Flanged bearing, assembly, and method of making and using the same

A bearing including a body having a first axial end and a second axial end; and at least one flange projecting radially from the second axial end of the body, where the at least one flange includes a first region, second region, and a stepped transition region between the first and second regions, where the second region is elevated axially above the first region so as to protrude axially outwardly, where 1) the second region extends partially circumferentially around the flange to form at least one segment, and/or 2) the first region extends from the body to the stepped transition region.

FIELD OF THE DISCLOSURE

This disclosure, in general, relates to flanged bearings, in particular flanged plain bearings with at least one flange and method of production and assembly thereof.

BACKGROUND

Flanged bearings, which comprise either one or two flanges, are known in a wide range of sizes. Flanged bearings made of composite materials consisting of a substrate layer and a low friction material layer overlay are also generally known. These flanged bearings may be disposed between an inner and an outer member in an assembly. The bearing may be used in assemblies with applications in the vehicle industry, for example, for door, hood, and engine compartment hinges, seats, steering columns, flywheels, balancer shaft bearings, etc., or may be used for non-automotive applications. Despite advances in the art, there is an ongoing need for improved bearings that have a longer lifetime, improved effectiveness, and improved performance within an assembly.

Skilled artisans 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 to improve understanding of embodiments of the invention. The use of the same reference symbols in different drawings indicates similar or identical items.

DETAILED DESCRIPTION

Also, the use of “a” or “an” is employed 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 one, at least one, or the singular as also including the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single embodiment is described herein, more than one embodiment may be used in place of a single embodiment. Similarly, where more than one embodiment is described herein, a single embodiment may be substituted for that more than one embodiment.

For purposes of illustration,FIG. 1includes a diagram showing a manufacturing process10for forming a bearing. The manufacturing process10may include a first step12of providing a base material, a second step14of coating the base material with a low friction coating to form a composite material and a third step16of forming the composite material into a bearing.

Referring to the first step12, the base material may be a substrate. In an embodiment, the substrate can at least partially include a metal support. According to certain embodiments, the metal support may include iron, copper, titanium, tin, nickel, aluminum, alloys thereof, or may be another type of metal. More particularly, the substrate can at least partially include a steel, such as, a stainless steel, carbon steel, or spring steel. For example, the substrate can at least partially include a 301 stainless steel. The 301 stainless steel may be annealed, ¼ hard, ½ hard, ¾ hard, or full hard. The substrate may include a woven mesh or an expanded metal grid. Alternatively, the woven mesh can be a woven polymer mesh using any of the polymers listed below. In an alternate embodiment, the substrate may not include a mesh or grid.

FIG. 2Aincludes an illustration of the composite material1000that may be processed according to first step12and second step14of the manufacturing process10. For purposes of illustration,FIG. 2Ashows the layer by layer configuration of a composite material1000after second step14. In a number of embodiments, the composite material1000may include a substrate1119(i.e., the base material noted above and provided in the first step12) and a low friction layer1104(i.e., the low friction coating applied in second step14). In a number of embodiments, the substrate1119may extend at least partially along a length of the composite material1000. As shown inFIG. 2A, the low friction layer1104can be coupled to at least a region of the substrate1119. In a particular embodiment, the low friction layer1104can be coupled to a surface of the substrate1119so as to form a low friction interface with another surface of another component. The low friction layer1104can be coupled to the radially inner surface of the substrate1119so as to form a low friction interface with another surface of another component. The low friction layer1104can be coupled to the radially outer surface of the substrate1119so as to form a low friction interface with another surface of another component.

The substrate1119can have a thickness, Ts, of between about 10 microns to about 2000 microns, such as between about 50 microns and about 1500 microns, such as between about 100 microns and about 500 microns, such as between about 150 microns and about 350 microns. In a number of embodiments, the substrate1119may have a thickness, Ts, of between about 100 and 500 microns. In a number of embodiments, the substrate1119may have a thickness, Ts, of between about 200 and 350 microns. It will be further appreciated that the thickness, Ts, of the substrate1119may be any value between any of the minimum and maximum values noted above. The thickness of the substrate1119may be uniform, i.e., a thickness at a first location of the substrate1119can be equal to a thickness at a second location therealong. The thickness of the substrate1119may be non-uniform, i.e., a thickness at a first location of the substrate1119can be different than a thickness at a second location therealong.

In a number of embodiments, the low friction layer1104can include a low friction material. Low friction materials may include, for example, a polymer, such as a polyketone, a polyaramid, a polyphenylene sulfide, a polyethersulfone, a polypheylene sulfone, a polyamideimide, ultra high molecular weight polyethylene, a fluoropolymer, a polybenzimidazole, a polyacetal, polybutylene terephthalate (PBT), polyethylene terephthalate (PET), a polyimide (PI), polyetherimide, polyetheretherketone (PEEK), polyethylene (PE), a polysulfone, a polyamide (PA), polyphenylene oxide, polyphenylene sulfide (PPS), a polyurethane, a polyester, a liquid crystal polymer (LCP), or any combination thereof. In an example, the low friction layer1104includes polyketone, such as polyether ether ketone (PEEK), polyether ketone, polyether ketone ketone, polyether ketone ether ketone, a derivative thereof, or a combination thereof. In an additional example, the low friction layer1104may include an ultra high molecular weight polyethylene. In another example, the low friction layer1104may include a fluoropolymer including fluorinated ethylene propylene (FEP), polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF), perfluoroalkoxy (PFA), a terpolymer of tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride (THV), polychlorotrifluoroethylene (PCTFE), ethylene tetrafluoroethylene copolymer (ETFE), or ethylene chlorotrifluoroethylene copolymer (ECTFE). The low friction layer1104may include a solid based material including lithium soap, graphite, boron nitride, molybdenum disulfide, tungsten disulfide, polytetrafluoroethylene, carbon nitride, tungsten carbide, or diamond like carbon, a metal (such as aluminum, zinc, copper, magnesium, tin, platinum, titanium, tungsten, iron, bronze, steel, spring steel, stainless steel), a metal alloy (including the metals listed), an anodized metal (including the metals listed) or any combination thereof. Fluoropolymers may be used according to particular embodiments.

