Ball and roller bearings and bearing components

Improved structures in bearings operable to receive and support shafts or members which are supported for rotation on shafts or pins. The balls and/or rollers and/or one or more of such components, such as the outer and inner races, are coated with hard, high strength synthetic diamond material deposited in situ thereon. In all forms, the synthetic diamond material coatings may be overcoated with thin layers of chromium, chromium alloys or similar materials which serve to protect the synthetic diamond material coating same.

SUMMARY OF THE INVENTION 
This invention relates to improvements in the structures of bearings 
employed to support shafts in rotation or assemblies for rotation about 
shafts and the like. While the invention is primarily directed to 
improvements in the structures of so-called ball and roller bearings, it 
is also directed to conventional cylindrically shaped bearing structures 
which do not contain a plurality of components such as balls or rollers. 
Conventional bearings, such as ball and roller bearings, bushings and the 
like, are not only subject to wear, such as frictional wear when the 
surfaces of bearing components and shafts engage during use, but also to 
failure resulting from the expansion or extension of surface 
irregularities, such as cracks and pits, created, for example, during the 
manufacture of such bearings and bearing components. Conventional 
machining, sintering, pressing, stamping, molding and other forming 
operations employed to form bearings and bearing components results in 
surface formations thereof which contain microirregularities such as 
surface cracks and the like which may be expanded during use as a result 
of frictional wear and impact forces applied to the surfaces containing 
such irregularities. 
The instant invention employs intense radiation directed at the surfaces of 
bearings and bearing components in the presence of a fluid, such as 
methane gas, containing carbon atoms which are caused by the intense 
radiation to deposit as a thin film of synthetic diamond material against 
the surface against which the radiation is directed. 
In one form of the instant invention, the carbon film fills in the tiny 
surface irregularities or cracks and forms a layer varying from a few 
millionths of an inch to a thousandth of an inch or more thick on the 
surface to which it is coated. The layer of synthetic diamond material 
serves a number of functions including protection against attrition and 
wear, protection against chemical corrosion and the effects of frictional 
heat. In a particular form of the invention, the radiation is sufficient 
to heat and reduce or melt the thin outer stratum of the surface being 
coated with the diamond film so as to reduce the size of or eliminate the 
cracks formed therein during the fabrication of the bearing. 
In a preferred modified form of the invention, after a thin layer of 
synthetic diamond film is formed on the surface of a bearing or bearing 
component, it is overcoated with a thin layer of a wear resistant dry 
lubricating material, such as hard chromium, chromium alloy or other 
suitable hard surfacing material. Such outer layer serves to protect the 
outer surface of the diamond coating on which it is disposed, from 
abrasive effects of abrasive elements provided in a lubricating material 
and the effect of surface wear during contact with adjacent shaft or 
bearing surfaces. 
Accordingly it is a primary object of this invention to provide new and 
improved structures in bearings utilized in rotational mechanical 
assemblies. 
Another object is to provide improvements in the structures of ball 
bearings. 
Another object is to provide improvements in the structures of roller 
bearings. 
Another object is to provide improvements in the structures of balls 
employed in ball bearings. 
Another object is to provide improvements in the structures of rollers 
employed in roller bearings assemblies. 
Another object is to provide improvements in the structures of races 
employed in ball or roller bearings. 
Another object is to provide improvements in the structures of cages 
employed in ball or roller bearing assemblies. 
Another object is to provide improved ball and roller bearing assemblies 
containing multiple components which contact each other, the contacting 
surfaces of which components are coated with thin hard synthetic diamond 
films. 
Another object is to provide improved ball and roller bearing assemblies 
containing multiple components which contact each other, the contacting 
surfaces of which components are coated with thin hard synthetic diamond 
films which are overcoated with lubricating protective coatings such as 
chromium, chromium alloys and the like. 
With the above and such other objects in view as may hereinafter more fully 
appear, the invention consists of the novel structures, article 
constructions and methods described in the following specification and 
illustrated in the drawings, but it is to be understood that variations 
and modifications may be resorted to which fall within the scope of the 
invention as claimed without departing from the nature and spirit of the 
invention.

DETAILED DESCRIPTION 
FIG. 1 shows details of a ball bearing, generally designated 10, formed of 
an assembly of hard load supporting balls 13 preferably formed of metal 
such as steel and supported in circular array between a cylindrically 
shaped steel outer race 11 and a steel inner race 14. A cage 15 also made 
of steel, such as stainless steel, is also supported between the two races 
to retain the balls spaced apart from each other in two circular arrays as 
shown. The balls 13, have the same diameters and may be formed of other 
suitable metal or hard ceramic and effect rolling movement when a machine 
element secured to the outer race 11 effects rotation about a shaft 
secured to the inner race 14 or vice versa. 
