 100 can have an overall inner radius IR from the central axis 500 to the inner radial end 6, and IR can be ≧1 mm, e.g., ≧5 mm, ≧7.5 mm, ≧10 mm, ≧15 mm, or ≧20 mm. The inner radius IR can be ≦20 mm, e.g., ≦15 mm, ≦10 mm, ≦7.5 mm, ≦5 mm, or ≦1 mm. The inner radius IR can vary along the circumference of the bearing 100. In some embodiments, the bearing 100 can have an overall inner radius IR of about 1 to 6 mm. It will be appreciated that the bearing 100 can have an overall inner radius IR that can be within a range between any of the minimum and maximum values ​​listed above. It will be further appreciated that the bearing 100 can have an overall inner radius IR that can be any value between any of the minimum and maximum values ​​listed above.

[0027] In some embodiments, as shown in FIGS. 3A-3B, the bearing 100 can have an overall outer radius OR from the central axis 500 to the outer radial end 7, where OR can be ≧0.5 mm, e.g., ≧1 mm, ≧5 mm, ≧10 mm, ≧15 mm, or ≧20 mm. The outer radius OR can be ≦35 mm, e.g., ≦30 mm, ≦20 mm, ≦15 mm, ≦10 mm, or ≦5 mm. The overall outer radius OR can vary along the circumference of the bearing 100. In some embodiments, the bearing 100 can have an overall outer radius OR of about 3 mm to 15 mm. It will be appreciated that the bearing 100 can have an overall outer radius OR that can be within a range between any of the minimum and maximum values ​​listed above. It will be further appreciated that the bearing 100 can have an overall outer radius OR that can be any value between any of the minimum and maximum values ​​listed above. Additionally, as discussed above, the radial flange 22W RF The radial width W of the radial flange 22 may be the difference between the distance between the outer radius OR and the inner radius IR. RF can be between 1 and 10 mm.

[0028] In some embodiments, as shown in Figures 3A-3B, the bearing 100 can have an overall length L from the first axial end 3 to the second axial end 5, where L can be ≧0.5 mm, ≧0.75 mm, ≧1 mm, ≧2 mm, ≧5 mm, or ≧10 mm. The length L can be ≦10 mm, for example, ≦7.5 mm, ≦5 mm, ≦2.5 mm, or ≦1 mm. In some embodiments, the bearing 100 can have an overall length L between about 5 and 50 mm. It will be appreciated that the bearing 100 can have an overall length L that can be within a range between any of the minimum and maximum values ​​listed above. It will be further appreciated that the bearing 100 can be any value between any of the minimum and maximum values ​​listed above.

[0029] In some embodiments, the bearing 100 may be included in an assembly 1000. The assembly 1000 may further include an inner member 28 and an outer member 30. In some embodiments, the bearing 100 may be disposed between the inner member 28 and the outer member 30. FIGS. 4 and 5 show the assembly 1000 in the form of an exemplary hinge 400, such as an automotive door hinge, hood hinge, bay hinge, or the like. The hinge 400 may include the inner member 28 (such as an inner hinge portion 402) and the outer hinge portion 404. The hinge portions 402 and 404 may be joined by the outer member 30 (such as rivets 406 and 408) and bearings 410 and 412. The bearings 410 and 412 may be bearings of embodiments of the present invention as previously described herein and designated by the numeral 100. FIG. 5 shows a cross-section of the hinge 400 showing the rivet 408 and the bearing 412 in more detail.

[0030] 6 illustrates an assembly 1000 in the form of another exemplary hinge 600, such as an automotive door hinge, hood hinge, engine bay hinge, etc. The hinge 600 may include a first hinge portion 602 and a second hinge portion 604 joined by a pin 606 and a bearing 608. The bearing 608 may be a bearing as previously described.

[0031] In an exemplary embodiment, FIG. 7 shows a non-limiting example of an assembly 1000 of an embodiment of an alternative hinge assembly 700 including disassembled automotive door hinge parts including bearing 704. FIG. 7 is an example of a profile hinge. Bearing 700 can be inserted into hinge door part 706. Bearing 704 can be a bearing of an embodiment herein, as previously described. Rivet 708 bridges hinge door part 706 and hinge body part 710. Rivet 708 can be fastened to hinge body part 710 via set screw 712 and held in place with hinge door part 706 via washer 702.