In an embodiment, the low friction layer1104can have a thickness, TFL, of between about 1 micron to about 500 microns, such as between about 10 microns and about 400 microns, such as between about 30 microns and about 300 microns, such as between about 50 microns and about 250 microns. In a number of embodiments, the low friction layer1104may have a thickness, TFL, of between about 100 and 350 microns. It will be further appreciated that the thickness, TFL, of the low friction layer1104may be any value between any of the minimum and maximum values noted above. The thickness of the low friction1104may be uniform, i.e., a thickness at a first location of the low friction layer1104can be equal to a thickness at a second location therealong. The thickness of the low friction1104may be non-uniform, i.e., a thickness at a first location of the low friction layer1104can be different than a thickness at a second location therealong. The low friction layer1104may overlie one major surface of the substrate1119, shown, or overlie both major surfaces. The substrate1119may be at least partially encapsulated by the low friction layer1104. That is, the low friction layer1104may cover at least a region of the substrate1119. Axial surfaces of the substrate1119may or may not be exposed from the low friction layer1104.

In an embodiment, the composite material1000may also include at least one adhesive layer1121that may couple the low friction layer1104to the substrate1119(i.e., the base material provided in the first step12) and a low friction layer1104(i.e., the low friction coating applied in second step14). In another alternate embodiment, the substrate1119, as a solid component, woven mesh or expanded metal grid, may be embedded between at least one adhesive layer1121included between the low friction layer1104and the substrate1119.

The adhesive layer1121may include any known adhesive material common to the bearing arts including, but not limited to, epoxy resins, polyimide resins, polyether/polyamide copolymers, ethylene vinyl acetates, ethylene tetrafluoroethylene (ETFE), ETFE copolymer, perfluoroalkoxy (PFA), or any combination thereof. Additionally, the adhesive can include at least one functional group selected from —C═O, —C—O—R, —COH, —COOH, —COOR, —CF2═CF—OR, or any combination thereof, where R is a cyclic or linear organic group containing between 1 and 20 carbon atoms. Additionally, the adhesive can include a copolymer. In an embodiment, the hot melt adhesive can have a melting temperature of not greater than 250° C., such as not greater than 220° C. In another embodiment, the adhesive may break down above 200° C., such as above 220° C. In further embodiments, the melting temperature of the hot melt adhesive can be higher than 250° C. or even higher than 300° C.

In an embodiment, the adhesive layer1121can have a thickness, TAL, of between about 1 micron to about 100 microns, such as between about 5 microns and about 80 microns, such as between about 10 microns and about 50 microns, such as between about 20 microns and about 40 microns. In a number of embodiments, the adhesive layer1121may have a thickness, TAL, of between about 15 and 60 microns. In a number of embodiments, the adhesive layer1121may have a thickness, TAL, of between about 30 and 100 microns. It will be further appreciated that the thickness, TAL, of the adhesive layer1121may be any value between any of the minimum and maximum values noted above. The thickness of the adhesive layer1121may be uniform, i.e., a thickness at a first location of the adhesive layer1121can be equal to a thickness at a second location therealong. The thickness of the adhesive layer1121may be non-uniform, i.e., a thickness at a first location of the adhesive layer1121can be different than a thickness at a second location therealong.

FIG. 2Bincludes an illustration of another embodiment. For purposes of illustration,FIG. 2Bshows the layer by layer configuration of a composite material1001after second step14. According to this particular embodiment, the composite material1001may be similar to the composite material1000ofFIG. 2A, except this composite material1001may also include corrosion protection layers1704,1705, and1708, and a corrosion resistant layer1125that can include an adhesion promoter layer1127and an epoxy layer1129that may couple to the substrate1119(i.e., the base material provided in the first step12) and a low friction layer1104(i.e., the low friction coating applied in second step14).

The substrate1119may be coated with corrosion protection layers1704and1705to prevent corrosion of the substrate1119prior to processing. Additionally, a corrosion protection layer1708can be applied over layer1704. Each of layers1704,1705, and1708can have a thickness of about 1 to 50 microns, such as about 7 to 15 microns. Layers1704and1705can include aluminum, zinc, magnesium, nickel, tin or any alloy thereof, a phosphate of zinc, iron, manganese, or any combination thereof, or a nano-ceramic layer. Further, layers1704and1705can include functional silanes, nano-scaled silane based primers, hydrolyzed silanes, organosilane adhesion promoters, solvent/water based silane primers, chlorinated polyolefins, passivated surfaces, commercially available zinc (mechanical/galvanic) or zinc-nickel coatings, or any combination thereof. Layer1708can include functional silanes, nano-scaled silane based primers, hydrolyzed silanes, organosilane adhesion promoters, solvent/water based silane primers. Corrosion protection layers1704,1706, and1708can be removed or retained during processing.

