Formable bearings and bearing devices

A formed bearing assembly and a method of making the bearing is provided. The bearing assembly includes a housing and a bearing space formed therein. A slide is disposed within the bearing space and is movable along its longitudinal extent. A bearing is formed in the bearing space between the housing and the slide. The bearing is a solid, formed in the bearing space while in liquid state. At least a portion of the bearing forms the shape of at least a portion of the slide.

TECHNICAL FIELD

The present disclosure relates to bearing devices and methods of making the same. More particularly, the present disclosure is related to slide devices and methods of making the same that employ formable bearings.

BACKGROUND AND SUMMARY

Conventional slide devices typically require a precise bore formed within a housing, along with equally precise machined bearings inserted into that bore. Such precise sizing and alignment required between the housing, bearing, and ultimately the slide, increases the cost of the device. Furthermore, the bearings on such devices tend to be delicate and typically cannot withstand constant impact forces being exerted there against, without experiencing a deleterious effect.

Accordingly, an illustrative embodiment of the present disclosure provides a formed bearing assembly. The bearing assembly comprises a housing, a slide, and a bearing. Illustratively, the housing has a longitudinal extent and a bearing space formed along the longitudinal extent. The slide is disposed within the bearing space of the housing, and is movable along its longitudinal extent. The bearing is formed in the bearing space between the housing and the slide. At least a portion of the bearing forms the contour of at least a portion of the slide which is movable there along. The bearing is a solid, formed in the bearing space while in liquid state.

In the above and other embodiments, the bearing assembly may further comprise: an impact member attached to the slide; a bearing configured to receive an impact force external of the housing; a resilient bearing; a housing comprising at least one opening to receive a portion of a bearing when in liquid state to assist securing the bearing to the housing; an impact member comprising an impact surface configured to receive an impact force; an impact surface oriented in tandem with at least a portion of a bearing and wherein the bearing is configured to receive an impact force; and an impact surface oriented askew to at least a portion of a bearing and wherein the bearing is configured to receive an impact force.

Another illustrative embodiment of the present disclosure provides a formed slide bearing assembly. The assembly comprises a housing, a slide, and a bearing. The housing has a longitudinal extent and has a bearing space formed along the longitudinal extent. The slide is disposed within the bearing space of the housing and is movable along its longitudinal extent. The bearing is formed in the bearing space between the housing and the slide. At least a portion of the bearing forms the contour of at least a portion of the slide which is movable there along. The bearing is a resilient material, and is configured to mitigate the effects of an impact force exerted on the slide.

In the above and other embodiments, the bearing assembly may further comprise: an impact member attached to the slide; an impact member comprising an impact surface configured to receive an impact force; an impact surface being oriented in tandem with at least a portion of the bearing and the bearing being configured to receive the impact force; and an impact surface being oriented askew to at least a portion of a bearing configured to receive the impact force.

Another illustrative embodiment of the present disclosure provides a method of making a slide formable bearing assembly. The method comprises: providing a housing having a bearing space formed therein; disposing a core in the bearing space; disposing liquid bearing material in the bearing space between the core and the housing; allowing solidification of the bearing material; removing the core exposing a cavity; and inserting a movable member into the cavity.

In the above and other embodiments, the method may further comprise the step or steps of: attaching a movable member to an actuator; attaching the housing to a guide assembly; providing a guide assembly comprising a base back plate; attaching a core guide to the core; providing a space configured to receive the core guide to locate the core in the bearing space; providing a space in the housing to receive liquid bearing material; providing a wall in the housing with an opening disposed therethrough to receive bearing material; sealing the wall during the disposition of the liquid bearing material in the bearing space; securing the housing to the base during the disposition of the liquid bearing material in the bearing space; securing the housing to the back plate during the disposition of the liquid bearing material in the bearing space; coupling the housing to a slide assembly; coupling the housing to an actuator; coupling the housing to a cylinder actuator; and coupling the housing to a pneumatic actuator.

Another illustrative embodiment of the present disclosure provides an impact assembly. The assembly comprises a housing, a slide, a bearing, and an impact member. The housing has a longitudinal extent and has a bearing space formed along the longitudinal extent. The slide is disposed within the bearing space of the housing, and is movable along its longitudinal extent. The bearing is formed in the bearing space between the housing and the slide. The impact plate is coupled to the slide, and is configured to receive an impact member. An impact against the impact member causes the slide to exert a force against the bearing. The bearing is configured to absorb the force from the slide.

