Torque performance bearing and method of making and using same

Abstract

1. A bearing (400), comprising a sidewall (402) including a substrate (1119) and a low friction layer (1104) overlying the substrate, the sidewall further including an unformed section (440), at least one slot (442) in the unformed section, and at least one protrusion (450) extending from the unformed section forming a generally concave or convex cross-sectional shape in the sidewall.

Description

[Technical field]

[0001] The present disclosure relates generally to bearings, and more particularly to bearings with defined torque or linear sliding performance. Summary of the Invention [Problem to be solved by the invention]

[0002] Generally, bearings constrain relative motion to a desired motion and reduce friction between moving parts. One type of bearing may be located in the gap between the outer surface of an inner component and the inner surface of a bore of an outer component in an assembly. Exemplary assemblies may include doors, hoods, tailgates, engine compartment hinges, seats, steering columns, flywheels, drive shaft assemblies, friction brakes, spindle drives, or other assemblies, particularly those used in automotive applications. Sometimes it is necessary to have coordinated torque variations across components such as inner components (such as shafts) and outer components (such as housings) in such assemblies. Such torque variations can cause sizing issues, hardness, noise, and undesirable wear over the life of the assembly. Furthermore, in certain friction brake or spindle drive assemblies for vehicle doors, low variation in friction torque performance may be important to stop the door at any position and compensate for spring forces for more reliable safety control. Thus, there is a continuing need for improved bearings that provide improved torque performance while maintaining a long life of the assembly.

[0003] An embodiment of the invention may include a bearing comprising a sidewall including a substrate and a low friction layer overlying the substrate, the sidewall further including an unformed section, at least one slot in the unformed section, and at least one protrusion extending from the unformed section forming a generally concave cross-sectional shape in the sidewall.

[0004] An embodiment of the invention may include a bearing comprising a sidewall including a substrate and a low friction layer overlying the substrate, the sidewall including an unformed section, at least one slot in the unformed section, and at least one protrusion extending from the unformed section forming a generally convex cross-sectional shape in the sidewall.

[0005] An embodiment of the invention may include an assembly including an outer component including a bore in the outer component, an inner component disposed within the bore, and a bearing disposed between the inner and outer components, the bearing including a sidewall including a substrate and a low friction layer overlying the substrate, the sidewall further including an unformed section, at least one slot in the unformed section, and at least one protrusion extending from the unformed section forming a generally concave or convex cross-sectional shape in the sidewall.

[0006] An embodiment of the invention may include an assembly including an outer component including a bore in the outer component, an inner component disposed within the bore, and a bearing disposed between the inner and outer components and secured to the outer component, the bearing including a sidewall including a substrate and a low friction layer overlying the substrate, the sidewall further including an unformed section, at least one slot in the unformed section, and at least one protrusion extending from the unformed section forming a generally concave or convex cross-sectional shape in the sidewall, the bearing having a friction torque with the inner or outer component, the bearing having a life of at least 1 million cycles and a friction torque change of the assembly over a temperature range of -40°C to 80°C within ±20%.

[0007] An embodiment of the invention may include a method including disposing a bearing between an inner component and an outer component, the bearing including a sidewall including a substrate and a low friction layer overlying the substrate, the sidewall further including an unformed section, at least one slot in the unformed section, at least one protrusion extending from the unformed section, and a generally concave or convex cross-sectional shape in the sidewall.

[0008] An embodiment of the invention may include a method including disposing a bearing between an inner component and an outer component, the bearing including a sidewall including a substrate and a low friction layer overlying the substrate, the sidewall further including an unformed section, at least one slot in the unformed section, and at least one protrusion extending from the unformed section forming a generally concave or convex cross-sectional shape in the sidewall; and rotating or translating the bearing to create a friction torque with the inner or outer component, the friction torque varying within ±20% for an assembly having a life of at least 1 million cycles and over a temperature range of -40°C to 80°C. [Brief description of the drawings]

[0009] The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art by referencing the accompanying drawings. [Figure 1] FIG. 1 includes a method of producing a bearing, according to one embodiment. [Figure 2A] FIG. 2A includes a cross-sectional view of one embodiment of a bearing material for a bearing, according to one embodiment. [Figure 2B] FIG. 2B includes a cross-sectional view of an embodiment of a bearing material for a bearing, according to one embodiment. [Figure 2C] FIG. 2C includes a cross-sectional view of an embodiment of a bearing material for a bearing, according to one embodiment. [Figure 3A] FIG. 3A is a schematic diagram illustrating surface contours of a low-friction material for a bearing, according to an embodiment. [Figure 3B] FIG. 3B is a schematic diagram showing, for purposes of illustration, a simplified version of the geometric lines shown in FIG. 3A. [Figure 3C] FIG. 3C is a schematic diagram showing a straight line connecting the bottom of the recess and the apex of the protrusion along the contour line shown in FIG. 3A. [Figure 4A] FIG. 4A includes a perspective view of a bearing constructed in accordance with one embodiment. [Figure 4B] FIG. 4B includes a perspective view of a bearing constructed in accordance with one embodiment. [Figure 4C] FIG. 4C includes a perspective view of a bearing constructed in accordance with one embodiment. [Figure 4D] FIG. 4D includes a perspective view of a bearing constructed in accordance with one embodiment. [Figure 4E] FIG. 4E includes a perspective view of a bearing constructed in accordance with one embodiment. [Figure 4F] FIG. 4F includes a perspective view of a bearing constructed in accordance with one embodiment. [Figure 4G] FIG. 4G includes a perspective view of a bearing constructed in accordance with one embodiment. [Figure 4H] FIG. 4H includes a perspective view of a bearing constructed in accordance with one embodiment. [Figure 5A] FIG. 5A includes an axial cross-sectional view of the bearing of FIG. 4 in an assembly, according to one embodiment. [Figure 5B] FIG. 5B includes a radial cross-sectional view of the bearing of FIG. 3 in an assembly, according to one embodiment. [Figure 6] FIG. 6 includes a method of using a bearing according to one embodiment. [Figure 7] FIG. 7 includes a graph of friction torque curves versus test cycles for a bearing, according to one embodiment. [Figure 8] FIG. 8 includes a graph of normalized torque curves versus temperature for bearings using shaft samples with different surface roughness, according to one embodiment.

[0010] 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

[0011] The following description in combination with the drawings is provided to aid in understanding the teachings disclosed herein. The following discussion focuses on specific implementations and embodiments of the teachings. This focus is provided to help explain the teachings and should not be construed as a limitation on the scope or applicability of the teachings. However, other embodiments can be used based on the teachings disclosed in this application.

[0012] The terms "comprises," "comprising," "includes," "including," "has," "having," or any other variations thereof, are intended to cover non-exclusive inclusions. For example, a method, article, or assembly that includes a list of features is not necessarily limited to only those features, but may include other features not expressly listed or that are inherent to such method, article, or assembly. Further, unless expressly stated to the contrary, "or" refers to an inclusive or, not an exclusive or. For example, a condition A or B is satisfied by any one 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).

[0013] Also, 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 understood as one, at least one, or the singular as including the plural, or vice versa, unless it is clear that this is meant to be otherwise. For example, where a single embodiment is described herein, two or more embodiments can be used in place of the single embodiment. Similarly, where two or more embodiments are described herein, the single embodiment can be replaced with two or more embodiments.

[0014] 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 in the art of bearings and bearing assemblies.

[0015] For purposes of illustration, Figure 1 includes a method of producing a low friction material according to the above-described embodiments. The forming process 10 may include a first step 12 of providing a base material, a second step 14 of coating the base material with a low friction coating to form the low friction material, and a third step 16 of forming the low friction material into a bearing.

[0016] Referring to the first step 12, the base material may be a substrate. In an embodiment, the substrate may at least partially comprise a metal, a plastic, or a ceramic. In an embodiment, the substrate may at least partially comprise a metal. According to certain embodiments, the metal may comprise iron, bronze, magnesium, zinc, copper, titanium, tin, aluminum, alloys thereof, or may be another type of metal. More specifically, the substrate may at least partially comprise a steel, such as stainless steel, carbon steel, or spring steel. For example, the substrate may at least partially comprise 301 stainless steel. The 301 stainless steel may be annealed, ¼ hard, ½ hard, ¾ hard, or full hard. Furthermore, the steel may comprise stainless steel containing chromium, nickel, or combinations thereof. A particular stainless steel is 301 stainless steel. The base material and / or substrate may be of any structure or shape. In an embodiment, the base material and / or substrate may be a plate, sheet, woven fabric, mesh, grid, expanded sheet, perforated sheet, or metal foam, or combinations thereof. For example, in some embodiments, the substrate may include a plate and a woven fabric. In other embodiments, the substrate may include a metal plate and a different metal covering the metal plate. The substrate may include a woven mesh or expanded metal grid, an expanded sheet, or a perforated sheet. Alternatively, the woven mesh may be a woven polymer mesh. In alternative embodiments, the substrate may not include a mesh or grid.