As stated above, the composite material1001may further include a corrosion resistant layer1125. The corrosion resistant layer1125can have a thickness of about 1 to 50 microns, such as about 5 to 20 microns, and such as about 7 to 15 microns. The corrosion resistant layer1125can include an adhesion promoter layer1127and an epoxy layer1129. The adhesion promoter layer1127can include a phosphate of zinc, iron, manganese, tin, or any combination thereof, or a nano-ceramic layer. The adhesion promoter layer1127can include functional silanes, nano-scaled silane based layers, hydrolyzed silanes, organosilane adhesion promoters, solvent/water based silane primers, chlorinated polyolefins, passivated surfaces, commercially available zinc (mechanical/galvanic) or Zinc-Nickel coatings, or any combination thereof. The epoxy layer1129can be a thermal cured epoxy, a UV cured epoxy, an IR cured epoxy, an electron beam cured epoxy, a radiation cured epoxy, or an air cured epoxy. Further, the epoxy layer1129can include polyglycidylether, diglycidylether, bisphenol A, bisphenol F, oxirane, oxacyclopropane, ethylenoxide, 1,2-epoxypropane, 2-methyloxirane, 9,10-epoxy-9,10-dihydroanthracene, or any combination thereof. The epoxy layer1129can further include a hardening agent. The hardening agent can include amines, acid anhydrides, phenol novolac hardeners such as phenol novolac poly[N-(4-hydroxyphenyl)maleimide] (PHPMI), resole phenol formaldehydes, fatty amine compounds, polycarbonic anhydrides, polyacrylate, isocyanates, encapsulated polyisocyanates, boron trifluoride amine complexes, chromic-based hardeners, polyamides, or any combination thereof. Generally, acid anhydrides can conform to the formula R—C═O—O—C═O—R′ where R can be CXHYXZAUas described above. Amines can include aliphatic amines such as monoethylamine, diethylenetriamine, triethylenetetraamine, and the like, alicyclic amines, aromatic amines such as cyclic aliphatic amines, cyclo aliphatic amines, amidoamines, polyamides, dicyandiamides, imidazole derivatives, and the like, or any combination thereof. Generally, amines can be primary amines, secondary amines, or tertiary amines conforming to the formula R1R2R3N where R can be CXHYXZAUas described above. In an embodiment, the epoxy layer1129can include fillers to improve the conductivity, such as carbon fillers, carbon fibers, carbon particles, graphite, metallic fillers such as bronze, aluminum, and other metals and their alloys, metal coated carbon fillers, metal coated polymer fillers, or any combination thereof. The conductive fillers can allow current to pass through the epoxy coating and can increase the conductivity of the coated bearing as compared to a coated bearing without conductive fillers.

In an embodiment, the composite material1000,1001can have a thickness, TSW, in a range of 0.1 mm and 5 mm, such as in a range of 0.15 mm and 2.5 mm, or even in a range of 0.2 mm and 1.5 mm. It will be further appreciated that the thickness, TSWof the composite material1000,1001may be any value between any of the minimum and maximum values noted above. The thickness, TSWof the composite material1000,1001may be uniform, i.e., a thickness at a first location of the composite material1000,1001can be equal to a thickness at a second location therealong. The thickness, TSWof the composite material1000,1001may be non-uniform, i.e., a thickness at a first location of the composite material1000,1001can be different than a thickness at a second location therealong.

In an embodiment, under step14ofFIG. 1, any of the layers on the composite material1000,1001as described above, can each be disposed in a roll and peeled therefrom to join together. Joining may be done under pressure, and optionally at elevated temperatures (e.g., pressed), and with an adhesive. Any of the layers of the composite material1000,1001as described above, may be laminated together such that they at least partially overlap one another. The sheet may be formed into a substrate1119having radial inner and outer surfaces. A low friction layer1104may encapsulate the substrate1119such that at least one of the radial inner and outer surfaces of the substrate1119may be located within the low friction layer1104.

Referring now to the third step16of the manufacturing process10as shown inFIG. 1, according to certain embodiments, forming the composite material1000,1001into a bearing may include gluing the low friction layer1104or any intervening layers can to the substrate1119using a melt adhesive1121to form a laminate. The laminate can be cut into blanks that can be formed into the bearing. The cutting of the laminate into a blank may include use of a stamp, press, punch, saw, deep drawing, or may be machined in a different way. Cutting the laminate into a blank can create cut edges including an exposed region of the substrate1119. The blanks can be formed into the bearing, such as by rolling and flanging the laminate to form a semi-finished bearing of a desired shape. The forming of the bearing from the blank may include use of a stamp, press, punch, saw, deep drawing, or may be machined in a different way. In some embodiments, the edges of the blank may be bent into a flange in a secondary operation. In other embodiments, the bearing may be formed through a single operation process including forming the flange. The bearing may be formed as a single unit or unitary piece of material.