[0032] 8 illustrates an assembly 1000 in the form of an exemplary headset assembly 800 for a two-wheeled vehicle, such as a bicycle or motorcycle. A steerer tube 802 may be inserted into a head tube 804. Bearings 806 and 808 may be disposed between the steerer tube 802 and the head tube 804 to maintain alignment and prevent contact between the steerer tube 802 and the head tube 804. The bearings 806 and 808 may be bearings of embodiments herein, as previously described. Additionally, seals 810 and 812 may prevent contamination of the sliding surfaces of the bearings with dirt and other particulate matter.

[0033] All such assemblies described above are exemplary and are not meant to limit the use of bearing 100 in other potential assemblies. For example, bearing 100 can be used in assembly 1000 for powertrain assembly applications (such as belt tensioners) or other assembly applications having limited space.

[0034] In an embodiment, the bearing 100 has a breaking elongation A 50 A 50 may be at least 20, at least 35, at least 45, at least 50, or even at least 60. In further embodiments, the bearing 100 has a breaking elongation A 50 A 50 can be 75 or less, for example, 50 or less, or 35 or less. 50 It will be further understood that the elongation at break A can be within a range between any of the minimum and maximum values ​​listed above. 50 It will be further understood that can be any value between any of the minimum and maximum values ​​listed above. For example, the breaking elongation A 50 can be ≧23%.

[0035] In an embodiment, the bearing 100 has a tensile strength R m Rm is at least 75N / mm 2 or at least 100N / mm 2 In a further embodiment, the bearing 100 may have a tensile strength R m R m is 1,000N / mm 2 For example, 500N / mm 2 Less than or equal to 250N / mm 2 The tensile strength R can be as follows: m It will be appreciated that the tensile strength R can be within a range between any of the minimum and maximum values ​​listed above. m It will be further understood that R can be any value between any of the minimum and maximum values ​​listed above. For example, the tensile strength R m 90 to 140N / mm 2 It can be between.

[0036] In an embodiment, the bearing 100 has a yield point Y p and Y p is at least 25N / mm 2 , at least 50N / mm 2 , at least 75N / mm 2 , at least 100N / mm 2 , and even at least 150N / mm 2 In a further embodiment, the bearing 100 may have a yield point Y p and Y p is 500N / mm 2 For example, 250N / mm 2 Below, 100N / mm 2 or less than 75N / mm 2 The tensile strength R can be as follows: m It will be appreciated that the tensile strength R can be within a range between any of the minimum and maximum values ​​listed above. m It will be further understood that Y can be any value between any of the minimum and maximum values ​​listed above. For example, the yield point Y p ≧35N / mm 2It can be said that:

[0037] FIG. 9 shows a graph of sizing pin oversize versus bearing inner diameter versus wall thickness reduction relative to the material thickness of the bearing compared to existing prior art bearings according to some embodiments. Bearing A is the bearing 100 according to embodiments shown herein. Bearing B is a bearing with a non-metallic backing with a metal grid substrate embedded with a low friction layer comprising polytetrafluoroethylene according to embodiments shown herein. Bearing C is a bearing with a metal grid substrate embedded with a low friction layer comprising polytetrafluoroethylene having a thickness of 0.7 mm according to known bearings. Bearing D is a bearing with a metal backing with a metal grid substrate embedded with a low friction layer comprising polytetrafluoroethylene having a thickness of 1 mm according to known bearings. Bearing E is a bearing with a structured steel substrate embedded with a low friction layer comprising polytetrafluoroethylene having a thickness of 0.5 mm according to known bearings. As shown, when a sizing pin is introduced to the bearing between the inner component 28 and the outer component 30 in the assembly 1000, the wall thickness reduction relative to the material thickness of bearing A according to embodiments shown herein has a larger value than bearings C, D, and E. As shown, the embodiment of Bearing A exhibits stiffer behavior than non-metallic backed Bearing B, but has wall thickness reduction that is nearly as good as non-metallic backed Bearing B known in the art.