[0017] In some embodiments, the substrate may be spring steel. The spring steel substrate may be annealed, ¼ hard, ½ hard, ¾ hard, or full hard. The spring steel substrate may have a tensile strength of 600 MPa or more, such as 700 MPa or more, such as 750 MPa or more, such as 800 MPa or more, such as 900 MPa or more, or such as 1000 MPa or more. The spring steel substrate may have a tensile strength of 1500 MPa or less, or such as 1250 MPa or less.

[0018] In other embodiments, the substrate can have a coating. The coating can be a layer of another metal or alloy. In embodiments, the coating can be a metal or alloy containing at least one of the following metals: chromium, molybdenum, tungsten, manganese, iron, ruthenium, osmium, cobalt, rhodium, iridium, nickel, palladium, platinum, copper, silver, gold, zinc, cadmium, mercury, aluminum, gallium, indium, thallium, silicon, germanium, tin, lead, antimony, and bismuth. In yet other embodiments, the coating can be a copper alloy, a copper-tin alloy, a copper-zinc alloy, bronze, phosphor bronze, silicon bronze, brass, or any combination thereof.

[0019] FIG. 2A includes a diagram of a low friction material or composite 1000 that may be formed according to the first step 12 and the second step 14 of the forming process 10 for forming a low friction material for a bearing according to the above-described embodiment. For illustrative purposes, FIG. 2A shows the layer-by-layer configuration of the low friction material 1000 after the second step 14. In some embodiments, the low friction material 1000 may include a substrate 1119 (i.e., the base material provided in the first step 12) and a low friction layer 1104 (i.e., the low friction coating applied in the second step 14). As shown in FIG. 2A, the low friction layer 1104 may be bonded to at least a portion of the substrate 1119. In certain embodiments, the low friction layer 1104 may be bonded to a surface of the substrate 1119 to form a low friction interface with another surface of another component. The low friction layer 1104 may be bonded to a radially inner surface of the substrate 1119 to form a low friction interface with another surface of another component. The low friction layer 1104 may be bonded to a radially outer surface of the substrate 1119 to form a low friction interface with another surface of another component. In another embodiment, the substrate 1119 may be embedded within the low friction layer 1104 to provide a low friction layer 1104 on both sides of the substrate 1119.

[0020] The low friction layer may be textured, as described in more detail below. In some embodiments, the low friction layer 1104 may include a low friction material. The low friction material may include a polymer, such as, for example, polyketone, polyaramid, polyimide, polyetherimide, polyphenylene sulfide, polyethersulfone, polysulfone, polyphenylene sulfone, polyamideimide, ultra-high molecular weight polyethylene, fluoropolymer, polyamide, polybenzimidazole, or any combination thereof. In one example, the low friction layer 1104 may include polyketone, polyaramid, polyimide, polyetherimide, polyamideimide, polyphenylene sulfide, polyphenylene sulfone, fluoropolymer, polybenzimidazole, derivatives thereof, or combinations thereof. In a particular example, the low friction / wear resistant layer includes a polymer, such as polyketone, thermoplastic polyimide, polyetherimide, polyphenylene sulfide, polyethersulfone, polysulfone, polyamideimide, derivatives thereof, or combinations thereof. In a further example, the low friction / wear resistant layer comprises a polyketone, such as polyether ether ketone (PEEK), polyether ketone, polyether ketone ketone, polyether ketone ether ketone, derivatives thereof, or combinations thereof. In a further embodiment, the low friction / wear resistant layer may be ultra-high molecular weight polyethylene.Exemplary fluoropolymers include fluorinated ethylene propylene (FEP), polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), perfluoroalkoxy (PFA), terpolymers of tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride (THV), polychlorotrifluoroethylene (PCTFE), ethylene tetrafluoroethylene copolymer (ETFE), ethylene chlorotrifluoroethylene copolymer (ECTFE), polyacetal, polybutylene terephthalate (PBT), polyethylene terephthalate (PE), and the like. The present invention may include any of a variety of materials, including but not limited to, polyimide (PI), polyetherimide, polyetheretherketone (PEEK), polyethylene (PE), polysulfone, polyamide (PA), polyphenylene oxide, polyphenylene sulfide (PPS), polyurethane, polyester, liquid crystal polymer (LCP), or any combination thereof.The low friction layer 1104 may include solid-based materials including lithium soap, graphite, boron nitride, molybdenum disulfide, tungsten disulfide, polytetrafluoroethylene, carbon nitride, tungsten carbide, or diamond-like carbon, metals (aluminum, zinc, copper, magnesium, tin, platinum, titanium, tungsten, lead, iron, bronze, steel, spring steel, stainless steel, etc.), metal alloys (including the metals listed), anodized metals (including the metals listed), or any combination thereof. According to certain embodiments, fluoropolymers may be used. In one embodiment, the low friction layer 1104 may not include polytetrafluoroethylene (PTFE).

[0021] In some embodiments, the low friction layer 1104 may further include fillers including fiberglass, carbon fiber, silicon, PEEK, aromatic polyester, carbon particles, bronze, fluoropolymer, thermoplastic fillers, aluminum oxide, polyamidimide (PAI), PPS, polyphenylene sulfone (PPSO2), LCP, aromatic polyester, molybdenum disulfide, tungsten disulfide, graphite, grapheme, expanded graphite, boron nitride, talc, calcium fluoride, or any combination thereof. Additionally, the fillers may include alumina, silica, titanium dioxide, calcium fluoride, boron nitride, mica, wollastonite, silicon carbide, silicon nitride, barium sulfate, zirconia, carbon black, pigments, or any combination thereof. In certain embodiments, the low friction layer 1104 may include an organic filler including polytetrafluoroethylene (PTFE), polyamide (PA), polyetheretherketone (PEEK), polyimide (PI), polyamideimide (PAI), polyphenylene sulfide (PPS), polyphenylene sulfone (PPSO2), liquid crystal polymer (LCP), perfluoroalkoxy polymer (PFA), polyoxymethylene (POM), polyethylene (PE), UHMWPE, ethylene propylene diene, or a mixture thereof. In one embodiment, the low friction layer 1104 may include only polytetrafluoroethylene (PTFE) as a filler. The filler may be in the form of beads, fibers, powder, mesh, or any combination thereof. The filler may be at least 1% by weight, such as at least 5% by weight, or even 10% by weight, based on the total weight of the low friction layer.

[0022] The substrate 1119 can have a thickness Ts of at least about 0.05 mm, e.g., at least about 0.1 mm, at least about 0.15 mm, at least about 0.2 mm, at least about 0.25 mm, at least about 0.3 mm, at least about 0.35 mm, at least about 0.4 mm, or at least about 0.45 mm. The substrate 1119 can have a thickness Ts of about 5 mm or less, about 4 mm or less, about 3 mm or less, about 2.5 mm or less, about 2 mm or less, about 1.5 mm or less, about 1 mm or less, about 0.9 mm or less, about 0.8 mm or less, about 0.7 mm or less, about 0.6 mm or less, about 0.55 mm or less, or about 0.5 mm or less. It will be further understood that the thickness Ts of the substrate 1119 can be any value between any of the minimum and maximum values ​​mentioned above. The thickness of the substrate 1119 can be uniform, i.e., the thickness of the substrate 1119 at a first location can be equal to the thickness at a second location along the substrate 1119. The thickness of the substrate 1119 may be uniform, ie, the thickness of the substrate 1119 at a first location may be different from the thickness at a second location along the substrate 1119.