For purposes of illustration,FIGS. 3A-5illustrate a number of bearing embodiment shapes (generally designated300,400, and500) that can be formed from the blanks. In a number of embodiments, the bearing300,400,500shown inFIGS. 3A-5may be produced by rolling of an appropriately dimensioned piece of composite material1000,1001which may be initially present as a blank as described above.FIG. 3Aillustrates a top perspective view of a bearing300that can be formed as described by the forming process above.FIG. 3Billustrates a radial cross-sectional view of a bearing300that can be formed as described by the forming process above.FIG. 4illustrates a radial cross-sectional view of a bearing400that can be formed as described by the forming process above.FIG. 5illustrates a top perspective view of a bearing500that can be formed as described by the forming process above.

Referring now toFIGS. 3A-3B, in a number of specific embodiments, the bearing may be a plain bearing300. In a number of embodiments, the bearing300may be a sliding bearing. The bearing300may extend in the axial direction relative to a central axis3000. The central axis3000is oriented longitudinally extending along the length of the bearing300. The bearing300may include a bearing sidewall308. The sidewall308may include a body310that may form an annular shape having a first axial end303and a second axial end305, as viewed in longitudinal cross-section. The bearing may have an outer radial end307and an inner radial end306. The bearing300may have an annular shape that is substantially L shaped. In other words, the bearing300may have an L bearing cross-section extending in the radial and axial direction as shown inFIG. 3B. Other annular shapes of the bearing are possible. The opposite ends of a rolled piece of the composite material1000,1001forming the bearing300may be bound at an axial gap330that extends in the axial direction along the body310. Axial gaps330extending nonlinearly and/or obliquely to the central axis3000of the bearing300are also possible. In a number of particular embodiments, the axial gap330may be welded or otherwise coupled by other means to form a closed bearing300. In some embodiments, the axial gap330may be left uncoupled. The bearing300may include a bore350extending down the axial length of the bearing300and adapted to house an internal component of an assembly. The bore350may be parallel to the central axis3000. The bore350may be formed by bending a planar composite material1000,1001into a generally cylindrical shape.

The bearing300sidewall308may further include at least one flange322. As shown inFIGS. 3A-3B, the flange322may project radially outwardly from at least one of the first axial end303or the second axial end305. Alternatively, the flange322may project radially inwardly from at least one of the first axial end303or the second axial end305. The flange322may extend from the inner radial end306to the outer radial end307. Alternatively, the flange322may extend from the outer radial end307to the inner radial end306. In some embodiments, the flange322may be positioned at the second axial end305of the bearing300. In a number of embodiments, the outer radial end307may form the outer radius OR of the bearing300when measured radially from the central axis3000. In a number of embodiments, the inner radial end306may form the inner radius IR of the bearing300when measured radially from the central axis3000. In other words, a radial width of the flange322WRFmay be the distance from the difference in distance of the outer radius OR and the inner radius IR. In a number of embodiments, the flange322may include an axial split327. The axial split327may provide a gap in the flange322. In certain embodiments, as shown inFIGS. 3A-3B, the axial split327can be contiguous with the axial gap330in the body310. In other embodiments, the axial split327can be non-contiguous with the axial gap330in the body310. In a number of embodiments, as shown inFIG. 3A, the flange322may include a plurality of axial splits327,345to form a segmented flange322.

In a number of embodiments, as shown inFIGS. 3A-3B, the bearing300may have an overall inner radius, IR, from the central axis3000to the inner radial end306, and IR can be ≥1 mm, such as ≥5 mm, ≥10 mm, ≥15 mm, ≥20 mm, or ≥50 mm. The inner radius IR can be ≤50 mm, such as ≤20 mm, ≤15 mm, ≤10 mm, ≤5 mm, or ≤1 mm. The inner radius IR may vary along the circumference of the bearing300. In a number of embodiments, the bearing300can have an overall inner radius, IR, of between about 3 to 50 mm. It will be appreciated that the bearing300can have an overall inner radius, IR, which may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the bearing300can have an overall inner radius, IR, which may be any value between any of the minimum and maximum values noted above.

In a number of embodiments, as shown inFIGS. 3A-3B, the bearing300may have an overall outer radius, OR, from the central axis3000to the outer radial end307, and OR can be ≥1.5 mm, such as ≥5 mm, ≥10 mm, ≥20 mm, ≥40 mm, or ≥70 mm. The outer radius OR can be ≤80 mm, such as ≤50 mm, ≤30 mm, ≤20 mm, ≤10 mm, or ≤5 mm. The overall outer radius, OR, may vary along the circumference of the bearing300. In a number of embodiments, the bearing300can have an overall outer radius, OR, of between about 5 to 60 mm. It will be appreciated that the bearing300can have an overall outer radius, OR, that may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the bearing300can have an overall outer radius, OR, that may be any value between any of the minimum and maximum values noted above. Further, as stated above, the radial width of the flange322, WRF, may be the distance from the difference in distance of the outer radius OR and the inner radius IR.

In a number of embodiments, as shown inFIGS. 3A-3B, the bearing300can have an overall height, H, from first axial end303to the second axial end305, and H can be ≥0.5 mm, 0.75 mm, ≥1 mm, ≥2 mm, ≥5 mm, ≥10 mm, or ≥50 mm. The height, H, can be ≤500 mm, such as ≤250 mm, ≤150 mm, ≤100 mm, or ≤50 mm. In a number of embodiments, the bearing300can have an overall height, H, of between about 5 to 50 mm. It will be appreciated that the bearing300can have an overall height, H, which may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the bearing300can have an overall height, H, which may be any value between any of the minimum and maximum values noted above.

