# US 2016/0258486 A1 · Highstrength low friction engineered material for bearings and other applications

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 2016/0258486 A1
- Document ID: US20160258486A1
- Status: Published application
- Kind: A1
- Application number: 15/153,541
- Filed: 2016-05-12
- Published: 2016-09-08
- Earliest claimed: 2012-11-20
- Assignees: Federal-Mogul Corporation
- Applicants: Federal-Mogul Corporation
- Inventors: David Saxton
- Web page: https://patentgrep.com/patent/US20160258486A1

## CPC

- F16C 33/145: {of sintered porous bearings}
- C25D 3/30: of tin
- C25D 3/38: of copper
- C25D 5/10: Electroplating with more than one layer of the same or of different metals (for bearings C25D7/10)
- C25D 7/00: Electroplating characterised by the article coated
- F16C 33/04: Brasses; Bushes; Linings
- F16C 33/1095: {with solids as lubricant, e.g. dry coatings, powder}
- F16C 33/121: {Use of special materials}
- F16C 33/128: {Porous bearings, e.g. bushes of sintered alloy}
- F16C 33/24: with different areas of the sliding surface consisting of different materials
- F16C 33/28: with embedded reinforcements shaped as frames or meshed materials
- B29C 64/135: the energy source being concentrated, e.g. scanning lasers or focused light sources
- B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12}
- B32B 2307/746: Slipping, anti-blocking, low friction
- B33Y 10/00: Processes of additive manufacturing
- B33Y 80/00: Products made by additive manufacturing
- C23C 18/32: Coating with nickel, cobalt or mixtures thereof with phosphorus or boron (C23C18/50 takes precedence)
- F16C 2204/52: Alloys based on nickel, e.g. Inconel
- F16C 2240/40: Linear dimensions, e.g. length, radius, thickness, gap
- Y10T 156/10: Methods of surface bonding and/or assembly therefor
- Y10T 428/24322: Composite web or sheet
- Y10T 428/24331: including nonapertured component
- Y10T 428/24339: Keyed
- Y10T 428/2462: with partial filling of valleys on outer surface
- Y10T 428/24942: including components having same physical characteristic in differing degree
- F16C: SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- C25D: PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A high strength, low friction engineered material includes a low friction material filling interstices of a metal microlattice. The metal typically comprises 5 volume % to 25 volume % and the interstices typically comprise 75 volume % to 95 volume %, based on the total volume of the metal microlattice and the interstices. The low friction material preferably fills 100 volume % of the interstices. The metal microlattice can be formed of a single layer, or multiple layers, for example layers of nickel, copper, and tin. The low friction material is typically a polymer, such as polytetrafluoroethylene (PTFE), polyamide (PAI), polyetheretherketone (PEEK), polyethylene (PE), or polyoxymethylene (POM). The low friction material can also include additive particles to modify the material properties. The engineered material can be used in various automotive applications, for example as a bearing, or non-automotive applications.

## Claims

### Claim 1

A method of forming an engineered material, comprising the steps of:
forming a microlattice of metal, the metal microlattice presenting a plurality of interstices; and
disposing a low friction material in the interstices of the metal microlattice, the low friction material having a coefficient of friction less than the coefficient of friction of the metal microlattice.

### Claim 2 (depends on 1)

The method of claim 1, wherein the step of disposing the low friction material in the interstices of the metal microlattice includes at least one of rolling and infiltrating the low friction material in the interstices.

### Claim 3 (depends on 1)

The method of claim 1, wherein the step of forming the metal microlattice includes applying the metal to a template polymer microlattice.

### Claim 4 (depends on 3)

The method of claim 3, wherein the step of applying the metal includes applying a plurality of layers formed of different metals; and heating the layers to alloy the different metals together.

### Claim 5 (depends on 3)

The method claim 3 including preparing the template polymer microlattice by conveying light along predetermined paths into a reservoir of UV curable resin in liquid form, and transforming the UV curable resin along the predetermined light paths into a plurality of interconnected solid polymer fibers.

### Claim 6 (depends on 1)

The method of claim 1, wherein the step of disposing a low friction material in the interstices of the metal microlattice includes filling the interstices of the metal microlattice.

### Claim 7 (depends on 1)

The method of claim 1, wherein the metal microlattice is formed of nickel; the metal microlattice comprises a plurality of struts interconnected to one another and presenting the interstices; and each of the struts includes a hollow opening.

### Claim 8 (depends on 7)

The method of claim 7, wherein the metal microlattice is present in an amount of approximately 15 volume % and the interstices are present in an amount of approximately 85 volume %, based on the total volume of the metal microlattice and the interstices; and each of the struts is disposed at an angle of 50° to 90° relative to horizontal, has a diameter of about 50 micrometers, and a wall thickness of about 15 micrometers surrounding the hollow opening.

### Claim 9 (depends on 1)

The method of claim 1, wherein the low friction material includes at least one of polytetrafluoroethylene (PTFE), polyamide (PAI), polyetheretherketone (PEEK), polyethylene (PE), polyoxymethylene (POM), tin, and bismuth.

### Claim 10 (depends on 9)

The method of claim 9, wherein the low friction material includes particles selected from the group consisting of ceramic, graphite molybdenum disulfide, copper, and silver.

