# US 11,441,609 B2 · Bearing material, bearing element and method

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- Number: US 11,441,609 B2
- Document ID: US11441609B2
- Status: Granted
- Kind: B2
- Application number: 16/212,666
- Filed: 2018-12-06
- Published: 2019-06-13
- Granted: 2022-09-13
- Earliest claimed: 2017-12-07
- Assignees: Mahle International GmbH; Mahle Engine Systems UK Ltd
- Applicants: Mahle International GmbH; Mahle Engine Systems UK Limited
- Inventors: Kayleigh McEwan; Jennifer Harvey
- Web page: https://patentgrep.com/patent/US11441609B2

## CPC

- F16C 33/201: {Composition of the plastic}
- C08K 3/08: Metals
- C08K 5/34924: {containing cyanurate groups; Tautomers thereof}
- C08L 79/08: Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
- C09D 7/63: organic
- C09D 7/69: {Particle size larger than 1000 nm}
- C09D 179/08: Polyimides; Polyester-imides; Polyamide-imides; Polyamide acids or similar polyimide precursors
- F16C 17/022: {with a pair of essentially semicircular bearing sleeves}
- F16C 33/203: {Multilayer structures, e.g. sleeves comprising a plastic lining}
- F16C 33/208: {Methods of manufacture, e.g. shaping, applying coatings}
- C08K 5/34928: {Salts}
- C08K 2003/0812: {Aluminium}
- C08K 2201/005: Additives being defined by their particle size in general
- C08L 2201/02: Flame or fire retardant/resistant
- C08L 2201/50: Aqueous dispersion, e.g. containing polymers with a glass transition temperature (Tg) above 20°C
- F16C 2202/50: Lubricating properties
- F16C 2208/02: comprising fillers, fibres
- F16C 2208/42: Polyamideimide [PAI] (F16C2208/58 takes precedence)
- F16C 2223/30: Coating surfaces
- F16C 2240/48: Particle sizes
- F16C 2360/22: Internal combustion engines
- F16C: SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- C08K: Use of inorganic or non-macromolecular organic substances as compounding ingredients (paints, inks, varnishes, dyes, polishes, adhesives C09)
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)

## Abstract

A bearing material may include a polymeric matrix of polyamide-imide (PAI) polymer material and a plurality of melamine cyanurate particles dispersed within the polymeric matrix.

## Claims

### Claim 1

A bearing material, comprising:
a polymeric matrix of polyamide-imide (PAI) polymer material;
a plurality of metal flakes composed of aluminum; and
a solid lubricant consisting of melamine cyanurate, the melamine cyanurate comprising a plurality of melamine cyanurate particles dispersed within and distributed evenly throughout the polymeric matrix;
wherein the plurality of melamine cyanurate particles have an average particle size of 0.5 μm to 3 μm; and
wherein about 8 wt % to about 12 wt % of the bearing material is melamine cyanurate.

### Claim 2 (depends on 1)

The bearing material according to claim 1, further comprising at least one of a dispersant, an adhesion agent, and a leveller.

### Claim 3

A bearing element, comprising:
a bearing material including a polymeric matrix of polyamide-imide (PAI) polymer material;
a plurality of melamine cyanurate particles dispersed within and distributed evenly throughout the polymeric matrix such that the bearing material has a uniform composition;
wherein the plurality of melamine cyanurate particles have an average particle size of 0.5 μm to 3 μm;
wherein the plurality of melamine cyanurate particles have a bulk density of 0.24 g/ml, a D10 of 0.5 μm, a D50 of 1.3 μm, and a D90 of 4.7 μm; and
wherein about 8 wt % to about 12 wt % of the bearing material is melamine cyanurate.

### Claim 4

A method of forming a bearing material, comprising mixing a polyamide-imide (PAI) polymer material with a plurality of particles of melamine cyanurate to define a dispersion, wherein:
mixing the polyamide-imide (PAI) polymer material with the plurality of particles of melamine cyanurate includes evenly distributing the plurality of particles of melamine cyanurate throughout the dispersion; and
the plurality of melamine cyanurate particles have a bulk density of 0.24 g/ml, a D10 of 0.5 μm, a D50 of 1.3 μm, and a D90 of 4.7 μm.