In a number of embodiments, as shown inFIGS. 3A-3B, the at least one flange322may project radially outwardly from the second axial end305of the body310of the bearing300. In an embodiment, the flange322may be positioned to project orthogonal to the body310. In other embodiments, the flange322may be positioned to project non-orthogonal to the body310. In some embodiments, the flange322may form an angle α with the body310(and the central axial3000). Angle α may be in a range from at least 0° to 180°. The angle α may be 30° or greater, such as 45° or greater, 55° or greater, or 85° or greater. The angle α may be 150° or less, such as 135° or less, 120° or less, 90° or less, or 60° or less. In a number of specific embodiments, the angle α may be in a range of 60° to 120°.

In a number of embodiments, as shown inFIGS. 3A-3B, the flange322may include first region324, second region328, and a stepped transition region326between the first and second regions,324,328. In a number of embodiments, the second region may be elevated axially above the first region so as to protrude axially outwardly. The stepped transition region326may form an inclined angle θ relative to a line parallel to the central axis, where the inclined angle θ is in a range from about 10° to about 90°. The angle θ may be 10° or greater, such as 25° or greater, 35° or greater, or 45° or greater. The angle θ may be 85° or less, such as 75° or less, 65° or less, 55° or less, or 50° or less. In a number of specific embodiments, the angle θ may be in a range of 30° to 90°. In a number of embodiments, the second region328and/or stepped transition region326may be adapted to at least partially axially deform so as to provide axial tolerance compensation. Specifically, the second region provides a compressive force of X (N).

In a number of embodiments, as shown inFIG. 3B, the flange322can have a thickness, TRF, of between about 0.5 mm to about 10 mm, such as between about 0.75 mm and about 8 mm, such as between about 1 mm and about 5 mm, such as between about 1.5 mm and about 4 mm. In a number of embodiments, the flange322can have a thickness, TRF, of between about 0.7 to 5 mm. It will be appreciated that the flange322can have a thickness, TRF, which may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the flange322can have a thickness, TRF, which may be any value between any of the minimum and maximum values noted above. It may also be appreciated that the thickness, TRF, of the flange322may vary around the circumference of the bearing300.

In a number of embodiments, as shown inFIG. 3B, the height of the stepped transition region326, hstep, can be ≥0.15 mm, ≥0.25 mm, ≥0.5 mm, ≥1 mm, ≥2 mm, or ≥5 mm. The height the stepped transition region326, hstep, can be ≤10 mm, such as ≤7.5 mm, ≤5 mm, ≤2.5 mm, or ≤1 mm. It will be appreciated that the height of the stepped transition region326, hstep, may be within a range between any of the minimum and maximum values noted above. It will be further appreciated that the height of the stepped transition region326, hstep, may be any value between any of the minimum and maximum values noted above. It may also be appreciated that the height of the stepped transition region326, hstep, may vary around the circumference of the bearing300.

The stepped transition region326may extend a total thickness, TRF, of the flange322by at least 50% and not greater than 400%, such as at least 70% and not greater than 500%, at least 85% and not greater than 400%, or at least 100% and not greater than 300%, based on a thickness of the flange having no step included. The stepped transition region326may increase the thickness of the flange322by at least 0.1 mm.

In a number of embodiments, as shown inFIG. 3A, the flange322may have a surface area, SAF, and the second region328extends less than 80% of the surface area, SAF, of the flange322, such less than 75% of the surface area, SAF, less than 60% of the surface area, SAF, less than 50% of the surface area, SAFor even less than 30% of the surface area, SAF.

In a number of embodiments, as shown inFIGS. 3A-3B, the stepped transition region326may be annular around the circumference of the flange322. In this embodiment, the first region324may extend from the body to the stepped transition region and defines a maximum first axial height, hmax1, defined as the distance from the first axial end to the maximum height of the first region, and the second region extending from the stepped transition region defines a second maximum axial height, hmax2, defined as the distance from the first axial end to the maximum height of the second region, and where hmax1<hmax2. In a number of embodiments, hmax1≤0.99 hmax2, such as hmax1≤0.95 hmax2, or hmax1≤0.90 hmax2.

In a number of embodiments, as shown inFIG. 3A, the sidewall308or body310may include at least one protrusion370, which may be oriented in the radial direction. The at least one protrusion370may provide more stiffness for the body310or the flange322. In a number of embodiments, the protrusion370may provide radial tolerance compensation and stiffness support for at least one of the body310or the flange322. The protrusion370may include at least one undulation, depression, groove, trough, plateau, ramp, projection, or deformation in the radial direction. The protrusion370may be oriented radially outward or radially inward from a line parallel to the central axis3000. The protrusion370may have a circular, polygonal, oval, or semi-circular cross-sectional shape. In a number of embodiments, the protrusion370may be located on the body310. In a number of embodiments, the protrusion370may be disposed in the axial distance between the first axial end303and the second axial end305. In a number of embodiments, the protrusion370may be at the first axial end303or the second axial end305. In other words, the protrusion370may extend anywhere along the circumference of the body310. In an embodiment, the protrusion370may be on the flange322. The forming of the protrusion370may include use of a stamp, press, punch, saw, deep drawing, or may be machined in a different way.