[0023] The low friction layer 1104 has a thickness T of at least about 0.05 mm, e.g., at least about 0.1 mm, at least about 0.15 mm, at least about 0.2 mm, at least about 0.25 mm, at least about 0.3 mm, at least about 0.35 mm, at least about 0.4 mm, or at least about 0.45 mm. SL The low friction layer 1104 can have a thickness T of about 5 mm or less, about 4 mm or less, about 3 mm or less, about 2.5 mm or less, about 2 mm or less, e.g., about 1.5 mm or less, about 1 mm or less, about 0.9 mm or less, about 0.8 mm or less, about 0.7 mm or less, about 0.6 mm or less, about 0.55 mm or less, or about 0.5 mm or less. SL Furthermore, the thickness T of the sliding layer 1104 can be SLIt will be appreciated that may be any value between any of the minimum and maximum values ​​mentioned above. The thickness of the low friction layer 1104 may be uniform, i.e., the thickness of the low friction layer 1104 at a first location may be equal to the thickness at a second location along it. The thickness of the low friction layer 1104 may be non-uniform, i.e., the thickness of the low friction layer 1104 at a first location may differ from the thickness at a second location along it. It will be appreciated that different low friction layers 1104 may have different thicknesses. The low friction layer 1104 may be on one major surface of the illustrated substrate 1119 or on both major surfaces. The substrate 1119 may be at least partially encapsulated by the low friction layer 1104. That is, the low friction layer 1104 may cover at least a portion of the substrate 1119. An axial surface of the substrate 1119 may be exposed from the low friction layer 1104.

[0024] FIG. 2B includes a diagram of an alternative embodiment of a low friction material or composite that may be formed according to the first step 12 and the second step 14 of the forming process 10 for forming a low friction material for a bearing according to the above-described embodiment. For illustrative purposes, FIG. 2B shows the layer-by-layer configuration of the low friction material 1002 after the second step 14. According to this particular embodiment, the low friction material 1002 may be similar to the composite material 1000 of FIG. 2A, except that the low friction material 1002 may also include at least one adhesive layer 1121 that may bond the low friction layer 1104 to the substrate 1119 (i.e., the base material provided in the first step 12) and the low friction layer 1104 (i.e., the low friction coating applied in the second step 14). In another alternative embodiment, the substrate 1119 may be embedded between at least one adhesive layer 1121 included between the low friction layer 1104 and the substrate 1119 as a solid component, a woven mesh or an expanded metal grid.

[0025] The adhesive layer 1121 may comprise any known adhesive material common to the bearing art, 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 may comprise 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 1-20 carbon atoms. Additionally, the adhesive may comprise a copolymer. In one embodiment, the hot melt adhesive may have a melting temperature of 250°C or less, such as 220°C or less. In another embodiment, the adhesive may decompose above 200°C, such as above 220°C. In further embodiments, the melting temperature of the hot melt adhesive may be greater than 250°C, or even greater than 300°C. The adhesive layer 1121 may have a thickness of about 1-50 microns, such as about 7-15 microns. In one embodiment, the hot melt adhesive may have a melting temperature of 250° C. or less, such as 220° C. or less. In another embodiment, the adhesive may decompose above 200° C., such as above 220° C. In further embodiments, the melting temperature of the hot melt adhesive may be above 250° C., or even above 300° C.

[0026] The adhesive layer 1121 has a thickness T of about 1 micron to about 80 microns, for example, about 10 microns to about 50 microns, for example, about 20 microns to about 40 microns. AL In some embodiments, the adhesive layer 1121 may have a thickness T of about 3 to 20 microns. AL In some embodiments, the adhesive layer 1121 may have a thickness T of about 10 to 60 microns. AL The adhesive layer 1121 may have a thickness T ALIt will be further understood that may be any value between any of the above minimum and maximum values. The thickness of adhesive layer 1121 may be uniform, i.e., the thickness of adhesive layer 1121 at a first location may be equal to the thickness at a second location along it. The thickness of adhesive layer 1121 may be non-uniform, i.e., the thickness of adhesive layer 1121 at a first location may differ from the thickness at a second location along it.

[0027] The thickness of the adhesive layer 1121 may essentially correspond to the roughness of the substrate 1119, defined as the distance Rmax between the maximum profile peak height and the maximum profile bottom depth of the roughness profile of the surface of the substrate 1119. In this way, it can be ensured that a sufficiently thick adhesive layer 1121 is applied to the substrate 1119 so that a full-surface adhesive bond between the low-friction layer 1104 and the substrate 1119 is guaranteed. The adhesive layer 1121 should also not be manufactured too thick. In this case, there is a risk that when joining the layers, parts of the adhesive layer 1121 may be extruded from the adhesive bond or that cohesive failure may occur within the parts of the adhesive layer 1121 that protrude above the roughness profile of the substrate 1119 surface when the low-friction material is subjected to shear stresses.

[0028] For example, the surface roughness of the substrate 1119 may be at least about 0.01 microns, at least about 0.02 microns, at least about 0.05 microns, at least about 0.1 microns, at least about 0.5 microns, at least about 1 micron, at least about 2 microns, at least about 5 microns, at least about 10 microns, at least about 20 microns, at least about 50 microns, at least about 100 microns, at least about 200 microns, or at least about 400 microns. In other embodiments, the surface roughness can be less than about 400 microns, less than about 200 microns, less than about 100 microns, less than about 50 microns, less than about 25 microns, less than about 20 microns, less than about 15 microns, less than about 10 microns, less than about 5 microns, less than about 3 microns, less than about 2 microns, or even less than about 1 micron. In yet other embodiments, the substrate 1119 can have a surface roughness ranging from about 0.1 microns to about 400 microns, from about 0.5 microns to about 100 microns, or from about 1 micron to about 50 microns.

[0029] Furthermore, the surface of the substrate 1119 can be treated by electrolytic galvanization to roughen, upgrade or coat the surface. This is done before the application of the adhesive layer 1121. In other embodiments, the surface area of ​​the substrate 1119 can be increased by mechanical structuring. Structuring can include brushing, sandblasting, etching, perforating, pickling, punching, pressing, curling, deep drawing, warping reduction, incremental sheet forming, ironing, laser cutting, rolling, hammering, embossing, undercutting, and any combination thereof. For example, embossing of structures allows interlocking possibilities, which has a positive effect on the resulting bond strength.

[0030] FIG. 2C includes a diagram of an alternative embodiment of a low friction material or composite that may be formed according to the first step 12 and the second step 14 of the forming process 10 for forming a low friction material for a bearing according to the embodiments described above. For illustrative purposes, FIG. 2C shows the layer-by-layer configuration of the low friction material 1003 after the second step 14. According to this particular embodiment, the low friction material 1003 may be similar to the low friction material 1002 of FIG. 2B, except that the low friction material 1003 may also include at least one corrosion protection layer 1704, 1705, and 1708, and a corrosion resistant coating 1125 that may include an adhesion promoter layer 1127 and an epoxy layer 1129 that may bond to the substrate 1119 (i.e., the base material provided in the first step 12) and the low friction layer 1104 (i.e., the low friction coating applied in the second step 14).

[0031] The substrate 1119 may be coated with corrosion protection layers 1704 and 1705 to prevent corrosion of the low friction material 1003 prior to processing. Additionally, a corrosion protection layer 1708 may be added over layer 1704. Each of layers 1704, 1705, and 1708 may have a thickness of about 1-50 microns, for example about 7-15 microns. Layers 1704 and 1705 may include phosphates of zinc, iron, manganese, or any combination thereof, or nanoceramic layers. Additionally, layers 1704 and 1705 may 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 1708 may include functional silanes, nanoscale silane-based primers, hydrolyzed silanes, organosilane adhesion promoters, solvent / water-based silane primers. The corrosion protection layers 1704, 1705, and 1708 may be removed or retained during processing.

[0032] The low friction material 1003 may further include a corrosion resistant coating 1125. The corrosion resistant coating 1125 may have a thickness of about 1-50 microns, such as about 5-20 microns, and such as about 7-15 microns. The corrosion resistant coating 1125 may comprise an adhesion promoter layer 1127 and an epoxy layer 1129. The adhesion promoter layer 1127 may include a phosphate of zinc, iron, manganese, tin, or any combination thereof, or a nano-ceramic layer. The adhesion promoter layer 1127 may include a functional silane, a nano-scale silane-based layer, a hydrolyzed silane, an organosilane adhesion promoter, a solvent / water-based silane primer, a chlorinated polyolefin, a passivated surface, a commercially available zinc (mechanical / galvanic) or zinc-nickel coating, or any combination thereof. The epoxy layer 1129 may be a thermal cure epoxy, a UV cure epoxy, an IR cure epoxy, an electron beam cure epoxy, a radiation cure epoxy, or an air cure epoxy. Additionally, the epoxy layer 1129 may 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 layer 1129 may further include a hardener. The hardener may include amines, acid anhydrides, phenol novolac hardeners, such as phenol novolac poly[N-(4-hydroxyphenyl)maleimide] (PHPMI), resole phenol formaldehyde, aliphatic 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 are represented by the formula RC=OOC=O-R', where R is C, as described above. X H Y X Z A UThe amines may include aliphatic amines such as monoethylamine, diethylenetriamine, triethylenetetramine, etc., aromatic amines such as alicyclic amines, cyclic aliphatic amines, cycloaliphatic amines, amidoamines, polyamides, dicyandiamide, imidazole derivatives, etc., or any combination thereof.