[0038] FIG. 10 shows a graph of the bearing inner diameter versus the achievable flange width of the bearing compared to existing prior art bearings according to some embodiments. Bearing A is a bearing 100 having an aluminum 3003 alloy substrate with a low friction layer comprising polytetrafluoroethylene having a thickness of 0.5 mm according to embodiments shown herein. Bearing F is a bearing having an aluminum 3005 alloy substrate with a low friction layer comprising polytetrafluoroethylene having a thickness of 0.75 mm according to a known bearing. Bearing G is a bearing having an aluminum 3003 alloy substrate with a low friction layer comprising polytetrafluoroethylene having a thickness of 1 mm according to a known bearing. As shown, bearing A has a higher breaking elongation A. 50 , has a larger achievable flange width than bearings F and G known in the art.

[0039] Applications of such embodiments include, for example, the assembly 1000 for hinges, other vehicle components, and other industrial type applications, such as bicycles, solar, and the like. Additionally, the use of the bearing 100 or assembly 1000 can provide increased benefits in several applications, such as, but not limited to, vehicle tailgates, door frames, seat assemblies, powertrain applications (such as belt tensioners), or other types of applications. Various embodiments disclosed herein can have significant advantages over conventional solutions. According to embodiments herein, the bearings can exhibit higher corrosion resistance compared to existing bearings known in the art. Additionally, according to embodiments herein, the bearings can exhibit better flanging, stiffer behavior, and / or improved wall thickness reduction compared to existing bearings known in the art. Additionally, according to embodiments herein, the bearings can provide improved wall thickness reduction under sizing compared to bearings known in the art.

[0040] Many different aspects and embodiments are possible. Some of these aspects and embodiments are described below. After reading this specification, a person skilled in the art will understand that these aspects and embodiments are merely examples and do not limit the scope of the present invention. An embodiment may follow any one or more of the embodiments listed below.

[0041] Embodiment 1. A bearing having a thickness T S A substrate layer comprising an aluminum alloy having T S 0.6 mm, an adhesive layer, and a low-friction material layer covering the adhesive layer, 50 A bearing having a

[0042]

[0023] Embodiment 2. An assembly comprising an inner member, an outer member, and a bearing disposed between the inner member and the outer member, the bearing having a thickness T S A substrate layer comprising an aluminum alloy having T S 0.6 mm, an adhesive layer, and a low-friction material layer covering the adhesive layer, 50 1. An assembly comprising:

[0043] Embodiment 3. A bearing or assembly as described in any preceding embodiment, wherein the substrate layer comprises an aluminum alloy comprising 96.8 to 99 weight percent aluminum, 0.05 to 0.20 weight percent copper, 0 to 0.70 weight percent iron, 1 to 1.5 weight percent manganese, 0 to 0.6 weight percent silicon, and 0 to 0.1 weight percent zinc.

[0044] Embodiment 4. The bearing has a tensile strength R m Including R m However, it is about 90N / mm 2 from about 140N / mm 2 4. The bearing or assembly of any preceding embodiment, wherein the n is a number between 0 and 1.

[0045] Embodiment 5. The bearing has a yield point Y p Contains Y p≧ 35N / mm 2 4. The bearing or assembly of any preceding embodiment, having a value of

[0046] Embodiment 6. A bearing or assembly according to any of the preceding embodiments, wherein the bearing comprises an axial bearing portion and a radial flange.

[0047] Embodiment 7. The bearing or assembly of embodiment 6, wherein the radial flange has a thickness of less than 0.75 mm.

[0048] Embodiment 8. A bearing or assembly according to any of the preceding embodiments, wherein an adhesive layer is disposed between the substrate and the low friction material layer.

[0049] Embodiment 9. The bearing or assembly of embodiment 8, wherein the adhesive layer has a thickness of between 0.02 mm and 0.1 mm.

[0050] Embodiment 10. The bearing or assembly of embodiment 8, wherein the adhesive layer comprises a fluoropolymer.

[0051] Embodiment 11. A bearing or assembly according to any of the preceding embodiments, wherein the substrate layer has a thickness of from 0.1 mm to 0.5 mm.

[0052] Embodiment 12. A bearing or assembly according to any of the preceding embodiments, wherein the low friction layer has a thickness of from 0.05 mm to 0.25 mm.

[0053] Embodiment 13. A bearing or assembly according to any of the preceding embodiments, wherein the substrate comprises an aluminum 3003 alloy.

[0054] Embodiment 14. A bearing or assembly according to any preceding embodiment, wherein the low friction material layer comprises a fluoropolymer.