In a number of embodiments, as shown inFIGS. 3A-3B, the body310may include at least one coining region366, which may be oriented in the radial direction. The at least one coining region366may provide more stiffness for the body310or the flange322. In a number of embodiments, the coining region366may provide axial tolerance compensation and stiffness support for at least one of the body310or the flange322. The coining region366may include at least one undulation, depression, groove, trough, plateau, ramp, projection, or deformation in the axial direction. The coining region366may have a circular, polygonal, oval, or semi circular cross-sectional shape. In a number of embodiments, the coining region366may be located on the body310. In a number of embodiments, the coining region366may be disposed in the axial distance between the first axial end303and the second axial end305. In a number of embodiments, the coining region366may be at the first axial end303or the second axial end305. In other words, the coining region366may extend anywhere along the circumference of the body310. In one embodiment, the coining region366may be in the shape of a deformation in a radial direction so the body310may be non-parallel to the central axis3000of the bearing300as shown inFIG. 3A. The coining region366may be deformed radially outward or radially inward from a line parallel to the central axis3000. The forming of the coining region366may include use of a stamp, press, punch, saw, deep drawing, or may be machined in a different way.

As shown best inFIG. 3B, the coining region366may have a height HCR. The height HCRmay have a relationship with the height H of the bearing300such that HCR≥0.3 H, such as ≥0.25 H, ≥0.20 H, ≥0.15 H, ≥0.10 H, or ≥0.05 H. In another aspect, height HCRcan be ≤0.5H, such as ≤0.45H, ≤0.40H, ≤0.35H, ≤0.30H, ≤0.25H, ≤0.20H, ≤0.15H, ≤0.10 H, or ≤0.05 H. The height HCRof the coining region366may vary along the circumference of the bearing300about the central axis3000.

FIG. 4illustrates a radial cross-sectional view of a bearing400that can be formed as described by the forming process above. It will be appreciated that the reference numbers, features, and characteristics of the individual components of the bearing400may be substantially similar to the corresponding components of the bearing300illustrated inFIGS. 3A-3B. In addition, in the embodiment shown inFIG. 4, the second region428may form a first section428A and a second section428B. The first section428A of the second region428may be at a higher axial height than the second section428B of the second region428relative to the first axial end403of the bearing400. In an alternative embodiment, the first section428A of the second region428may be at a lower axial height than the second section428B of the second region428relative to the first axial end403of the bearing400. A second stepped transition region436may be disposed between the first section428A and the second section428B of the second region428. It should be contemplated that the second stepped transition region436may have all the range of lengths, thicknesses, and angles mentioned above regarding the stepped transition region326ofFIGS. 3A-3B.

FIG. 5illustrates a top perspective view of a bearing500that can be formed as described by the forming process above. It will be appreciated that the reference numbers, features, and characteristics of the individual components of the bearing500may be substantially similar to the corresponding components of the bearing300illustrated inFIGS. 3A-3B, and the corresponding components of the bearing400illustrated inFIG. 4. In an embodiment, as shown inFIG. 5, the second region528may extend at least partially circumferentially around the flange522to form at least one segment542. In an embodiment, the at least one segment542may include a plurality of segments542,542′,542″ with a plurality of stepped transition regions526,526′,526″ such that each segment542,542′,542″ may be adjacent a first region524. Each of the plurality of segments542,542′,542″ may each extend at least partially circumferentially around the flange522. In other words, the stepped transition regions526,526′,526″ may be oriented circumferentially such that the second regions528forms segments542,542′,542″ adjacent a first region524. The flange may include at least 3 stepped transition regions, such as at least 6 stepped transition regions (as shown), at least 8 stepped transition regions, or at least 10 stepped transition regions. In a number of embodiments, the segments in total may span less than 270° of a circumference of the flange, such as less than 225°, less than 180°, less than 135°, or less than 90°. It should be contemplated that the stepped transition regions526,526′,526″ may have all the range of lengths, thicknesses, and angles mentioned above regarding the stepped transition region326ofFIGS. 3A-3B.

In a number of embodiments, the bearing300,400,500may be including in an assembly2000. The assembly2000may further include an inner member, such as a shaft28. The assembly2000may include a bearing300,400,500surrounding the shaft28, the bearing300,400,500having a body310,410,510having a first axial end303,403,503and a second axial end305,405,505. The bearing300,400,500may further include forming at least one flange322,422,522on the second axial end305,405,505of the bearing300,400,500, where at least one flange322,422,522projects radially from the second axial end305,405,505of the body310,410,510, where the at least one flange322,422,522includes a first region324,424,524, second region328,428,528, and a stepped transition region326,426,526between the first region324,424,524and the second regions328,428,528, where the second region328,428,528may be elevated axially above the first region324,424,524so as to protrude axially outwardly, where 1) the second region328,428,528extends partially circumferentially around the flange322,422,522to form at least one segment, and/or 2) the first region324,424,524extends from the body310,410,510to the stepped transition region326,426,526and defines a maximum first axial height, hmax1, defined as the distance from the first axial end303,403,503to the maximum height of the first region324,424,524, and the second region1328,428,528extending from the stepped transition region326,426,526defines a second maximum axial height, hmax2, defined as the distance from the first axial end303,403,503to the maximum height of the second region326,426,526, and where hmax1<hmax2. The assembly2000may further include outer member30, such as a housing. In a number of embodiments, the bearing300,400,500may be disposed between the inner member28and the outer member30such that the bearing surrounds the inner member or shaft28. In a number of embodiments, the stepped transition region326,426,526may allow axial tolerance compensation between the bearing300,400,500and at least one of the inner member28or the outer member30. The stepped transition region326,426,526or resulting flange322,422,522may allow axial tolerance compensation of the inner member or shaft28of at least 0.1 mm and not greater than 5 mm.