[0033] In one embodiment, under step 14 of FIG. 1, any of the layers on the low friction material or composite 1000, 1002, 1003 can each be placed in a roll, peeled therefrom, and bonded together under pressure, at high temperature (hot or cold pressing or rolling), by adhesive, or any combination thereof, as described above. Any of the layers of the low friction material 1000 can be laminated together to at least partially overlap one another, as described above. Any of the layers on the low friction material 1000, 1002, 1003 can be applied together, as described above, using coating techniques such as, for example, physical or vapor deposition, spraying, plating, powder coating, or through other chemical or electrochemical techniques. In certain embodiments, the low friction layer 1104 can be applied by a roll-to-roll coating process, including, for example, extrusion coating. The low friction layer 1104 can be heated to a molten or semi-molten state and extruded through a slot die onto a major surface of the substrate 1119. In another embodiment, the low friction layer 1104 can be cast or molded.

[0034] In one embodiment, the low friction layer 1104 may be attached or otherwise adhered to the substrate 1119 to form a laminate. In one embodiment, the low friction layer 1104 or any layer may be attached or otherwise adhered to the substrate 1119 using a melt adhesive layer 1121 to form a laminate. In one embodiment, the low friction layer 1104 or any layer may be attached or otherwise adhered to the substrate 1119 as a polymer tape to form a laminate. In one embodiment, any of the intervening or protruding layers on the material or low friction material 1000, 1002, 1003 may form a laminate. The laminate may be cut into strips or blanks that may be formed into bearings. Cutting the laminate may include the use of a stamp, press, punch, saw, or may be machined in a different way. Cutting the laminate may create a cut edge that includes an exposed portion of the substrate 1119.

[0035] In other embodiments, under step 14 of FIG. 1, any of the layers on the low friction material 1000, 1002, 1003 as described above may be applied by coating techniques such as, for example, physical or vapor deposition, spraying, plating, powder coating, or through other chemical or electrochemical techniques. In certain embodiments, the low friction layer 1104 may be applied by a roll-to-roll coating process, including, for example, extrusion coating. The low friction layer 1104 may be heated to a molten or semi-molten state and extruded through a slot die onto a major surface of the substrate 1119. In another embodiment, the low friction layer 1104 may be cast or molded.

[0036] Referring now to the third step 16 of the forming process 10 as shown in FIG. 1, according to certain embodiments, forming the low friction material 1000, 1002, 1003 into a bearing may include a cutting operation. In an embodiment, the cutting operation may include the use of a stamp, press, punch, saw, deep drawing, or may be machined in a different manner. In some embodiments, the cutting operation may form a peripheral surface on the low friction material. The cutting operation may define a cutting direction starting from a first major surface toward a second major surface opposite the first major surface to form a peripheral surface or edge. Alternatively, the cutting operation may define a cutting direction starting from the second major surface toward the first major surface to form a peripheral surface or edge. The low friction material may now be shaped into a bearing for a desired application.

[0037] After forming the low friction material, the low friction material or bearing may be cleaned to remove any lubricants and oils used in the forming and shaping process. Additionally, cleaning may prepare the exposed surface of the substrate for application of a coating. Cleaning may include chemical cleaning with a solvent and / or mechanical cleaning, such as ultrasonic cleaning.

[0038] 1, in accordance with the embodiments described above, the low friction layer 1104 that covers the substrate 1119 within the substrate may be textured to have microscopically fine asperities (e.g., peaks and valleys on a surface) that form a low friction surface, rather than a macroscopic thickness variation of the low friction layer 1104 itself. The low friction surface may be one side of the low friction layer 1104, i.e., the side opposite the substrate 1119, as shown in FIG. 2C.

[0039] FIG. 3A is an enlarged view in which the X-axis is enlarged by 200 times and the Y-axis is enlarged by 1000 times. The surface shape of the low friction layer 1104 is obtained as the shape line C shown in FIG. 3. The shape line C represents the apex and bottom of the surface of the low friction layer 1104 in a cross section containing a plane parallel to the thickness direction of the low friction layer 1104. The shape line C is represented using an XY coordinate system. Specifically, the X-axis represents the arrangement between any two points, and the Y-axis represents the thickness direction of the low friction layer 1104, that is, the arrangement in the Y-axis direction represents the depth and height of the apex and bottom of the surface. Therefore, the shape line C contains the apex and bottom according to the surface shape of the low friction layer 1104.

[0040] FIG. 3B shows a simplified version of the shape line C shown in FIG. 3A for the purpose of explanation. The shape line C, which includes the apex and the bottom, is divided into upper and lower parts in the Y-axis direction based on a virtual straight line Lx parallel to the X-axis. When the low-friction surface of the low-friction layer 1104 is microscopically flat, the low-friction surface of the low-friction layer 1104, the X-axis, and the virtual straight line Lx are parallel to each other. When the shape line C is divided by the virtual straight line Lx, the concave region (bottom) protruding downward from the virtual straight line Lx and the convex region (apex) protruding upward from the virtual straight line Lx are separated from each other. In FIG. 4, the concave region is shown by "shading" and the convex region is shown by "diagonal lines". The virtual straight line Lx, which is arranged so that the sum S1 of the areas of the concave regions and the sum S2 of the areas of the extension regions are equal, is defined as the average line Lv of the extension and recess. That is, across the low friction surface of the low friction layer 1104, the sum S1 of the areas of the recessed regions protruding downward from the average line Lv of the extensions and recesses is equal to the sum S2 of the areas of the extensions protruding upward from the average line Lv of the extensions and recesses (S1=S2). The area protruding downward from the average line Lv of the extensions and recesses is defined as the bottom 21, and the area protruding upward from the average line Lv of the extensions and recesses is defined as the apex 22.

[0041] In this embodiment, the X-axis is defined as the central arrangement in the circumferential and radial directions of the surface of the low friction layer 1104 or low friction material, and is defined as the direction tangent to the circumferential direction for measurement. The number, arrangement, and direction of the positions during measurement can be arbitrarily adjusted for any two points, taking into consideration the application of the low friction layer 1104.

[0042] FIG. 3C is a schematic diagram of a simplified version of the shape line C shown in FIG. 3B for the purpose of illustration. In this embodiment, the relationship between the base 21 and the apex 22 adjacent to each other is used to further verify the performance of the low friction layer 1104 or low friction material. Each of the bases 21 has a base 31 at the deepest position of the base 21, i.e., the position closest to the substrate 1119. The convex portion 22 adjacent to the extension portion 21 has a apex 32 at the highest position of the apex 22, i.e., the position farthest from the substrate 1119. As described above, when the base 21 and the apex 22 are adjacent to each other with the average line Lv of the extension portion and the recess portion, the base 31 of the base 21 and the apex 32 of the apex 22 can be connected to each other with an imaginary straight line L. The slope of the straight line L is the measured distance 45 in the Y-axis direction between the base 31 of the base 21 and the apex 32 of the apex 22 divided by the measured distance 35 in the X-axis direction between the base 31 and the apex 32. The average of the slopes of the resulting lines L is the average slope SDQ or root mean square slope. In some embodiments, the root mean square slope of the low friction material may be less than 0.064.

[0043] Further, the root mean square gradient may have an average angle α from base to apex, which may be at least 0.01°, such as 0.05°, for example 0.1°, for example 0.15°, for example 0.5°, for example 1°, for example 1.5°, for example 2°, or for example 3°.

[0044] Furthermore, the apex material fraction Smr1 can be calculated as the percentage of low friction material that comprises the apex. In other words, the thickness of the substrate is T S Smr1 is the thickness T of the substrate or core surface. S from the total thickness T of the low friction material SL is the area material ratio dividing the reduced apex of the low friction material Smr1. The reduced apex is the area removed by the initial abrasion with the adjacent component. In some embodiments, the apex material fraction Smr1 of the low friction material may be less than 10%.