Coating the entire outer surfaces of the balls 13 and either the entire 
outer surfaces of the races 11 and 14 and cage 15 or just the surfaces 
thereof which make contact with the balls 13, is a hard synthetic diamond 
material 17 formed in situ on such components by the deposition of carbon 
atoms from a carbon atom containing material such as methane gas mixed 
with hydrogen when such gas mixture and the article therein are subject to 
intense radiation such as suitable microwave radiation which is beamed at 
the surface or surfaces being coated. Such synthetic diamond material 
coats the balls 13, the outer race 11 or the inner surfaces of the 
illustrated ball engaging channels 12 formed therein, the cage 15 or just 
the semi-cylindrical surfaces 16 thereof which engage the balls and the 
inner race 14 or just the outer cylindrical surface thereof. 
The depth or thickness of such synthetic diamond coating may vary from 
several millions of an inch to a thousandth of an inch or more depending 
on the size of the bearing, loading expected thereon during use, 
temperature of operation and impact forces which may be applied thereto. 
Large ball bearings may require synthetic diamond coatings in the range of 
0.001" to 0.010" or more. Overcoating such synthetic diamond layer is a 
layer of a hard solid lubricating material such as chromium of the same or 
greater thickness than the hard carbon coating which serves to protect the 
synthetic diamond coating from erosion due to rolling friction. 
The combination of the synthetic diamond coating and its overcoating of 
chromium serve to substantially enhance the wear resistance and life of 
the components coated therewith, particularly in preventing microcavities 
or cracks which normally are formed in the outer stratum of the machined 
elements, from expanding and eventually resulting in the destruction of 
the component or in rendering it inefficient in operation. 
Depending on the thicknesses of the synthetic diamond layer and chromium 
overcoating layer, either or both such coatings may serve to enhance the 
strength of the component to which they are applied and to absorb a 
substantial amount of the load and impact forces applied during operation 
of the bearing. While the primary function of the synthetic diamond 
coating is to protect the component from experiencing failure of the 
surface stratum of the base material thereof by distributing impact and 
load forces applied thereto and preventing the formation and/or extension 
of surface defects such as small cracks and occlusions, it also serves to 
resist deformation in shape of the balls, the inner and outer races and, 
if applied, the cage. Frictional wear of the semi-cylindrical surfaces of 
the side walls of the cage ball retaining portions will also be greatly 
reduced, particularly if the synthetic diamond coating is overcoated with 
chromium. 
FIG. 2 shows a roller bearing generally designated 20, formed of an 
assembly of an outer race 21, and an inner race 24 having a plurality of 
semi-cylindrical cavities 25 formed therein with the outer race containing 
a channel 22 configured to accommodate a plurality of cylindrical bearing 
rollers 23 slidably or rollably supported within the cavities 25. A 
cylindrical bearing sleeve 26 is secured within the inside bore 24A of the 
inner race 24. 
The rollers 23 are coated with a synthetic diamond material layer 
completely surrounding each roller 23 and formed in situ thereon by the 
deposition and consolidation of carbon atoms stripped from molecules of 
carbon atom containing gas, such as methane subjected to a beam or beams 
of high intensity microwave radiation or the like. Such thin coating of 
synthetic diamond material is also applied to the semi-cylindrical 
surfaces of the recesses 25 in the inner race 24 and the wall surfaces of 
channel 22 formed in the outer race 21. Notation 
In addition to the synthetic diamond material coating the outer surfaces of 
the rollers 23 and channel 22 in the outer race, the synthetic diamond 
material coats the semi-cylindrical surfaces of recesses 25 in the outer 
surface of inner race 24. Such synthetic diamond material may also extend 
completely around all of the surfaces of the outer race 21 and the 
cylindrical outer surface 24B of the inner race 24 as well as the side 
walls of such races and the outer and inner walls of the outer and inner 
races. 
Such synthetic diamond material may coat the inside surface of sleeve 26. 
However, if a friction fit is required between such inner surface and a 
shaft supporting the assembly 20, such synthetic diamond material may be 
eliminated from sleeve 26. 
A thin layer of chromium extends across all or selected portions of the 
synthetic diamond surfaces to protect same against rolling or sliding 
frictional wear, scouring, chemical corrosion and erosion. 
In the bearing structures 10 and 20 illustrated in FIGS. 1 and 2, select 
portions of the various bearing components may be coated with synthetic 
diamond and chromium layers, rather than the whole outer surfaces thereof. 