In the above and other embodiments, the impact assembly may further comprise: an impact plate being oriented in tandem with at least a portion of the bearing; an impact member being oriented askew to at least a portion of the bearing; an impact member being oriented in tandem with at least a portion of the slide; an impact member being attached to the slide; an impact member being formed integral with the slide; an impact member being oriented in tandem with at least a portion of the slide and at least a portion of the bearing wherein the force of the impact is directed to the bearing; an actuator being attached to the housing; and an actuator being attached to the slide to move the slide relative to the housing.

Additional features and advantages of the method of forming the bearings and the bearing devices will become apparent to those skilled in the art upon consideration of the following detailed descriptions exemplifying the best mode of carrying out these methods and devices as presently perceived.

Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates embodiments of bearing devices and the method of making formable bearings, and such exemplification is not to be construed as limiting the scope of the devices or methods in any manner.

DETAILED DESCRIPTION OF THE DRAWINGS

A perspective view of a mold assembly2is shown inFIG. 1. This illustrative mold assembly2comprises a guide assembly4and a bearing part or housing6. In this illustrative embodiment, guide assembly4comprises a base plate8and a back plate10. Guide assembly4is configured to position housing6to receive a bearing. A mold core12is shown inserted within bearing space14. (See, also,FIG. 2.) Illustratively, liquid bearing material16can be poured through bearing space opening18about the periphery of mold core12to fill bearing space14. Once the bearing material16is solidified, a bearing is formed.

Openings30, disposed in housing6, illustratively serve to hold liquid bearing material within housing6during formation. This allows the bearing material, deposited into housing6, to attach to the same without the use of adhesives, chemical bonding, or other means. Consequently, a high precision bearing surface is provided between moving parts at a reduced cost. In this illustrative embodiment, openings30, located between bearing space14and the exterior of housing6, are illustratively covered by a covering32. (See, also,FIG. 2.) This prevents bearing material16, which is poured into bearing space14, from exiting housing6. This covering can be temporary, since the liquid bearing material solidifies to produce the bearing surface. It is appreciated that this covering32can be any suitable barrier, including adhesive tape or silicone sealer, for example.

Mold core12, in this illustrative embodiment, comprises a core guide20that is illustratively attached thereto and seated within a guide22. This assists aligning mold core12in a desired location within bearing space14during deposit of bearing material16. (See, also,FIG. 2.) As further shown inFIG. 1, housing6is illustratively located and/or secured into position by pins28and fasteners24,26, which seat housing6in the desired position to receive bearing material16.

It is appreciated that the embodiment of housing6and assembly4shown inFIGS. 1 and 2are for illustrative purposes. And though this embodiment shows a slide bearing, it is appreciated that other embodiments of the core may be of any size, shape, or cross-section, and can be for any type of moving part that requires contact with a bearing surface, be it round, spherical, square, cylindrical, etc. It is further appreciated that the bearing material used herein can be a urethane, as well as other bearing materials, such as nylon. The bearing material may also be any other like material known by those skilled in the art or to be developed in the future. In an alternative embodiment, such bearing material may also be a non-liquid material, such as a putty or other formable material, that can be deposited into a space and be formed into an effective bearing surface.

FIG. 2is a side cross-sectional view of mold assembly2. The cross-sectional portion of housing6shows bearing space14filled with bearing material16between the same and core12. Also shown is bearing material16and openings30, which provide the aforementioned attachment of bearing material16to housing6. Also shown are core guides20, each illustratively positioned on opposing sides of core12to assist in guiding or locating the same adjacent bearing space14. When bearing material16is solidified, core12can be removed and a slide replaced therein. (See alsoFIGS. 9,15, and21.) It is appreciated, that in the illustrative embodiment, the bearing spaces and surfaces need not be precisely manufactured for the housing. Rather, a space is made and a core placed in a desired position. The bearing material will form around the core and fill the space, creating the desired alignment.

An exploded view of an illustrative mold assembly40is shown inFIG. 3. This illustrative embodiment comprises a base plate8and a core12attached thereto. Core12is attached to plate8via fasteners42that extend through bores44of plate8and into the bottom of core12. Also shown are fasteners24which attach to or extend through washers46and into bores48to secure a housing thereto. Pins28are fitted in bores50to further assist in aligning housing6onto the mold assembly. Core guides20are shown illustratively attached to core12via fasteners52disposed through washer54and bores56.

It is appreciated that the positioning of the components of mold assembly40shown herein can be of any size, shape, or character to accommodate any desired housing. It is further appreciated that shown herein is one illustrative example of how a housing can be secured to a mold assembly to produce a bearing under repeatable conditions. It is the positioning of the housing with respect to the core and the mold assembly that creates the precision in forming the bearing.