FIGS. 6 and 7illustrate an assembly2000in the form of an exemplary hinge600, such as an automotive door hinge, hood hinge, engine compartment hinge, and the like. Hinge600can include an inner member28(such as an inner hinge region602) and an outer hinge region604. Hinge regions602and604can be joined by outer members30(such as rivets606and608) and bearings610and612. Bearings610and612can be bearings as previously described and labeled300,400,500herein.FIG. 7illustrates a cross section of hinge600, showing rivet608and bearing612in more detail.

FIG. 8illustrates an assembly2000in the form of another exemplary hinge800. Hinge800can include a first hinge region802and a second hinge region804joined by a pin806and a bearing808. Bearing808can be a bearing as previously described and labeled300,400,500herein.

In an exemplary embodiment,FIG. 9depicts a non-limiting example of an assembly2000in the form of an embodiment of another hinge assembly900including the parts of a disassembled automobile door hinge including bearing904.FIG. 9is an example of a profile hinge. The bearing904may be inserted in hinge door part906. Bearing904can be a bearing as previously described and labeled300,400,500herein. Rivet908bridges the hinge door part906with hinge body part910. Rivet908may be tightened with hinge body part910through set screw912and hold in place with the hinge door part906through washer902.

FIG. 10illustrates an assembly2000in the form of an exemplary headset assembly10000for a two-wheeled vehicle, such as a bicycle or motorcycle. A steering tube1002can be inserted through a head tube1004. Bearings1006and1008can be placed between the steering tube1002and the head tube1004to maintain alignment and prevent contact between the steering tube1002and the head tube1004. Bearings1006and1008can be bearings as previously described and labeled300,400,500herein. Additionally, seals1010and1012can prevent contamination of the sliding surface of the bearing by dirt and other particulate matter.

Such assemblies noted above are all exemplary and are not meant to limit the use of the bearing300,400,500in potential other assemblies. For example, the bearing300,400,500may be used in an assembly2000for a powertrain assembly application (such as belt tensioners) or other assembly applications with limited space.

In an embodiment, the bearing300,400,500can provide an axial tolerance compensation of at least 0.1 mm in an axial direction relative to the inner member or outer member, such as at least 0.2 mm, at least 0.3 mm, at least 0.5 mm, at least 1 mm, at least 2 mm, or even at least 5 mm. In a further embodiment, the assembly2000can be installed or assembled by an assembly force of no greater than 10,000 N in the axial direction to the inner member or outer member, such as no greater than 5,000 N, no greater than 1,000 N, no greater than 500 N, no greater than 100 N, no greater than 50 or even no greater than 10 N.

The method of forming the bearing300,400,500may include providing a blank. The bearing300,400,500may be formed from a blank including a laminate including a substrate1119and a low friction layer1104overlying the substrate1119. The method may further include forming a bearing300,400,500from the blank, the bearing having a body310having a first axial end303and a second axial end305. The method may further include forming at least one flange322on the second axial end305of the bearing300, where at least one flange322projects radially from the second axial end305of the body310, where the at least one flange322includes a first region324, second region328, and a stepped transition region326between the first and second regions324,326, where the second region328may be elevated axially above the first region324so as to protrude axially outwardly, where 1) the second region328extends partially circumferentially around the flange322to form at least one segment, and/or 2) the first region324extends from the body310to the stepped transition region326and defines a maximum first axial height, hmax1, defined as the distance from the first axial end303to the maximum height of the first region324, and the second region328extending from the stepped transition region326defines a second maximum axial height, hmax2, defined as the distance from the first axial end303to the maximum height of the second region326, and where hmax1<hmax2.

Applications for such embodiments include, for example, assemblies1000for hinges and other vehicle components. Further, use of the bearing300,400,500or assembly2000may provide increased benefits in several applications such as, but not limited to, vehicle tail gates, door frames, seat assemblies, powertrain applications (such as belt tensioners), or other types of applications. According to embodiments herein, the flanges of the bearings may provide desired axial preload and improved axial tolerance compensation compared to existing bearings known in the art. Further, according to embodiments herein, the bearings may be a simple installation and be retrofit and cost effective across several possible assemblies of varying complexity. As a result, these designs can significantly reduce noise, harshness, and vibration properties while providing improved torque performance, thereby increasing lifetime and improving effectiveness and performance of the assembly, the bearing, and its other components.

A bearing, comprising: a body having a first axial end and a second axial end; and at least one flange projecting radially from the second axial end of the body, wherein the at least one flange comprises a first region, second region, and a stepped transition region between the first and second regions, wherein the second region is elevated axially above the first region so as to protrude axially outwardly, wherein 1) the second region extends partially circumferentially around the flange to form at least one segment, and/or 2) the first region extends from the body to the stepped transition region and defines a maximum first axial height, hmax1, defined as the distance from the first axial end to the maximum height of the first region, and the second region extending from the stepped transition region defines a second maximum axial height, hmax2, defined as the distance from the first axial end to the maximum height of the second region, and wherein hmax1<hmax2.