For example, just the balls 13 and the rollers 23 may be so coated and 
overcoated; the outer surface 14A of the inner race 14 against which the 
balls 13 roll and/or the inner surfaces of channels 12 formed in the outer 
race 11. Similar composite coatings may be applied to the outer surfaces 
of the rollers 23, the walls of the semi-cylindrical cavities 25 in inner 
race 24, the outer surface 24B of inner race 24 or any other surfaces 
subjected to rolling or sliding wear, chemical attack, surface erosion or 
failure caused the extension of cavities or microcracks formed during 
machining same to shape. 
The inner race 14 or sleeve 26 may also serve as a bearing per se, made of 
suitable metal or high strength ceramic material and having the inside 
surface thereof coated with synthetic diamond material as described for 
retaining and supporting or being supported by a cylindrical shaft forming 
part of a machine assembly such as a power driven or drivable member of 
assembly. As set forth above, such synthetic diamond coating may cover 
just the cylindrical inside surface of such bearing or the entire bearing 
and the portion of such synthetic diamond coating which is aligned with 
such shaft may be coated with one of the metals described above, such as 
chromium, to lubricate and protect the surface of the diamond material 
coating such shaft. While the shaft may be the shaft of a motor or motor 
driven assembly, such bearing may support or be supported by another 
machine element, pillow blocks or assembly for supporting the shaft as it 
rotates on such shaft. 
FIG. 3 shows structural details of the synthetic diamond coatings, the 
protective overcoatings and the substrates coated. The substrate 52, which 
may be any of the configurations hereinabove described, is made of 
suitable metal, metal alloy, cermet or ceramic material or combinations 
thereof fabricated by casting, molding, extrusion, machining, forging or 
one or more of such processes. The synthetic diamond coating 51 may be 
deposited as carbon atoms stripped from molecules of such gas as methane 
or other hydrocarbon, vaporous hydrocarbon or carbon atom containing 
material, combinations of gas and vapor carbon atom containing materials, 
preferably with suitable hydrogen gas mixed therewith to provide suitably 
efficient deposition and synthetic diamond layer formation to the desired 
thickness which may vary in the range of 0.000001" to 0.010" and, for most 
applications in the range of a few millions of an inch to a few 
thousandths of an inch. The overcoating 50 of chromium is shown completely 
covering the synthetic diamond coating 51 and may be applied by 
electroless or electrical deposition, vapor deposition, detonation or 
plasma plating. Thickness of depths of such overcoating may range from 
0.00001 to several thousands of an inch or more and preferably in the 
range of a few thousands of an inch or less. 
The coatings of synthetic hard diamond or diamond-like material may be 
applied to the entire articles or select portions of such articles 
subjected to frictional wear, weathering, temperature or chemical 
corrosive effects, and destruction caused by the expansion of surface 
defects such as surface cracks formed during fabrication. The coating may 
be formed of carbon atoms deposited thereon from gas, vapor or liquid 
molecules containing such carbon atoms, as a result of passing high 
intensity radiation, such as microwave radiation or the like, through such 
carbon atom containing fluids, by means shown and described in my parent 
application Ser. No. 032,307, now U.S. Pat. No. 4,859,493. The coatings 
may vary in thicknesses from a few millionths of an inch to a thousandth 
of an inch or more depending on the expected use of the articles or 
assemblies including the corrosive and erosive atmosphere to which they 
are subjected. Thicker films in the range of 0.0001" to 0.001" or more may 
be provided to substantially enhance the tensile and compressive strengths 
of the articles or components. A where the article or component is 
subjected to movement and abrasion or frictional wear during use, which 
wear or abrasion may have a detrimental effect on the diamond film or 
coating, a thin coating of a solid lubricant protective material, such as 
chromium, chromium alloys or the like, may be applied over the diamond 
coating after it is formed in situ on the substrate or select portion of 
the outer surface thereof. Such chromium may also be deposited as chromium 
atoms present in the gas, vapor or liquid disposed adjacent the surface of 
the article, while carbon atoms are deposited or sequentially after the 
deposition of carbon atoms to provide either a composite layer of carbon 
and chromium atoms or one or more layers of carbon atoms interposed 
between one or more layers of chromium atoms or coatings thereof. 
Certain modifications to the structures and methods for making same may be 
found in my parent application Ser. No. 032,307, now U.S. Pat. No. 
4,859,493 and in pending patent application Ser. No. 032,352 filed Mar. 