An exploded view of another illustrative mold assembly58is shown inFIG. 4. This embodiment, similar to the embodiment disclosed inFIG. 1, also comprises a back plate10. It is appreciated that such an assembly can take on any variety of configurations and have guides, such as guide pins28, and fasteners24and26to locate and secure the housing at any desired location to create the appropriate bearing surface.FIG. 4also shows fasteners60that attach back plate10to base plate8.

FIGS. 5Aand B are several views of housing6. As will be discussed further herein with regard to illustrative devices or assemblies that use formable bearings, housing6is an example of the types of housing used as a component of the slide assemblies, such as assemblies104and204. (SeeFIGS. 9 and 15.) This illustrative embodiment comprises a face bracket15located adjacent opening18. Face bracket15comprises a bore21configured to receive a piston rod from a cylinder, such as rod110shown inFIG. 11. Bracket15can also be used to secure housing6to one of the mold assemblies fromFIG. 1 through 3, and/or attach to an assembly line as part of a slide assembly. The longitudinal extent17of housing6further defines bearing space14. A recess19is shown for receiving a slide stop, such as stop126. (See, for example,FIG. 11.) Brackets23extend from the longitudinal extent17of housing6, illustratively for mounting purposes.FIG. 5Bis a side view of housing6showing the illustrative profile of bracket23and the edge of face bracket15. Also shown is bearing space14of longitudinal extent17.

FIG. 6Athrough C are several views of an illustrative mold core12. Illustratively, ridges68are located on the periphery surface of core12. These ridges68form corresponding channels within the bearing surface to allow lubricant and/or dirt and debris to pass therethrough. Thus, the shape and contour of the bearing can be defined by simply making a corresponding core. Also shown is a bore27configured to receive a fastener that attaches core guide20to core12. (See, also,FIGS. 1 and 2.)

FIG. 7Athrough C are several views of housing6with bearing70formed and solidified therein. As shown inFIG. 7A, bearing70forms cavity72along the longitudinal extent17. Also shown in this cross-sectional view is the manner in which bearing70attaches itself to housing6. The openings30that are disposed through housing6are shown filled with the bearing material70. Filling these openings30secures bearing70to housing6. This, again, allows the bearing to be secured without requiring a physical or chemical bond between housing6and bearing70. Recess19, shown inFIG. 7B, is not filled with bearing material70. This allows recess19to receive the slide stop. The front view of housing6shown inFIG. 7Cdepicts the cross-section of bearing surfaces74. A slide can be inserted into cavity72and ride along surfaces74.

FIG. 8Athrough C show another illustrative housing6, also with bearing70, cavity72, and bearing surface74. It is noted that housing6fromFIG. 8differs from that shown inFIG. 7by virtue of bracket76that is attached to longitudinal extent17. Bracket76can be used to secure to one of the mold assemblies, as shown inFIG. 1, and/or to mount to an assembly line.

FIGS. 9Aand B are perspective views of an illustrative embodiment of a stopper100. Stopper100illustratively comprises a cylinder102which can be a pneumatic, hydraulic, or an electrical cylinder. Stopper100also comprises a bearing assembly104having a slide106, an impact plate108attached thereto, a piston rod110extending from cylinder102, and a thrust washer112that attaches slide106to rod110. (See alsoFIGS. 10Aand B.) It is contemplated that stopper100is configured to receive an impact force on impact plate108, and that force is absorbed by the bearing within assembly104. The bearing70is made from a resilient or like material that will be able to absorb at least a potion of the impact force. Accordingly, slides may be configured so that the formable bearing can receive an impact force, rather than avoid the impact force. Stopper126, located on slide106and its corresponding recess19, is shownFIG. 9B.

FIGS. 10Aand B are perspective views of stopper100with piston rod110located in the extended position. By extending rod110, impact plate108is exposed from assembly104. Plate108is, thus, available to receive an impact force63. Also shown is the engagement between recess19and stop126. This engagement limits the length of travel of slide106and plate108.