[0045] Furthermore, the bottom material portion Smr2 can be calculated as the percentage of low friction material that comprises the bottom. In other words, the thickness of the substrate is T S and Smr2 is the thickness T of the substrate or core surface.S from the total thickness T of the low friction material S The reduced base is the area material ratio dividing the reduced base of the low friction material. The reduced base is the area that holds the liquid (e.g., grease) applied to the surface to improve lubrication. In some embodiments, the base material portion Smr1 of the low friction material may be less than 75%. The resulting textured low friction layer 1104 may have a minimum distance between at least one apex 22 of the plurality of apexes 22 and at least one base 21 of the plurality of bases 21 of 0.05 mm.

[0046] 4A-H show a bearing 400 including an embodiment formed from a blank of material or composite 1000, 1002, 1003 as described above. FIGS. 4A-H include similar features as shown and labeled as such in FIGS. 2A-C. For a description of these elements, see the previous description of FIGS. 2A-C. Referring first to FIG. 4A, the bearing 400 can include a sidewall 402 having a first axial end 420 and a second axial end 422. As shown in FIG. 4A, the sidewall 402 can be formed from a blank as described above and can include a substrate 1119 (e.g., spring steel) that can be bent into a ring-like (substantially annular or at least partially annular) shape about a central axis 4000 to form an aperture. The sidewall 402 may further include a low friction layer 1104 that conforms to the shape of the sidewall 402, such as formed as the low friction layer 1104 from a blank of the composite material 1000, 1002, 1003, as described above. In some embodiments, the sidewall 402 may be curved such that the ends overlap. In yet further embodiments, the sidewall may be a continuous unbroken ring. Alternatively, as shown in FIG. 4E, the ends of the sidewall 402 may not meet (e.g., may be formed as a split ring), thereby leaving an axial gap 406 adjacent the circumference of the sidewall 402.

[0047] 4A , the bearing 400 and / or the sidewall 402 may have an inner surface 430 and an outer surface 432. In some embodiments, the inner surface 430 of the bearing 400 and / or the sidewall 402 may have a low friction layer 1104 that conforms to the shape of the sidewall 402 with the substrate 1119 forming the outer surface 432, such as formed from the composite material 1000, 1002, 1003 as described above. In other words, the low friction layer 1104 may be located on the outside of the sidewall 402. Alternatively or additionally, the outer surface 432 of the bearing 400 may have a low friction layer 1104 that conforms to the shape of the sidewall with the substrate 1119 forming the inner surface 430, such as formed from the composite material 1000, 1002, 1003 as described above. In other words, the low friction layer 1104 may be located on the inside of the sidewall 402. In other embodiments, the low friction layer 1104 may be laminated to both sides of the bearing 400 and / or sidewall 402 .

[0048] As shown in FIG. 4A, in some embodiments, the sidewall 402 of the bearing can include a flat circumferentially extending rim 409 of composite material at at least one axial end 420, 422 of the bearing 400. Alternatively, as shown in FIG. 4D, the flat circumferentially extending rim 409 can be located at only one axial end 422 of the bearing 400. The circumferentially extending rim 409 can be uniform and can extend at least a portion of the circumference of the bearing 400 about the central axis 4000. Alternatively, in some embodiments, the circumferentially extending rim 409 can be distinct and can include multiple circumferentially extending rims 409, 409' between adjacent slots 442, as shown in FIG. 4H. Additionally, the sidewall 404 of the bearing 400 can include at least one slot 442 that can extend radially through the sidewall 402. The at least one slot 442 can include multiple slots 442 that can extend radially through the sidewall 402. Each slot 442 may also be spaced from an adjacent slot 442 by at least one unformed section 440 of the bearing 400, which may be formed in continuity with the rim 409 and spaced apart circumferentially. In other words, the unformed section 440 may include the rim 409 and may be provided at at least one of the axial ends 420, 422 of the bearing 400. In one embodiment, the at least one slot 442 may extend at least 5%, such as at least 10%, such as at least 15%, such as at least 25%, such as at least 35%, or such as at least 50% of the axial length of the sidewall 402. In one embodiment, the at least one slot 442 (or unformed section 440) formed in the sidewall 402 may be of different sizes, different shapes, or different sizes and shapes. In another aspect, the at least one slot 442 (or unformed section 440) may include a first end and a second end, and each end may be rounded, as best shown in FIG. 4B. Additionally, at least one slot 442 may be circumferentially and longitudinally centered within each unformed section 440. The at least one slot 442 (or unformed section 440) may be formed by punching, stamping, cutting, or another method.

[0049] In one embodiment, at least one of the slots 442 may have a polygonal cross section from the central axis 4000. In one embodiment, at least one of the slots 442 may have an arcuate cross section from the central axis 4000. In yet another embodiment, as shown in FIGS. 4A-4B, at least one of the slots 442 may have an arcuate portion and a polygonal portion. In another embodiment, at least one of the slots 442 may have a semicircular or semi-elliptical cross section from the central axis 4000. In another embodiment, as shown in FIG. 4C, at least one of the slots 442 may have a variable cross section (e.g., including the area of ​​linear space and the area of ​​arcuate space) from the central axis 4000. In one embodiment, at least two of the slots 442 may have the same geometric shape or size compared to each other. In further embodiments, all of the slots 442 may have the same geometric shape or size compared to each other. In another embodiment, at least one of the slots 442 may have a different geometric shape or size compared to each other. In further embodiments, all of the slots 442 may have different geometric shapes or sizes compared to one another. In certain embodiments, the slots 442 may span the axial gap 406, as shown in FIG. 4E.

[0050] Referring again to FIG. 4A, in certain embodiments, the sidewall 402 may have a length L, and the at least one slot may have a length L. S Furthermore, L S ≧80%L, e.g., ≧85%L, or ≧90%. S ≦99%L, for example ≦98%L≦97%L≦96%L≦95%L. Also, S a can be within a range between and including any of the percentages of L values ​​described herein.

[0051] In another embodiment, at least one unformed section 440 has a width W US Further, each slot 442 may have a width W SIn certain embodiments, W S ≧50%W US , e.g. ≧55%W US , ≧60%W US , ≧65%W US , ≧70%W US , ≧75%W US , ≧80%W US , ≧85%W US , or ≧90%W US In another embodiment, W S ≦99%W US , e.g. ≦98%W US , ≦97%W US , ≦96%W US , or ≦95%W US It can be said that W S is the above-mentioned W US The percentages can be within a range between and including any of the values.

[0052] In another embodiment, at least one unformed section 440 has a length L S and width W S where L S :W S can be at least 1:1, at least 1.5:1, at least 2:1, at least 2.5:1, at least 3:1, at least 5:1, or at least 10:1. S :W S can be 100:1 or less. S :W S can be in a range between and including any of the percentages of the above values.

[0053] Referring again to FIG. 4A, the sidewall 402 and / or the at least one unformed section 440 may include at least one protrusion 450 extending from the sidewall 402. In some embodiments, the at least one protrusion 450 may include multiple protrusions 450. In one embodiment, the protrusion 450 may extend along the axial length of the unformed section 440. In one embodiment, the protrusion 450 may extend the entire axial length of the unformed section 440. In one embodiment, the protrusion 450 may extend the entire surface area of ​​the unformed section 440. As shown in FIG. 4A, the at least one protrusion 450 may extend from the unformed section to form a generally convex cross-sectional shape in the sidewall 402. Alternatively, as shown in FIG. 4B, the at least one protrusion 450 may extend from the unformed section to form a generally concave cross-sectional shape in the sidewall 402. Alternatively, as shown in FIG. 4D, at least one protrusion 450 may extend from the unformed section to form a generally concave cross-sectional shape in the sidewall 402, and at least one protrusion 450′ may extend from the unformed section to form a generally convex cross-sectional shape in the sidewall 402. In one embodiment, the at least one protrusion 450 may be rounded or arcuate radially relative to the central axis 4000. In one embodiment, the at least one protrusion 450 may be linear or polygonal radially relative to the central axis 4000. In one embodiment, the protrusions 450 and the slots 442 may be alternated around the sidewall 402. In one embodiment, at least two protrusions 450 or at least two slots 442 may be sequentially arranged around the sidewall 402.