### Claim 5 (depends on 4)

The method according to claim 4, wherein mixing the polyamide-imide (PAI) polymer material with the plurality of particles of melamine cyanurate includes adding a quantity of the plurality of particles of melamine cyanurate to the polyamide-imide (PAI) polymer material such that the plurality of particles of melamine cyanurate form about 2 wt % to about 30 wt % of the dispersion.

### Claim 6

A method of forming a bearing element, comprising:
depositing onto a bearing element substrate a bearing material including a polymeric matrix of polyamide-imide (PAI) polymer material and a plurality of melamine cyanurate particles dispersed within and distributed evenly throughout the polymeric matrix such that the bearing material has a uniform composition; and
mixing a plurality of aluminum flakes, a leveller, and an adhesion agent with the polyamide-imide (PAI) polymer material and the plurality of particles of melamine cyanurate such that:
the plurality of particles of melamine cyanurate form about 8 wt % to about 12 wt % of the bearing material;
the plurality of melamine cyanurate particles have a D10 of 0.5 μm, a D50 of 1.3 μm, and a D90 of 4.7 μm;
the plurality of aluminum flakes form about 26 wt % of the bearing material; and
the leveller forms less than 0.5 wt % of the bearing material.

### Claim 7 (depends on 3)

The bearing element according to claim 3, further comprising a bearing element substrate and an overlay layer disposed on the bearing element substrate, wherein the overlay layer is composed of the bearing material.

### Claim 8 (depends on 7)

The bearing element according to claim 7, wherein the plurality of melamine cyanurate particles have an average particle size smaller than a thickness of the overlay layer.

### Claim 9 (depends on 7)

The bearing element according to claim 7, wherein the overlay layer has a thickness of 3 μm to 25 μm.

### Claim 10 (depends on 3)

The bearing element according to claim 3, further comprising a bearing element substrate and a plurality of overlay layers disposed on the bearing element substrate one on top of another, wherein each of the plurality of overlay layers is composed of the bearing material.

### Claim 11 (depends on 1)

The bearing material according to claim 1, wherein the plurality of melamine cyanurate particles is the only solid lubricant material dispersed within the polymeric matrix.

### Claim 12 (depends on 1)

The bearing material according to claim 1, wherein the plurality of melamine cyanurate particles have a bulk density of 0.24 g/ml, a D10 of 0.5 μm, a D50 of 1.3 μm, and a D90 of 4.7 μm.

### Claim 13 (depends on 6)

The method according to claim 6, further comprising:
mixing the polyamide-imide (PAI) polymer material with the plurality of particles of melamine cyanurate to define the bearing material; and
maintaining suspension of the plurality of particles of melamine cyanurate within the polyamide-imide (PAI) polymer material prior to depositing the bearing material onto the bearing element via agitating the bearing material.

### Claim 14 (depends on 6)

The method according to claim 6, wherein:
depositing the bearing material onto the bearing element substrate includes depositing a plurality of sub-layers of the bearing material on top of one another; and
the method further comprises removing solvent from each of the plurality of sub-layers via performing a flash-off process between each successive deposition of a sub-layer of the plurality of sub-layers.

### Claim 15 (depends on 1)

The bearing material according to claim 1, further comprising a leveller distributed throughout the polymeric matrix, wherein:
the plurality of aluminum metal flakes form about 26 wt % of the bearing material; and
the leveller forms less than 0.5 wt % of the bearing material.

### Claim 16 (depends on 15)

The bearing material according to claim 15, wherein the plurality of melamine cyanurate particles have a D10 of 0.5 μm, a D50 of 1.3 μm, and a D90 of 4.7 μm.

### Claim 17 (depends on 1)

The bearing material according to claim 1, wherein the plurality of melamine cyanurate particles have a bulk density of 0.24 g/ml and the average particle size of the plurality of melamine cyanurate particles is 1 μm to 2 μm.

### Claim 18 (depends on 1)

The bearing material according to claim 1, wherein the bearing material does not contain graphite, MoS2, nor polytetrafluoroethylene (PTFE).

### Claim 19 (depends on 3)

The bearing element according to claim 3, wherein the bearing element is structured as a crankshaft bearing shell for an internal combustion engine.