Expansion reduction of metal component assemblies using composites

Patent metadata

Field	Value
Publication number	US-9284981-B2
Application number	US-201414278050-A
Country	US
Kind code	B2
Filing date	May 15, 2014
Priority date	May 15, 2014
Publication date	Mar 15, 2016
Grant date	Mar 15, 2016

Abstract

Methods for minimizing thermal expansion in an assembly, e.g., a bearing assembly, for a vehicle are provided. The assembly has at least two components with substantially different linear coefficients of thermal expansion (CLTEs). The assembly has a polymeric composite with a first CLTE, a lightweight metal component (e.g., a housing) with a second CLTE, and a third component (e.g., a bearing component) having a third CLTE. The second CLTE is ≧25% more than the third CLTE. The first CLTE is less than or equal to the third CLTE, so that the polymeric composite structure coupled to the first surface reduces radial thermal expansion of the first metal component and minimizes separation of the second surface of the first metal component from the second component.

First claim

What is claimed is:

1. A method of minimizing thermal expansion in a component assembly for a vehicle having at least two components with substantially different linear coefficients of thermal expansion, the method comprising:
coupling a polymeric composite structure having a first coefficient of linear thermal expansion (CLTE) and a modulus of greater than or equal to about 40 GPa to a first surface of a first metal component having a second CLTE, where the first metal component further defines a second surface opposite to the first surface disposed in proximity with a second component having a third CLTE, wherein the second CLTE is greater than or equal to about 25% more than the third CLTE, while the first CLTE is less than or equal to the third CLTE, so that the polymeric composite structure coupled to the first surface reduces radial thermal expansion of the first metal component and minimizes separation of the second surface of the first metal component from the second component, wherein the coupling comprises attaching the polymeric composite structure to the first metal component via one or more mechanical interlock features.

2. The method of claim 1 , wherein the first CLTE is less than or equal to about 10×10 −6 /° C., the second CLTE is greater than or equal to about 20×10 −6 /° C., and the third CLTE is less than or equal to about 20×10 −6 /° C.

3. The method of claim 1 , further comprising forming the one or more mechanical interlock features in the first surface of the first metal component by machining.

4. The method of claim 1 , wherein the coupling comprises applying a pre-preg composite material to the first surface of the first metal component, followed by curing the pre-preg composite material to form the polymeric composite structure.

5. The method of claim 1 , wherein the first surface of the first metal component is circumferential and the polymeric composite structure is a band or ring structure disposed around the first surface.

6. The method of claim 1 , wherein the polymeric composite structure is disposed along discrete discontinuous regions of the first surface.

7. The method of claim 1 , wherein the first metal component comprises a metal selected from the group consisting of: aluminum, magnesium, and alloys thereof, the second component comprises a material selected from the group consisting of: steel, and ceramic, and the polymeric composite structure comprises a thermoplastic resin and a plurality of reinforcing materials selected from the group consisting of: carbon fibers, glass fibers, and combinations thereof.

8. The method of claim 1 , wherein the first metal component is a bearing assembly housing and the second component is a portion of a preloaded bearing component.

9. A method of minimizing thermal expansion in a preloaded bearing assembly for a vehicle having at least two components with substantially different linear coefficients of thermal expansion, the method comprising:
coupling a polymeric composite structure having a first coefficient of linear thermal expansion (CLTE) and a modulus of greater than or equal to about 40 GPa to a first surface of a housing formed of a lightweight metal having a second CLTE, where the housing further defines a second surface opposite to the first surface disposed in proximity with a bearing component having a third CLTE, wherein the second CLTE is greater than or equal to about 25% more than the third CLTE, while the first CLTE is less than or equal to the third CLTE, so that the polymeric composite structure coupled to the first surface reduces radial thermal expansion of the housing and minimizes separation of the second surface of the housing from the bearing component, wherein the coupling comprises attaching the polymeric composite structure to the first metal component via one or more mechanical interlock features.

10. The method of claim 9 , wherein the first CLTE is less than or equal to about 10×10 −6 /° C., the second CLTE is greater than or equal to about 20×10 −6 /° C., and the third CLTE is less than or equal to about 20×10 −6 /° C.

11. The method of claim 9 , wherein the housing comprises a metal selected from the group consisting of: aluminum, magnesium, and alloys thereof, the bearing component comprises a material selected from the group consisting of: steel, and ceramic, and the polymeric composite structure comprises a thermoplastic resin and a plurality of reinforcing materials selected from the group consisting of: carbon fibers, glass fibers, and combinations thereof.

12. The method of claim 9 , wherein the bearing component is part of a tapered roller bearing assembly.

13. The method of claim 9 , wherein the bearing component is an angular contact ball bearing.

Assignees

• Gm Global Tech Operations Inc

Inventors

• Kia Hamid G
• Treib William E

Classifications

• Y10T29/49645

  Thrust bearing · CPC title

• Y10T29/49638

  Repairing · CPC title

• B32B2262/101

  Glass fibres · CPC title

• B32B27/06

  as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)} · CPC title

• B32B15/20

  comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)} · CPC title