[0054] In some embodiments, the at least one protrusion 450 may include at least one projection 460 extending radially inward or outward from the outer surface 432 or inner surface 430 of the bearing 400. The at least one projection 460 may be located on the unformed section 440 or the circumferential rim 409. The projection 460 may be formed from the composite material 1000, 1002, 1003 via stamping (e.g., pressed using a suitably shaped die, rotary wave molding, etc.). The projection 460 may be an axially elongated ridge that may be similar in shape to the corrugations used in conventional bearings. In another embodiment, the projection 460 may have a polygonal cross section from the central axis 4000. The projection 460 may include at least one polygonal angle. In yet another embodiment, at least one of the projections 460 may have an arcuate portion and a polygonal portion. In another embodiment, the projection 460 may have a semicircular cross section from the central axis 4000. In another embodiment, the protrusions 460 may have a variable cross-section from the central axis 4000. In one embodiment, at least two of the protrusions 460 may have the same geometric shape or size compared to one another. In a further embodiment, all of the protrusions 460 may have the same geometric shape or size compared to one another. In another embodiment, at least one of the protrusions 460 may have a different geometric shape or size compared to one another. In a further embodiment, all of the protrusions 460 may have a different geometric shape or size compared to one another.

[0055] 4C, 4F, and 4G show another bearing 400 with a slot 442 formed in an unformed section 440 of the sidewall 402. As shown, the slot 442 may be bifurcated or otherwise divided by a slot bridge 444. In some particular embodiments, the unformed section 440 may include a slot bridge 444 and may be located at an axial midpoint of the bearing 400. As shown in FIG. 4F, the slot bridge 444 may divide a generally convex or generally concave section of the sidewall 402. The slot bridge 444 may have a length L SB and L SB≧15% L, e.g., ≧20% L, or ≧25% L. In another embodiment, L SB ≦80%L, for example ≦75%L, ≦60%L, ≦55%L, ≦50%L. Also, L SB can be within a range between and including any of the percentages of L values ​​described herein.

[0056] Additionally, as shown in exemplary Figures 4F and 4G, the bearing 400 may include different cross-sectional shapes perpendicular to the central axis. As shown in exemplary Figure 4F, the bearing 400 may include an annular cross-sectional shape perpendicular to the central axis. As shown in exemplary Figure 4F, the bearing 400 may include a polygonal or rectilinear cross-sectional shape perpendicular to the central axis.

[0057] FIG. 4H illustrates another bearing 400 with a slot 442 formed in the unformed section 440 of the sidewall 402. As shown in FIG. 4H, the bearing 400 may include at least one radial flange 470. In some embodiments, the at least one radial flange 470 may be provided at at least one of the axial ends 420, 422 of the bearing 400. The at least one radial flange 470 may be generally annular about the central axis 4000. The at least one radial flange 470 may extend radially outward from the inner surface 430 to the outer surface 432. Alternatively, the radial flange 470 may extend radially inward from the outer surface 432 to the inner surface 430 (not shown). In some embodiments, the radial flange 470 may form a generally flat outermost axial surface at the first axial end 420 or the second axial end 422 of the bearing 400. In some embodiments, the radial flange 470 may form a generally flat outermost radial surface on the outer surface 432 of the first axial end 420 or the second axial end 422 of the bearing 400. In some embodiments, the radial flange 470 may be an extension of the inner surface 430 and the outer surface 432 and thus may include a low friction layer 1104 that conforms to the shape of the sidewall 402, such as formed as the low friction layer 1104 from a blank of the composite material 1000, 1002, 1003 as described above.

[0058] In some embodiments, the flanges may be uniform and may extend at least a portion of the circumference of the bearing 400 around the central axis 4000. In some embodiments, the at least one radial flange may include multiple flanges 470, 470'. In some embodiments, the radial flange 470 may include at least one axial split 477 to form a "star flange", as described above. The axial split 477 may provide a gap within the flange 470. In some embodiments, the flange 470 may include multiple axial splits 477 providing a segmented flange. In certain embodiments, the axial split 477 may be continuous with the axial gap 406 of the sidewall 402. In other embodiments, the axial split 477 may be discontinuous with the axial gap 406 of the sidewall 402. In other words, in some embodiments, the multiple flanges 470, 470' may be separate in the form of radial tabs.

[0059] In operation, a bearing may be located adjacent to an opposing component. In operation, a bearing may be located between two opposing (mating) components. For example, it may be located in an annular space between an inner component (e.g., shaft) and a bore of an outer component (e.g., housing). In other words, the inner component contacts the inner surface of the bearing and the outer component contacts the outer surface of the bearing. FIG. 5A shows an axial cross-sectional view through an assembly 590 including one embodiment of a bearing 500. FIGS. 5A-5B include similar features as shown and labeled in FIGS. 24A-4H. See the preceding discussion of FIGS. 4A-4H for a description of these elements. Assembly 590 incorporates, for example, bearing 500 shown in FIG. 4B. Thus, FIG. 5A includes similar features as shown and labeled in FIG. 4B. See the preceding discussion of FIG. 4B for a description of these elements. Assembly 590 includes a housing 592 or outer component. The housing 592 has an axial bore 594 formed therein that can receive a shaft 596 or inner component.

[0060] An annular gap exists between the outer surface 596A of the shaft 596 and the inner surface 592B of the housing 592. This annular gap may be variable because the diameters of the shaft 596 and the hole 594 of the housing 592 may vary within manufacturing tolerances. To prevent vibration of the shaft 596 within the hole 594 of the housing 592, the annular gap may be filled with a bearing 500 to create a zero clearance fit between the components. FIG. 5A shows that the bearing 500 includes a sidewall 502 having a substrate 1119 on the outer surface 532 and a low friction layer 1104 on the inner surface 530. Additionally, in this embodiment, the protrusion 550 extends radially inward toward the inner component 596. In use, the circumferential protrusion 550 of the bearing 500 may be radially compressed within the annular gap between the shaft 596 of the housing 592 such that the protrusion 550 contacts the inner component 596. Thus, bearing 500 reduces the annular gap to zero, so there may be no clearance between components in assembly 590. Bearing 500 may be secured relative to housing 592 by frictional engagement at the contact area between sidewall 502 and housing 592 or inner surface 592B of the outer component. Low friction layer 1104 may reduce the torque required during use of bearing 500 in assembly 590 while maintaining a desired torque range.

[0061] FIG. 5B shows an axial cross-sectional view through an assembly 590 including another embodiment of the bearing 500. The assembly 590 incorporates, for example, the bearing 500 shown in FIG. 4B. Thus, FIG. 5B includes similar features as those shown and labeled as such in FIG. 4A. For a description of these elements, see the previous description of FIG. 4A. The assembly 590 may also include a housing 592 or outer component and a shaft 596 or inner component. In the illustrated embodiment, the bearing 500 may be held on the shaft 596. The outer diameter of the shaft 596 may be larger than the inner diameter of the exemplary bearing 500 shown in FIG. 4B at rest. Thus, the bearing 500 may expand (the axial gap 506 must expand) to fit the bearing 500 around the surface 596A of the shaft 596. Furthermore, in this embodiment, the protrusion 550 extends radially outward toward the outer component 592. Inside the hole 594 of the housing 592, the protrusion 550 may be compressed within the annular gap or space between components at the inner surface 592B of the housing 592.

[0062] 5B shows that the bearing 500 includes a sidewall 502 having a substrate 1119 on the inner surface 530 and a low friction layer 1104 on the outer surface 532. In use, the circumferential protrusion 550 of the bearing 500 may be radially compressed within the annular gap between the shaft 596 and the housing 592 such that the protrusion 550 contacts the outer component 592. The bearing 500 may thus reduce the annular gap to zero, such that there may be no clearance between the components in the assembly 590. The bearing 500 may be secured relative to the housing 592 by frictional engagement at the contact area between the sidewall 502 and the outer surface 596A of the inner component 596. The low friction layer 1104 may reduce the torque required during use of the bearing 500 in the assembly 590 while maintaining a desired torque range. Additionally, optionally, the protrusions 560 on the bearing 500 may be compressed within the assembly 590 in a similar manner.