31, 1987, reference being made directly thereto as part of the instant 
disclosure. Further modifications are noted as follows: 
1. Scanning a select portion or portions of the surface or surfaces of the 
articles described and illustrated in the drawings with one or more 
radiation beams of laser and/or electron radiation may be effected to 
provide such coating or coatings on a select area or areas of the outer 
suface or surfaces of the articles to the exclusion of another area or 
areas thereof for functional and/or economic purposes. Such an electon 
beam or laser beam may be employed in combination with microwave radiation 
and passed through a carbon atom containing gas, such as methane, 
surrounding all or part of the article or assembly to be coated, and 
employed to effect or increase the rate of deposition of carbon atoms to 
form the synthetic diamond coating and/or to heat the substrate to bond 
the deposited material(s) to the substrate. 
2. Such functions as the operation of the radiation beam generating means, 
the intensity and frequency thereof, if varied, the direction and focus 
thereof, the flow and replenishment of carbon atom containing gas and 
hydrogen gas to the reaction chamber and, if employed, flow thereof as one 
or more streams within such chamber to the vicinity of the surface(s) 
being coated, the movement and/or prepositioning of the article or 
material being coated to, within and from the reaction chamber and the 
flow of any additional material, to be combined with the carbon atoms in 
the coating, to the reaction chamber and surface of the article(s) being 
coated, may all be automatically controlled by a computer with or without 
the generation of feedback signals generated by one or more sensors of 
such variables as deposited coating thickness, rate of deposition, 
temperature, beam position, article position, etc. 
3. Synthetic diamond coatings as described may be overcoated with 
protective coatings of chromium, alloys containing chromium, metal alloys 
containing such metal atoms as vanadium, tungsten, titanium, molybdenum 
and/or such metals per se, which serve to protect and/or lubricate the 
surface of the synthetic diamond coatings to resist frictional wear and 
abrasion during operation and use of the coated article. In certain 
applications, the synthetic diamond coating will serve to electrically 
insulate the article. In others, it will protect the surface coated 
therewith from heat and/or chemical corrosion. In others, the surface(s) 
coatings will impart greater resistance to wear and abrasion. Surface 
attrition due to impact forces and loading during use may also be lessened 
or eliminated by such hard synthetic diamond coatings(s) which may be 
applied as a single or plurality of layers per se or combined or 
overcoated with one or more layers of the described metals and/or metal 
alloys to lubicate and protect the surface of the synthetic diamond 
coating. 
4. Coatings formed of a plurality of layers of synthetic diamond material 
formed as described between respective layers of the same or different 
metals, metal alloys and/or ceramic materials may be employed to enhance 
the physical, chemical resistance and electrical characteristics of the 
articles described. Such multiple coatings may also be employed to 
substantially enhance the strength and stiffness of the articles. 
5. Certain of the articles of manufacture described above may be fabricated 
by compressing particles of metal, various ceramic materials or mixtures 
of either or both materials with fine particles of synthetic diamond 
produced, for example, as set forth in my U.S. Pat. No. 4,859,493 and 
employed to strengthen the composite. Short filaments of synthetic diamond 
or composites thereof sa set forth in such patent may also be mixed with 
such particulate material(s) to form articles of the type(s) described 
herein having superior substrate strength and corrosion resistence. 
Compression of such mixture(s) between dies with or without the addition 
of a resin binder while simultaneous and/or sequentially heating same to 
effect sintering or otherwise consolidating the metal particles into a 
defined shape may be effected prior to the described coating with 
synthetic diamond material. 
6. The described articles may also be formed by compressing particulate 
material with resinous binder particles, then sintering at a temperature 
to burn away the resin leaving a porous substrate of desired shape. By 
placing such porous substrate in a chamber containing a mixture of 
hydrocarbon gas and hydrogen under pressure, molecules of the gas mixture 
will flow into the pores or intersticies of such substrate, particularly 
if the chamber and substrate therein are first subjected to suitable 
vacuum. Thereafter, by generating and directing suitable microwave energy 
through the gas and substrate, carbon atoms will be stripped from the gas 
molecules containing same and will form as synthetic diamond or 
diamond-like material on the surfaces of the walls of the internal 
interstices, thus providing a new high strength structure of select 
external shape which is internally reinforced with synthetic diamond 
material and is externally coated with such material providing a hard 
outer shell which is highly resistant to erosion, surface attrition, wear 
and chemical corrosion. 
7. The term synthetic diamond material employed herein refers to high 
strength coatings, filaments or particles of carbon exhibiting the 
chemical and physical characterics (e.g. strength) of diamond. For certain 
of the articles and applications described above, the carbon atoms 
stripped from the molecules of hydrocarbon gas, such as methane, by 
microwave energy may form hard high strength coatings which do not quite 
exhibit the hardness of diamond but will suffice for many applications.