### Claim 11 (depends on 1)

The method of claim 1, wherein the step of forming the metal microlattice includes:
preparing a template polymer microlattice having a predetermined structure;
the step of preparing the template polymer microlattice including disposing a perforated mask over a reservoir of ultra-violet (UV) curable resin in liquid form, and passing multiple beams of light through the perforated mask and into the reservoir along predetermined paths, and transforming the liquid UV curable resin along the predetermined light paths into a plurality of interconnected solid polymer fibers to form the template polymer microlattice;
the solid polymer fibers of the template polymer microlattice each extending at an angle of 50° to 90° relative to horizontal;
the step of preparing the template polymer microlattice being a continuous process and occurring at a rate greater than 1 mm2 per minute;
coating the template polymer microlattice with the metal to form the metal microlattice;
the step of coating the template polymer microlattice including plating or electrodepositing the metal onto the template polymer microlattice, and applying a greater amount of the metal to one area of the template polymer microlattice relative to other areas of the template polymer microlattice;
the step of coating the template polymer microlattice including forming a plurality of struts each surrounding one of the solid polymer fibers, the struts being interconnected to one another and presenting the plurality of interstices therebetween to form the metal microlattice;
the struts of the metal microlattice each having a diameter of about 50 micrometers, a wall thickness of about 15 micrometers, and extending at an angle of 50° to 90° relative to horizontal;
the metal microlattice being present in an amount of approximately 15 volume percent and the interstices being present in an amount of approximately 85 volume percent, based on the total volume of the metal microlattice and the interstices; and
removing the template polymer microlattice from the metal microlattice by heating the template polymer microlattice;
the step of disposing the low friction material in the interstices of the metal microlattice including:
at least one of rolling and infiltrating the low friction material into the interstices;
the low friction material including at least one of polytetrafluoroethylene (PTFE), polyamide (PAI), polyetheretherketone (PEEK), polyethylene (PE), and polyoxymethylene (POM);
the low friction material including particles selected from the group consisting of ceramic, graphite molybdenum disulfide, copper, and silver;
the step of disposing the low friction material in the interstices of the metal microlattice including filling the interstices; and
further comprising the step of sintering the low friction material disposed in the interstices of the metal microlattice.

### Claim 12

A method of forming a bearing, comprising the steps of:
forming an engineered material by providing a microlattice of metal, the metal microlattice presenting a plurality of interstices; and
disposing a low friction material in the interstices of the microlattice, the low friction material having a coefficient of friction less than the coefficient of friction of the metal microlattice.

### Claim 13 (depends on 12)

The method of claim 12 including attaching a backing to the engineered material.

### Claim 14 (depends on 12)

The method of claim 12, wherein the step of disposing the low friction material in the interstices of the metal microlattice includes at least one of rolling and infiltrating the low friction material in the interstices.

### Claim 15 (depends on 12)

The method claim 12 including preparing a template polymer microlattice by conveying light along predetermined paths into a reservoir of UV curable resin in liquid form, and transforming the UV curable resin along the predetermined light paths into a plurality of interconnected solid polymer fibers; and wherein the step of forming the metal microlattice includes applying the metal to a template polymer microlattice.

### Claim 16 (depends on 15)

The method of claim 15, wherein the step of applying the metal includes applying a plurality of layers formed of different metals; and heating the layers to alloy the different metals together.

### Claim 17 (depends on 12)

The method of claim 12, wherein the step of disposing a low friction material in the interstices of the metal microlattice includes filling the interstices of the metal microlattice.

### Claim 18 (depends on 12)

The method of claim 12, wherein the metal microlattice is formed of nickel; the metal microlattice comprises a plurality of struts interconnected to one another and presenting the interstices; and each of the struts includes a hollow opening.

### Claim 19 (depends on 12)

The method of claim 12, wherein the low friction material includes at least one of polytetrafluoroethylene (PTFE), polyamide (PAI), polyetheretherketone (PEEK), polyethylene (PE), polyoxymethylene (POM), tin, and bismuth; and the low friction material includes particles selected from the group consisting of ceramic, graphite molybdenum disulfide, copper, and silver.

### Claim 20 (depends on 12)

The method of claim 12, wherein the step of forming the metal microlattice includes:
preparing a template polymer microlattice having a predetermined structure;
the step of preparing the template polymer microlattice including disposing a perforated mask over a reservoir of ultra-violet (UV) curable resin in liquid form, and passing multiple beams of light through the perforated mask and into the reservoir along predetermined paths, and transforming the liquid UV curable resin along the predetermined light paths into a plurality of interconnected solid polymer fibers to form the template polymer microlattice;
the solid polymer fibers of the template polymer microlattice each extending at an angle of 50° to 90° relative to horizontal;
the step of preparing the template polymer microlattice being a continuous process and occurring at a rate greater than 1 mm2 per minute;
coating the template polymer microlattice with the metal to form the metal microlattice;
the step of coating the template polymer microlattice including plating or electrodepositing the metal onto the template polymer microlattice, and applying a greater amount of the metal to one area of the template polymer microlattice relative to other areas of the template polymer microlattice;
the step of coating the template polymer microlattice including forming a plurality of struts each surrounding one of the solid polymer fibers, the struts being interconnected to one another and presenting the plurality of interstices therebetween to form the metal microlattice;
the struts of the metal microlattice each having a diameter of about 50 micrometers, a wall thickness of about 15 micrometers, and extending at an angle of 50° to 90° relative to horizontal;
the metal microlattice being present in an amount of approximately 15 volume percent and the interstices being present in an amount of approximately 85 volume percent, based on the total volume of the metal microlattice and the interstices; and
removing the template polymer microlattice from the metal microlattice by heating the template polymer microlattice;
the step of disposing the low friction material in the interstices of the metal microlattice including:
at least one of rolling and infiltrating the low friction material into the interstices;
the low friction material including at least one of polytetrafluoroethylene (PTFE), polyamide (PAI), polyetheretherketone (PEEK), polyethylene (PE), and polyoxymethylene (POM);
the low friction material including particles selected from the group consisting of ceramic, graphite molybdenum disulfide, copper, and silver;
the step of disposing the low friction material in the interstices of the metal microlattice including filling the interstices; and
further comprising the step of sintering the low friction material disposed in the interstices of the metal microlattice.