[0063] As mentioned above, the bearing 500 may be located between two opposing (mating) components in the assembly 590. For example, it may be located in the annular space between a first component (e.g., a shaft) and a bore of a second component (e.g., a housing). The first or second components may be made of any material known in the art, including, but not limited to, aluminum, magnesium, zinc, iron, or alloys thereof. The surface roughness of the opposing components may be at least about 0.01 microns, at least about 0.02 microns, at least about 0.05 microns, at least about 0.1 microns, at least about 0.5 microns, at least about 1 micron, at least about 2 microns, at least about 5 microns, at least about 10 microns, at least about 20 microns, at least about 50 microns, at least about 100 microns, at least about 200 microns, or at least about 400 microns. In other embodiments, the surface roughness may be less than about 400 microns, less than about 200 microns, less than about 100 microns, less than about 50 microns, less than about 25 microns, less than about 20 microns, less than about 15 microns, less than about 10 microns, less than about 5 microns, less than about 3 microns, less than about 2 microns, or even less than about 1 micron. In yet other embodiments, the opposing components may have a surface roughness ranging from about 0.1 microns to about 400 microns, from about 0.5 microns to about 100 microns, or from about 1 micron to about 50 microns. In certain embodiments, at least one surface of the first component or the second component has a surface roughness of less than 0.4 microns. At least one of the inner or outer sides of the bearing 500 may contact the opposing component to create a low friction interface.

[0064] In at least one embodiment, the assembly 590 can include a lubricant in any of its components. In at least one embodiment, the lubricant can include a grease including at least one of the following: lithium soap, lithium disulfide, graphite, mineral or vegetable oil, silicone grease, fluoroether-based grease, apiezone, food grade grease, petrochemical grease, or different types. In at least one embodiment, the lubricant can include an oil including at least one of the following: Group I-Group III+ oils, paraffinic oil, naphthenic oil, aromatic oil, bio-lubricant, castor oil, canola oil, palm oil, sunflower seed oil, rapeseed oil, tall oil, lanolin, synthetic oil, poly alpha-olefin, synthetic ester, polyalkylene glycol, phosphate ester, alkylated naphthalene, silicate ester, ionic fluid, multiply alkylated cyclopentane, petrochemical-based oil, PTFE-thickened grease, or different types. In at least one embodiment, the lubricant may include a solid-based lubricant including at least one of lithium soap, graphite, boron nitride, molybdenum disulfide, tungsten disulfide, polytetrafluoroethylene, metal, metal alloy, or may be of a different type. In some embodiments, the grease may be present on at least 25% of the total surface area of ​​the bearing. In some embodiments, the bottom of the low friction layer may contain or accommodate the grease.

[0065] As a result of the embodiments herein, an assembly 590 may be formed. The assembly 590 may include an outer component 592 including a hole 594 in the outer component 592, an inner component 596 disposed within the inner component 596 and the outer component 592, and a bearing 500 including a sidewall 502 including a substrate 1119 and a low friction layer 1104 overlying the substrate, the sidewall further including an unformed section 540, at least one slot 532 in the unformed section, and at least one protrusion 550 extending from the unformed section forming a generally concave or convex cross-sectional shape in the sidewall. The bearing 500 may have a friction torque with the inner component 596 or the outer component 594, and the friction torque change of the assembly 590 over a temperature range of -40°C to 80°C may be within ±20%. Additionally, the bearings 500 in the assembly 590 may have a wear rate of less than 0.01 mm / 100k revolutions.

[0066] 6 illustrates a method according to some embodiments. As shown in FIG. 6A, the method may include step 602 of disposing a bearing between an inner component and an outer component, the bearing including a sidewall including a substrate and a low friction layer overlying the substrate, the sidewall further including an unformed section, at least one slot in the unformed section, and at least one protrusion extending from the unformed section forming a generally concave or convex cross-sectional shape in the sidewall. Optionally, the method may further include step 604 of rotating or translating the bearing to create a friction torque with the inner or outer component, the friction torque change of the assembly may be within ±20% over a life of at least 1 million cycles and a temperature range of -40°C to 80°C. EXAMPLES

[0067] FIG. 7 includes a graph of friction torque curves versus test cycles for a bearing according to one embodiment. As shown in FIG. 7, a friction torque curve for a bearing according to an embodiment herein (specifically the embodiment of FIG. 4B) can be obtained by placing a bearing between a shaft having a surface roughness of 0.2 microns and a housing. The bearing can be rotated at a speed of 200 rpm, with one cycle including 5 seconds of clockwise rotation, 5 seconds of rest, 5 seconds of counterclockwise rotation, and 5 seconds of rest. Each cycle can include 30-40 cycles (e.g., 33 cycles). A total of 60,000 cycles were tested. As shown in FIG. 7, the friction torque variation can be less than + / - 0.3 N·m over 4 million cycles. As shown, a bearing according to an embodiment herein can provide an initial contact pressure and have compensation for wear of the sliding layer over time, while the sliding layer can have a stable coefficient of friction and a low wear rate. These two coefficients can provide a stable torque over the life of the bearing, with torque degradation within the assembly being only 7% after 2 million test cycles and 15% after 4 million test cycles, respectively. According to embodiments herein, the bearings within the assembly can exhibit a life of at least 1 million cycles and a friction torque change within the assembly over a temperature range of -40°C to 80°C, which can be within ±20%.

[0068] FIG. 8 includes a graph of normalized torque curves versus temperature for bearings using shaft samples with different surface roughnesses according to an embodiment. As shown in FIG. 8, the normalized torque was calculated as the average torque value at different temperatures as shown. Using the same test as FIG. 7 described above, data was calculated for bearings according to embodiments (specifically the embodiment of FIG. 4B) having shafts and housings with surface roughnesses of 0.1 microns and 0.2 microns. As shown in FIG. 8, the normalized torque decreases as the temperature decreases. As shown, the bearings according to embodiments herein can provide initial contact pressure and have compensation for wear of the sliding layer over time, while the sliding layer can have a relatively stable coefficient of friction and low wear rate within a certain temperature range. These two coefficients can provide a stable torque for the bearings over a temperature range of -30C to 80C, with torque degradation within the assembly within ±20%.

[0069] Applications of the embodiments include, for example, assemblies for hinges and other vehicle components. Additionally, the use of the bearings or assemblies may provide improved benefits in a number of applications, such as, but not limited to, doors, hoods, tailgates, engine compartment hinges, seats, steering columns, flywheels, drive shaft assemblies, power train applications (such as belt tensioners), or other types of applications. In accordance with certain embodiments herein, the bearings may be part of a friction brake or spindle drive, including, but not necessarily limited to, those used in vehicle door assemblies.

[0070] Bearings according to embodiments herein may provide improved, consistent friction torque over the life of the assembly, allowing vehicle door assemblies to stop the door at any position and compensate for spring forces for more reliable safety control. Additionally, bearings according to embodiments herein may reduce noise / vibration, reduce wear on bearing surfaces and mating components, and reduce component complexity and assembly time, thereby extending the life, improving appearance, and improving the effectiveness and performance of assemblies, bearings, and other components.

[0071] 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 illustrative and do not limit the scope of the present invention. An embodiment may follow any one or more of the embodiments listed below.

[0072] Embodiment 1: A bearing comprising a sidewall comprising a substrate and a low friction layer overlying the substrate, the sidewall further comprising an unformed section, at least one slot in the unformed section, and at least one protrusion extending from the unformed section forming a generally concave cross-sectional shape in the sidewall.

[0073] Embodiment 2: A bearing comprising a sidewall comprising a substrate and a low friction layer overlying the substrate, the sidewall further comprising an unformed section, at least one slot in the unformed section, and at least one protrusion extending from the unformed section forming a generally convex cross-sectional shape in the sidewall.

[0074] Embodiment 3: An assembly comprising: an outer component including a hole in the outer component; an inner component disposed within the hole; and a bearing disposed between the inner component and the outer component, the bearing including a sidewall including a substrate and a low friction layer overlying the substrate, the sidewall further including an unformed section, at least one slot in the unformed section, and at least one protrusion extending from the unformed section forming a generally concave or convex cross-sectional shape in the sidewall.

[0075] Embodiment 4: An assembly comprising: an outer component including a hole in the outer component; an inner component disposed within the hole; and a bearing disposed between the inner component and the outer component and secured to the outer component, the bearing including a sidewall including a substrate and a low friction layer overlying the substrate, the sidewall further including an unformed section, at least one slot in the unformed section, and at least one protrusion extending from the unformed section forming a generally concave or convex cross-sectional shape in the sidewall, the bearing having a friction torque with the inner or outer component, the bearing having a life of at least 1 million cycles and a friction torque change of the assembly over a temperature range of -40°C to 80°C within ±20%.