An exploded view of stopper100is shown inFIG. 11. The exploded view shows extension and retraction air ports114and116, respectively, coupled to cylinder102. It is contemplated, however, that cylinder102may be of any variety of actuator, recognized by those skilled in the art, including electrical or hydraulic. Rod110extends from cylinder102, and is caused to selectively extend and retract relative to cylinder102when power is delivered through ports114and116. Rod110also extends through a bore21disposed through bracket15on bearing assembly104. Bearing assembly104comprises housing6shown inFIG. 1. It is contemplated, however, that such a bearing assembly104, like housing6, is of illustrative configuration. It is further contemplated that other such bearing assemblies could be used so long as the bearing, illustratively like the bearing70of assembly104, is resilient and/or shock absorbing. Fasteners122are illustratively disposed through bracket15of housing6, and attach to cylinder102thereto. Slide106is disposed into cavity72, which is lined by bearing70, thus, allowing slide106to move therein. Illustratively, stop126is attached to slide106to limit movement of the same, preventing it from being completely removed from housing6, unless stop126is removed or otherwise adjusted. In addition, rod110extends through bore128, disposed through slide106. In this illustrative embodiment, the contemplated impact point on the slide106is located on impact plate108. This causes slide106to either bend or move and cause a portion of bearing70to compress or otherwise deform. Rod110attaches to slide106by being disposed through oval bore128, and couple to thrust washers130. This prevents rod110from bending as either slide106bends, or bearing70compresses or deforms.

The side view of stopper100is shown inFIG. 12. In this illustrative embodiment, it is contemplated that a force63will impact plate108on slide106. This force63, depending on its size, may cause a portion of bearing70, particularly the portion located opposite the direction of force63, to compress. In the illustrative embodiment, urethane can be used for the bearing material. Because such is known for its absorbing properties, as well as its resiliency, after the impact of force63causes slide106to compress bearing70, the resiliency of bearing70will cause slide106to return to its original position. This is done without causing damage to rod110and cylinder102, because the oval bore128in slide106moves in direction134independently of piston rod110. (See, also,FIG. 11.)

FIG. 13is a perspective view of an illustrative assembly line employing stopper100. In this example, a sheet metal panel140is stopped in position prior to stamping. Slide106of stopper100is extended to receive the impact of the sheet metal panel140at a specific point along the assembly line. Once panel140has engaged stopper100at impact plate108, it is or can be properly positioned. Piston rod110and, consequently, slide106can then be retracted so panel140may slide there over and move into position on press142.

FIG. 14Athrough D are several views of slide106with impact plate108attached thereto.FIGS. 14A, C, and D, show an extension115that allows impact plate108to extend beyond slide106. Shown inFIGS. 14A, C, and D is illustrative oval bore128. This allows slide106to move relative to piston rod110without damaging the same. (See, also,FIG. 11.) A stop bore131is disposed illustratively through slide106and impact plate128. Bore131is configured to accommodate a slide stop, such as stop126. (SeeFIG. 12.) It is appreciated that the configuration of impact plate108is of illustrative nature and can be modified to suit any particular stopping need.

FIG. 15is a perspective view of an illustrative embodiment of a crowder device200. Crowder200is illustratively used to push parts into particular locations by extending and/or retracting its slide206. Crowder200is shown in the retracted position and comprises a formable bearing assembly204, similar to assembly104of stopper100. Crowder200further comprises a cylinder202, a slide206, and a bearing assembly204. Slide206is disposed through assembly204. Plate208is attached to slide206and rod210. (See, also,FIG. 16.) Any variety of accessories or toolings can be fitted onto plate208for any variety of moving tasks. (See, also,FIG. 19Athrough C.) It is appreciated that crowder200can operate by extending slide206in either the horizontal or vertical orientations.

A perspective view of crowder200is shown inFIG. 16, with slide206located in the extended position. It is appreciated from this view and, as contrasted fromFIG. 15, that plate208can push an object outward in direction233, or pull an object inward in direction235.

A perspective exploded view of crowder200is shown inFIG. 17. In this illustrative embodiment, similar to the stopper100, crowder200comprises a cylinder202that is a pneumatic cylinder having extension and retraction ports214,216. It is contemplated that the cylinder may also be either hydraulic or electrical. Rod210is extendable and retractable from cylinder202, and is disposed through bore218of bearing assembly204. Bearing70lines cavity72in assembly204. Note that bearing assembly204herein is distinguishable from assembly104by virtue of bracket76that allows the bearing assembly204to attach to a surface. (See, also,FIG. 7.) Fasteners222attach bearing assembly204to cylinder202via plate219. Slide206is disposed through cavity72, and is moveable along bearing70. A stop226, similar to stop126of stopper100, is attached to slide206to limit movement thereof.

Extending from slide206is a base228that receives the plate208. Plate208is configured to contact an article, or attach to a tooling that contacts an article, to move the same pursuant extension and retraction of rod210. In this illustrative embodiment, a bore230is disposed through base228. Illustratively, using washers232and fasteners234, plate208is attached to base228, and rod210is attached to base228, as well as extending and retracting slide206.