An assembly comprising: a shaft; and a bearing surrounding the shaft, wherein the bearing comprises: a body having a first axial end and a second axial end; and at least one flange projecting radially from the second axial end of the body, wherein the at least one flange comprises a first region, second region, and a stepped transition region between the first and second regions, wherein the second region is elevated axially above the first region so as to protrude axially outwardly, wherein 1) the second region extends partially circumferentially around the flange to form at least one segment, 2) the first region extends from the body to the stepped transition region and defines a maximum first axial height, hmax1, defined as the distance from the first axial end to the maximum height of the first region, and the second region extending from the stepped transition region defines a second maximum axial height, hmax2, defined as the distance from the first axial end to the maximum height of the second region, and wherein hmax1<hmax2.

A method for forming a bearing, comprising: providing a blank; forming a bearing from the blank, the bearing comprising a body having a first axial end and a second axial end; and forming at least one flange on the second axial end of the bearing, wherein at least one flange projects radially from the second axial end of the body, wherein the at least one flange comprises a first region, second region, and a stepped transition region between the first and second regions, wherein the second region is elevated axially above the first region so as to protrude axially outwardly, wherein 1) the second region extends partially circumferentially around the flange to form at least one segment, and/or 2) the first region extends from the body to the stepped transition region and defines a maximum first axial height, hmax1, defined as the distance from the first axial end to the maximum height of the first region, and the second region extending from the stepped transition region defines a second maximum axial height, hmax2, defined as the distance from the first axial end to the maximum height of the second region, and wherein hmax1<hmax2.

The bearing, assembly, or method of any of the preceding embodiments, wherein the at least one segment of the second region comprises a plurality of segments.

The bearing, assembly, or method of any of the preceding embodiments, wherein the stepped transition region extends circumferentially such that the second region forms a segment adjacent the first region.

The bearing, assembly, or method of embodiment 4, wherein the plurality of segments includes at least 3 segments.

The bearing, assembly, or method of any of the preceding embodiments, wherein the flange comprises at least 3 stepped transition regions, such as at least 6 stepped transition regions, at least 8 stepped transition regions, or at least 10 stepped transition regions.

The bearing, assembly, or method of embodiment 4, wherein the plurality of segments spans less than 270° of a circumference of the flange, such as less than 225°, less than 180°, less than 135°, or less than 90°.

The bearing, assembly, or method of any of the preceding embodiments, wherein hmax1≤0.99 hmax2, such as hmax1≤0.95 hmax2, or hmax1≤0.90 hmax2.

The bearing, assembly, or method of any of the preceding embodiments, wherein the stepped transition region has a height, hstep, of 0.05 mm to 5 mm.

The bearing, assembly, or method of any of the preceding embodiments, wherein the flange has a surface area, SAF, and the second region extends less than 80% of the surface area, SAF, of the flange.

The bearing, assembly, or method of any of the preceding embodiments, wherein the stepped transition region is annular.

The bearing, assembly, or method of any of the preceding embodiments, wherein the second region is adapted to at least partially axially deform so as to provide axial tolerance compensation.

The bearing, assembly, or method of any of the preceding embodiments, wherein, as viewed in radial cross-section, the first region has a radial length, LFR, and second region has radial length, LSR, where, LFR>LSR.

The bearing, assembly, or method of any of the preceding embodiments, wherein the second region provides a load capacity of 10 to 90% of the load capacity of a flange without stepped transition region.

The bearing, assembly, or method of any of the preceding embodiments, wherein the stepped transition region forms an inclined angle θ relative to a line parallel to the central axis, wherein the inclined angle θ is in a range from at least 30 degrees to 90 degrees.

The bearing, assembly, or method of any of the preceding embodiments, wherein the stepped portion extends a total thickness of the flange in axial direction by at least 5% and not greater than 40%, based on a thickness of the flange.

The bearing, assembly, or method of any of the preceding embodiments, wherein the bearing comprises an axial gap.

The bearing, assembly, or method of any of the preceding embodiments, wherein an inner radius of the bearing is at least 2.5 mm and not greater than 20 mm.

The bearing, assembly, or method of any of the preceding embodiments, wherein an outer radius of the bearing is at least 5 mm and not greater than 25 mm.

The bearing, assembly, or method of any of the preceding embodiments, wherein the bearing comprises a laminate comprising a substrate and a low friction layer.

The bearing, assembly, or method of embodiment 21, wherein the low friction layer comprises a polymer.

The bearing, assembly, or method of embodiment 22, wherein the polymer of the low friction layer comprises a fluoropolymer.

The bearing, assembly, or method of embodiment 21, wherein the substrate includes a metal.

The bearing, assembly, or method of embodiment 24, wherein the metal of the substrate is selected from the group of iron, aluminum, copper, nickel, or alloys thereof.

The bearing, assembly, or method of any of the preceding embodiments, wherein a thickness of the low friction layer is at least 1 micron and not greater than 500 microns.

The bearing, assembly, or method of any of the preceding embodiments, wherein a thickness of the substrate is at least 50 microns and not greater than 500 microns.

The bearing, assembly, or method of any of the preceding embodiments, wherein the flange is segmented.

Note that not all of the features described above are required, that a region of a specific feature may not be required, and that one or more features may be provided in addition to those described. Still further, the order in which features are described is not necessarily the order in which the features are installed.

Certain features 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 subcombinations.