Springs and methods of forming same

Abstract

A seal includes a polymeric jacket defining a seal surface and an inner cavity extending within the polymeric jacket along a length of the polymeric jacket. The seal further includes a spring extending within the inner cavity and including a plurality of laser cut spring elements. The seal can be disposed between a static component and a rotatable component.

1 . A seal comprising:
 a polymeric jacket defining a seal surface and an inner cavity extending within the polymeric jacket along a length of the polymeric jacket; and   a spring extending within the inner cavity and including a plurality of laser cut spring elements.   
     
     
         2 . The seal of  claim 1 , wherein an edge of the spring is free of a fracture surface. 
     
     
         3 . The seal of  claim 1 , wherein an edge of the spring is free of a separation. 
     
     
         4 . The seal of  claim 1 , wherein the polymer jacket includes a polymeric material selected from the group consisting of polyketone, polyaramid, a thermoplastic polyimide, a polyetherimide, a polyphenylene sulfide, a polyethersulfone, a polysulfone, a polyphenylene sulfone, a polyamideimide, ultra high molecular weight polyethylene, a thermoplastic fluoropolymer, a polyamide, a polybenzimidazole, a liquid crystal polymer, or any combination thereof. 
     
     
         5 . The seal of  claim 1 , wherein the polymer jacket further comprises a filler selected from the group consisting of a solid lubricant, a ceramic or mineral filler, a polymer filler, a fiber filler, a metal particulate filler, salts, or any combination thereof. 
     
     
         6 . The seal of  claim 1 , wherein the polymer jacket has a coefficient of friction of not greater than about 0.4. 
     
     
         7 . (canceled) 
     
     
         8 . The seal of  claim 1 , wherein the polymer has a Young's modulus of at least about 0.5 GPa. 
     
     
         9 . (canceled) 
     
     
         10 . The seal of  claim 1 , wherein the polymer jacket has an elongation of at least about 20%. 
     
     
         11 . (canceled) 
     
     
         12 . The seal of  claim 1 , wherein the spring is formed of a metal alloy selected from the group consisting of stainless steel, a copper alloy, a nickel alloy, or any combination thereof. 
     
     
         13 . The seal of  claim 1 , wherein the spring is formed of a sheet material having a thickness not greater than 10 mils. 
     
     
         14 - 17 . (canceled) 
     
     
         18 . A seal comprising:
 an annular jacket comprising a polymeric material and defining an annular cavity extending within the annular jacket; and   a spring extending within the annular cavity, the spring comprising a folded sheet metal including a plurality of laser cut spring elements.   
     
     
         19 . (canceled) 
     
     
         20 . (canceled) 
     
     
         21 . The seal of  claim 18 , wherein the polymeric material is selected from the group consisting of polyketone, polyaramid, a thermoplastic polyimide, a polyetherimide, a polyphenylene sulfide, a polyethersulfone, a polysulfone, a polyphenylene sulfone, a polyamideimide, ultra high molecular weight polyethylene, a thermoplastic fluoropolymer, a polyamide, a polybenzimidazole, a liquid crystal polymer, or any combination thereof. 
     
     
         22 . The seal of  claim 18 , wherein the annular jacket further comprises a filler selected from the group consisting of a solid lubricant, a ceramic or mineral filler, a polymer filler, a fiber filler, a metal particulate filler, salts, or any combination thereof. 
     
     
         23 . The seal of  claim 18 , wherein the annular jacket has a coefficient of friction of not greater than about 0.4. 
     
     
         24 . The seal of  claim 18 , wherein the annular jacket has a Young's modulus of at least about 0.5 GPa. 
     
     
         25 . The seal of  claim 18 , wherein the annular jacket has an elongation of at least about 20%. 
     
     
         26 . (canceled) 
     
     
         27 . (canceled) 
     
     
         28 . A method of forming a seal, the method comprising:
 dispensing a ribbon of sheet metal;   laser cutting a plurality of spring elements distributed longitudinally along the ribbon to form a spring work piece; and   folding the spring work piece to form a spring.   
     
     
         29 . The method of  claim 28 , wherein laser cutting includes laser cutting with a fiber laser. 
     
     
         30 . The method of  claim 28 , wherein laser cutting includes laser cutting the plurality of spring elements to extend latitudinally across the ribbon. 
     
     
         31 . The method of  claim 28 , wherein the plurality of spring elements extend to have a ratio of the width of a spring work piece formed from the ribbon to the width of the ribbon of at least 0.9. 
     
     
         32 .- 47 . (canceled)