[0076] Embodiment 5: A method comprising: disposing a bearing between an inner component and an outer component, the bearing comprising a sidewall comprising a substrate and a low friction layer overlying the substrate, the sidewall further comprising an unformed section, at least one slot in the unformed section, at least one protrusion extending from the unformed section, and a generally concave or convex cross-sectional shape in the sidewall.

[0077] Embodiment 6: A method comprising: disposing a bearing between an inner component and an outer component, the bearing comprising a sidewall comprising a substrate and a low friction layer overlying the substrate, the sidewall further comprising an unformed section, at least one slot in the unformed section, and at least one protrusion extending from the unformed section forming a generally concave or convex cross-sectional shape in the sidewall; and rotating or translating the bearing to create a friction torque with the inner or outer component, wherein the friction torque variation of the assembly over a temperature range of -40°C to 80°C is within ±20%.

[0078] Embodiment 7: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the bearing further comprises a protrusion.

[0079] Embodiment 8: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the protrusion comprises a radially linear protrusion.

[0080] Embodiment 9: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the protrusion comprises a radially arcuate protrusion.

[0081] Embodiment 10: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the slot extends over at least 50% of the axial length of the side wall.

[0082] Embodiment 11: At least one slot has a length L S and width W S Including L S :W S 7. The bearing, assembly or method of any one of embodiments 1-6, wherein the ratio of the ratio of the stoichiometric ...

[0083] Embodiment 12: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein at least one protrusion extends radially outward from the side wall.

[0084] Embodiment 13: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein at least one protrusion extends radially inward from the side wall.

[0085] Embodiment 14: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein at least one protrusion forms a concave cross-sectional shape in the side wall.

[0086] Embodiment 15: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein at least one protrusion forms a convex cross-sectional shape in the side wall.

[0087] Embodiment 16: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the protrusion comprises a plurality of protrusions.

[0088] Embodiment 17: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the slot comprises a plurality of slots.

[0089] Embodiment 18: A bearing, assembly, or method as described in embodiment 17, wherein the protrusions and slots are alternated around the side wall.

[0090] Embodiment 19: A bearing, assembly, or method as described in embodiment 17, wherein at least two protrusions or at least two slots are arranged sequentially around the side wall.

[0091] Embodiment 20: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the bearing has an annular cross-sectional shape perpendicular to the central axis.

[0092] Embodiment 21: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the bearing has a polygonal cross-sectional shape perpendicular to the central axis.

[0093] Embodiment 22: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the substrate comprises a porous metal selected from a mesh material, a grid, an expanded sheet, or a perforated sheet.

[0094] Embodiment 23: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the substrate comprises a metal, a plastic, or a ceramic.

[0095] Embodiment 24: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the substrate comprises aluminum, magnesium, zinc, iron, or an alloy thereof.

[0096] Embodiment 25: The bearing, assembly, or method of any one of embodiments 1-6, wherein the substrate comprises steel, spring steel, or stainless steel.

[0097] Embodiment 26: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the low friction layer comprises a polyketone, a polyaramid, a thermoplastic polyimide, a polyetherimide, a polyphenylene sulfide, a polyethersulfone, a polysulfone, a polyphenylene sulfone, a polyamideimide, an ultra-high molecular weight polyethylene, a thermoplastic fluoropolymer, a polyamide, a polybenzimidazole, or any combination thereof.

[0098] Embodiment 27: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the low friction layer comprises a fluoropolymer.

[0099] Embodiment 28: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the low friction layer comprises polytetrafluoroethylene.

[0100] Embodiment 29: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the low friction layer comprises PEEK.

[0101] Embodiment 30: A bearing, assembly, or method described in any one of embodiments 1 to 6, wherein the low friction layer includes asperities including a plurality of peaks and valleys, the low friction layer has a root mean square gradient of less than 0.064, and the low friction layer induces the formation of a film when engaged with a rotating interface with another component.

[0102] Embodiment 31: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the low friction layer is located on the outside of the sidewall.

[0103] Embodiment 32: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the low friction layer is located on the inside of the sidewall.

[0104] Embodiment 33: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the side wall comprises an axial gap.

[0105] Embodiment 34: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the unformed section is provided at at least one of the axial ends of the bearing.

[0106] Embodiment 35: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the unformed section is provided near the axial midpoint of the bearing.

[0107] Embodiment 36: A bearing, assembly, or method according to any one of embodiments 1 to 6, wherein the bearing further comprises at least one radial flange.

[0108] Embodiment 37: A bearing, assembly, or method as described in embodiment 35, wherein at least one radially oriented flange is provided on at least one of the axial ends of the bearing.

[0109] Embodiment 38: A bearing, assembly, or method as described in embodiment 35, wherein the at least one flange includes a plurality of flanges.

[0110] Embodiment 39: A bearing, assembly, or method as described in embodiment 38, wherein the multiple flanges include tabs.

[0111] Embodiment 40: A bearing, assembly, or method according to any one of embodiments 3 to 6, wherein the bearing has a wear rate of less than 0.01 mm / 100k revolutions.

[0112] Embodiment 41: A bearing, assembly, or method according to any one of embodiments 3 to 6, wherein the assembly is part of a spindle drive.

[0113] Embodiment 42: A bearing, assembly, or method according to any one of embodiments 3 to 6, wherein the assembly is part of a friction brake.

[0114] It should be noted that not all of the features described above are required, that a particular range of features may not be required, and that one or more features may be provided in addition to the features described. Still further, the order in which the features are listed is not necessarily the order in which the features are introduced.

[0115] 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.

[0116] Benefits, other advantages, and solutions to problems have been described above with respect to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature or features that may provide or make more prominent any benefit, advantage, or solution should not be construed as a critical, necessary, or essential feature of any or all of the claims.

[0117] 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 assemblies and systems that use the structures or methods described herein. Separate embodiments may 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 be provided separately or in any subcombination. Furthermore, references to values ​​described in ranges include any and all values ​​within that range. Many other embodiments may become apparent to those skilled in the art only 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, not restrictive.

Claims

1. A bearing, A sidewall comprising a substrate and a low friction layer overlying the substrate, the sidewall comprising: Unformed sections and at least one slot in the unformed section; at least one projection extending from the unformed section forming a generally concave cross-sectional shape in the sidewall; The side wall further comprises: A bearing comprising:

2. A bearing, A sidewall comprising a substrate and a low friction layer overlying the substrate, the sidewall comprising: Unformed sections and at least one slot in the unformed section; at least one projection extending from the unformed section forming a generally convex cross-sectional shape in the sidewall; The side wall further comprises: A bearing comprising:

3. 1. An assembly comprising: an outer component including an outer component hole; an inner component disposed within the bore; A bearing provided between the inner component and the outer component, the bearing comprising: a sidewall including a substrate and a low friction layer overlying the substrate, the sidewall comprising: Unformed sections and at least one slot in the unformed section; at least one projection extending from the unformed section forming a generally concave or convex cross-sectional shape in the sidewall; The side wall further comprises: a bearing including: An assembly comprising:

4. A bearing or assembly according to any preceding claim, wherein the bearing further comprises a protrusion.

5. A bearing or assembly according to any preceding claim, wherein the projection comprises a radially linear projection.

6. A bearing or assembly according to any preceding claim, wherein the projection comprises a radially arcuate projection.

7. A bearing or assembly according to any preceding claim, wherein the slot extends over at least 50% of the axial length of the side wall.

8. The at least one slot has a length L Ｓ and width W Ｓ Including L Ｓ :W Ｓ A bearing or assembly according to any one of claims 1 to 3, wherein the ratio is ≧2:

1.

9. A bearing or assembly according to any preceding claim, wherein said at least one protrusion extends radially outwardly from said side wall.

10. A bearing or assembly according to any preceding claim, wherein said at least one protrusion extends radially inwardly from said side wall.

11. A bearing or assembly according to any preceding claim, wherein said at least one protrusion defines a concave cross-sectional shape in said side wall.

12. A bearing or assembly according to any preceding claim, wherein said at least one protrusion defines a convex cross-sectional shape in said side wall.

13. A bearing or assembly according to any preceding claim, wherein the protrusion comprises a plurality of protrusions.

14. A bearing or assembly according to any preceding claim, wherein the slot comprises a plurality of slots.

15. 4. A bearing or assembly according to claim 1, wherein the low friction layer includes asperities including a plurality of peaks and valleys, the low friction layer having a root mean square gradient of less than 0.064, and the low friction layer induces the formation of a film when engaged with a rotating interface with another component.

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