A perspective view of an illustrative assembly line employing crowder assemblies200is shown inFIG. 18. In this example, crowder200can be used in conjunction with stopper100. Placement of sheet metal panel140in the desired location on the line can be assisted by crowder200in conjunction with tooling246. The sheet metal panel140can be placed on tooling246and transferred along the assembly line. Illustratively, sheet metal panel140can then engage impact plate108of stopper100, limiting its movement in ensuring desired placement in direction240. Sheet metal panel140can also be moved in directions242and244by use of tooling252on crowder200, which moves sheet metal panel140in either direction240or242to create desired alignment of sheet metal140within press142.

FIG. 19Athrough C show several views of crowder200. The formable bearing220in crowder200allows the same to absorb vertical shock from articles that drop onto it. For example, as shown inFIG. 19A, if a force245is exerted on, in this embodiment, tooling246, that force causes movement of plate208and, consequently, slide206in direction247. This may occur when the crowder is used to support the sheet metal panel or workpiece, or portion of the sheet metal is dropped onto the crowder. The resiliency of the formable bearing allows movement of slide106a distance (identified by arrows248), limited by surface250to which crowder200is illustratively attached. Plate208may impact surface250, but the resiliency in the bearing will absorb the force, thereby preventing damage to crowder200itself.FIGS. 16Band C show alternate embodiments of crowder200. Illustratively, the tooling attached to plate208include tooling252,254.

FIGS. 20Aand B are perspective views of crowder200showing illustrative switches256,258that can be attached thereto to serve functions known by those skilled in the art. For example, switches256and258can be used to limit the length crowder200extends or retracts, or activates another device. Switches256,258may also sense the relative positioning of slide206or piston rod210, or detect a workpiece.FIG. 20Cshows various views of an illustrative embodiment of switch258, which includes a mounting portion261. The switch or sensor portion263can be located at any desired location on mounting portion261. In addition, mounting portion261can be configured to attach to a mounting bar259, as shown inFIGS. 20Aand B. It is appreciated, however, that the configurations shown are illustrative. Switches256,258can be of any other configuration suitable for any desired purpose on crowder200. It is further appreciated that such switches can be used on stopper100and lifter300.

FIG. 21is a perspective view of a lifter300. Similar to crowder200, illustrative lifter300comprises a cylinder302, bearing assembly304, slide306, and plate308. An extended version of lifter300is shown inFIG. 22. Piston rod310extends from cylinder302to move plate308. The length of the extension stroke is determined by stop326(located on slide306) engaging recess319(located on housing6of assembly304). In contrast to crowder device200, however, lifter300is configured to lift or support work pieces or panels on plate308, or a tooling attached to the same.

FIG. 23is an exploded perspective view of lifter300. In this illustrative embodiment, and similar to crowder200, lifter300comprises a cylinder302that is a pneumatic cylinder having extension and retraction ports314,316. It is, again, contemplated that cylinder302could alternatively be a hydraulic or electric actuator. Rod310is extendable and retractable from cylinder302, and is disposed through bore318of bearing assembly304. Bearing320lines opening324, of assembly304and extends at least a portion of its length. Fasteners322attach bearing assembly304to cylinder302via plate315. Slide306is disposed through opening324and is moveable along bearing320. A stop326, similar to stop126of stopper100is attached to slide306to limit movement thereof. Extending from slide306is base328that receives plate308. Plate308is configured to engage an article, or attach to a tooling that engages an article, to move the same pursuant the extension and retraction of rod310. In this illustrative embodiment, a bore330is disposed through base328. Illustratively, washers332and fasteners334are used to attach plate308and rod310to base328, similar to previous embodiments.

FIG. 24is a perspective view of an illustrative assembly line, similar to the lines shown inFIGS. 13 and 18. In this example, lifters300are shown lifting a molded sheet metal panel140from press142. In this illustrative embodiment, tooling346is attached to plate308. Illustratively, lifters300are located on lower die350, and the sheet metal panel140rests on top of tooling346during insertion and removal of the panel140. After sheet metal140has been stamped, rod310is extended, thereby lifting sheet metal140up from lower die350to be removed and lead to the next process.

FIG. 25is another illustrative embodiment of a formable bearing slide apparatus400. This embodiment comprises a piston assembly402, located in housing404. Block406is movable reciprocally with piston assembly402. Guide rods408,410are illustratively located on opposite sides of piston assembly402to provide balanced movement of block406. On each rod408,410is formable bearings414,416, and418,420, respectively. These bearings can be formed in a manner similar to that previously described with respect toFIGS. 1 and 2.

Although the present disclosure has been described with reference to particular means, materials and embodiments, from the foregoing description, one skilled in the art can easily ascertain the essential characteristics of the present disclosure and various changes and modifications may be made to adapt the various uses and characteristics without departing from the spirit and scope of the present disclosure as set forth in the following claims.