[0055] Embodiment 15. The bearing of any of the preceding embodiments, wherein the low friction material layer comprises polytetrafluoroethylene.

[0056] Embodiment 16. The bearing or assembly of embodiment 6, wherein the radial flange includes an axial split.

[0057] Embodiment 17. A bearing or assembly according to embodiment 6, wherein the bearing comprises an axial gap in the axial bearing portion.

[0058] Embodiment 18. A bearing or assembly according to any of the preceding embodiments, wherein the bearing has an inside radius of 2.5 to 20 mm.

[0059] Embodiment 19. A bearing or assembly according to any of the preceding embodiments, wherein the bearing has an outer diameter of 5 to 25 mm.

[0060] Embodiment 20. A bearing or assembly according to any of the preceding embodiments, wherein the bearing has a length of 5 to 50 mm.

[0061] It should be noted that not all of the features described above are required, that some of the particular features may not be required, and that one or more features may be provided in addition to those described. Further still, the order in which the features are described is not necessarily the order in which the features are provided.

[0062] Certain features that are, for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination.

[0063] Although benefits, other advantages, and solutions to problems have been described above with respect to particular embodiments, the benefits, advantages, solutions to problems, and any features that may give rise to or make more evident any benefit, advantage, or solution should not be construed as critical, necessary, or essential features of any or all claims.

[0064] The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all elements and features of the apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are described in the context of a single embodiment for brevity may also be provided separately or in any subcombination. Furthermore, references to values ​​described in a range include all values ​​within that range, including the end range values ​​mentioned. Many other embodiments will be apparent to those skilled in the art after reading this specification. Other embodiments may be used and derived from this disclosure, such that structural substitutions, logical substitutions, or any changes may be made without departing from the scope of this disclosure. Thus, this disclosure should be considered as illustrative and not limiting.

Claims

1. A bearing, A substrate layer comprising an aluminum alloy having a thickness of ≦0.6 mm; An adhesive layer; a low friction material layer overlying the adhesive layer, wherein the bearing has an elongation to break of ≧23%.

2. 1. An assembly comprising: An inner member; An outer member; a bearing disposed between the inner member and the outer member, the bearing comprising: A substrate layer comprising an aluminum alloy having a thickness of ≦0.6 mm; An adhesive layer; and a low friction material layer overlying said adhesive layer, said bearing having an elongation to break of ≧23%.

3. The substrate layer comprises an aluminum alloy, and the aluminum alloy is 96.8 to 99% by weight of aluminum; 0.05 to 0.20 wt. % copper; 0 to 0.70 wt. % iron; 1 to 1.5 wt. % manganese; 0 to 0.6 wt. % silicon; 0-0.1 wt. % zinc.

4. The bearing has a resistance of about 90 N / mm2 to about 140 N / mm ２ 3. A bearing or assembly as claimed in claim 1 or 2, having a tensile strength having a value between

5. The bearing has a resistance of ≧35 N / mm ２ 3. A bearing or assembly as claimed in claim 1 or 2, having a yield point having a value of

6. A bearing or assembly according to claim 1 or 2, wherein the bearing comprises an axial bearing portion and a radial flange.

7. A bearing or assembly according to claim 6, wherein the radial flange has a thickness of less than 0.75 mm.

8. 3. A bearing or assembly according to claim 1 or 2, wherein the adhesive layer is disposed between the substrate and the low friction material layer.

9. A bearing or assembly according to claim 8, wherein the adhesive layer has a thickness of between 0.02 mm and 0.1 mm.

10. The bearing or assembly of claim 8 , wherein the adhesive layer comprises a fluoropolymer.

11. A bearing or assembly according to claim 1 or 2, wherein the substrate layer has a thickness of between 0.1 mm and 0.5 mm.

12. A bearing or assembly according to claim 1 or 2, wherein the low friction layer has a thickness between 0.05 mm and 0.25 mm.

13. A bearing or assembly according to claim 1 or 2, wherein the substrate comprises an aluminium 3003 alloy.

14. A bearing or assembly according to claim 1 or 2, wherein the low friction material layer comprises a fluoropolymer.

15. A bearing or assembly as claimed in claim 6 wherein said radial flange includes an axial split.

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