Bearing laminate comprising a foam layer

Abstract

A bearing laminate can include a metal support layer, a foam layer overlying the metal support layer, the foam layer including a polymeric foam; and a sliding layer overlying the polymeric foam layer, the sliding layer comprising a polymer matrix. Bearing articles made from the bearing laminate can have exceptional damping properties, such as a high damping ratio combined with a low dynamic stiffness.

What is claimed is: 
     
         1 . A bearing laminate comprising:
 a metal support layer;   a foam layer overlying the metal support layer, the foam layer including a polymeric foam; and   a sliding layer overlying the polymeric foam layer, the sliding layer comprising a polymer matrix.   
     
     
         2 . The bearing laminate of  claim 1 , wherein the laminate has a dynamic stiffness of at least 1 N/μm and not greater than 20 N/μm. 
     
     
         3 . The bearing laminate of  claim 1 , wherein the laminate has a damping ratio of at least 17% and not greater than 50%. 
     
     
         4 . The bearing laminate of  claim 1 , further comprising a first adhesive layer between the metal support and the foam layer and a second adhesive layer between the foam layer and the sliding layer. 
     
     
         5 . The bearing laminate of  claim 1 , wherein the polymeric foam includes a polyurethane foam, a polyethylene foam, a polyester foam, an acrylate foam, a polyvinyl chloride (PVC) foam, a silicon foam, a fluoropolymer foam, a nitrile butadiene rubber (NBR) foam, a ethylene propylene diene monomer (EPDM) foam, a polypropylene foam or any combination thereof. 
     
     
         6 . The bearing laminate of  claim 5 , wherein the polymeric foam includes polyurethane foam. 
     
     
         7 . The bearing laminate of  claim 1 , wherein the foam layer includes at least two foam sub-layers. 
     
     
         8 . The bearing laminate of  claim 7 , wherein the at least two foam sub-layers are connected to each other by an adhesive. 
     
     
         9 . The bearing laminate of  claim 1 , wherein the foam layer further comprises a reinforcing layer. 
     
     
         10 . The bearing laminate of  claim 1 , wherein the foam layer has a thickness of at least 0.1 mm and not greater than 2.0 mm. 
     
     
         11 . The bearing laminate of  claim 1 , wherein the polymeric foam has a density of at least 0.2 g/cm 3  and not greater than 0.9 g/cm 3 . 
     
     
         12 . A bearing article formed from a bearing laminate, the bearing laminate comprising:
 a metal support layer;   a foam layer overlying the metal support layer, the foam layer including a polymeric foam; and   a sliding layer overlying the polymeric foam layer, the sliding layer comprising a polymer matrix.   
     
     
         13 . The bearing article of  claim 12 , wherein the bearing article is adapted for use in a head restraint, a ball joint, a hinge, a seat structure, as a friction plate, a stabilizer bearing, or a dampener. 
     
     
         14 . The bearing article of  claim 12 , wherein the bearing laminate has a dynamic stiffness of at least 1 N/μm and not greater than 20 N/μm. 
     
     
         15 . The bearing article of  claim 12 , wherein the bearing laminate has a damping ratio of at least 17% and not greater than 50%. 
     
     
         16 . The bearing article of  claim 12 , wherein the polymeric foam includes a polyurethane foam, a polyethylene foam, a polyester foam, an acrylate foam, a polyvinyl chloride (PVC) foam, a silicon foam, a fluoropolymer foam, a nitrile butadiene rubber (NBR) foam, a ethylene propylene diene monomer (EPDM) foam, a polypropylene foam or any combination thereof. 
     
     
         17 . The bearing article of  claim 16 , wherein the polymeric foam includes polyurethane foam. 
     
     
         18 . A method for forming a bearing laminate, comprising:
 providing a metal support layer, a foam layer including a polymeric foam, and a sliding layer; and   joining the metal support layer, the foam layer, and the sliding layer using at least one adhesive and applying pressure and/or heat treatment.   
     
     
         19 . The method of  claim 18 , wherein the foam layer includes a polyurethane foam. 
     
     
         20 . The method of  claim 18 , wherein a thickness ratio of the polymeric foam layer to a total thickness of the laminate is at least 1:3 and not greater than 1:1.2.