CROSS-REFERENCE TO RELATED APPLICATION

[0001] This PCT International Patent Application claims the benefit of and priority to U.S. Provisional Patent Application Serial No. 62/743,213 filed on October 9, 2018, titled“Tapered Roller Bearing,” the entire disclosure of which is hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0002] The present invention relates to a tapered bearing assembly. More particularly, the present invention relates to a tapered bearing assembly having bearing elements caged to a raceway defined by an outer ring and further having an inner ring integral with a shaft.

2. Related Art

[0003] This section provides background information related to the present disclosure which is not necessarily prior art.

[0004] The development of bearings has coincided with the advancement of industry. By mechanically limiting and controlling relative motion between two parts, bearings have been used historically in many different types of applications. Whether they are used for facilitating linear or rotational movement between parts, bearings continue to be developed into ever sophisticated configurations. One of the most common types of bearings is commonly referred to as a roller bearing, which is used in applications to reduce friction while supporting axial or radial loads. Roller bearings typically include an inner ring and an outer ring separated by bearing elements like ball bearings that reduce rotational friction between the inner and outer rings. Roller bearings are commonly used in the automobile industry and can be found in gearboxes, pumps, and motors. One type of roller bearing that is regularly adapted to the above referenced applications is called a tapered roller bearing wherein the inner ring and outer ring are at least slightly conically shaped and the bearing elements are tapered. The bearing elements are retained within a raceway defined by an exterior surface of the inner ring and a cage element circumferentially spaces the bearing elements from one another. When developed, tapered roller bearings presented a geometrically superior shape for certain applications and thus have come into common usage in many applications over traditional roller bearings. One of the most common applications that utilize tapered roller bearings are wheel bearings used in automobiles and other various types of vehicles. While tapered roller bearings are superior in many applications, they are relatively complicated to assemble and require precision tooling and placement of interrelated parts.

[0005] Accordingly, there is a continuing desire to further refine bearing assembly designs that are capable of easy and inexpensive assembly while still meeting structural requirements in various applications.

SUMMARY OF THE INVENTION

[0006] This section provides a general summary of the disclosure and should not be interpreted as a complete and comprehensive listing of all of the objects, aspects, features and advantages associated with the present disclosure.

[0007] The subject invention provides a tapered bearing assembly that comprises an outer ring and an inner ring located within and axially aligned with the outer ring, a plurality of bearing elements located between and radially spacing the outer ring and the inner ring, a cage defining a plurality of pockets for circumferentially spacing the plurality of bearing elements, and a shaft being integrally formed with the inner ring. [0008] The subject invention further provides a method of assembling a tapered bearing assembly comprising the steps of providing a shaft, an inner ring, an outer ring, and a plurality of bearing elements. The method further comprises forming a raceway in the outer ring that is located between a front flange and a rear flange, placing the bearing elements into the raceway between the front flange and the rear flange, and placing the outer ring and bearing elements over the inner ring and in axial alignment.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The drawings described herein are for illustrative purposes only of selected embodiments and are not intended to limit the scope of the present disclosure. The inventive concepts associated with the present disclosure will be more readily understood by reference to the following description in combination with the accompanying drawings wherein:

[0010] Figure 1 illustrates an assembled prior art tapered bearing assembly;

[0011] Figures 2A, 2B and 2C illustrate an unassembled prior art tapered bearing assembly;

[0012] Figure 3 illustrates a tapered bearing assembly constructed in accordance with the present disclosure;

[0013] Figures 4A, 4B, and 4C illustrate the subject tapered bearing assembly presented in Figure 3 in an unassembled state; and

[0014] Figure 5 presents a flow chart illustrating a method of constructing the subject tapered bearing assembly presented in Figures 3 and 4A through 4C.

DESCRIPTION OF THE ENABLING EMBODIMENT

[0015] Example embodiments will now be described more fully with reference to the accompanying drawings. In general, the subject embodiments are directed to a tapered bearing assembly with a plurality of bearing elements retained in an outer ring. However, the example embodiments are only provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example

embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.

[0016] Referring to the Figures, wherein like numerals indicate corresponding parts throughout the views, the tapered bearing assembly of the present disclosure is intended for providing a design with a simplified and streamlined production.

[0017] With reference initially to Figure 1, an assembled prior art tapered roller assembly 20 is shown. The tapered bearing assembly 20 includes an outer ring 22 and an inner ring 24 separated by a plurality of bearing elements 26. The inner ring 24 includes an outer surface 28 that defines a raceway 30 spaced between a front flange 32 and a rear flange 34. The bearing elements 26 are shown axially retained within the raceway 30 between flanges 32, 34. A cage 36 radially holds each bearing element 26 in the raceway 30 while circumferentially spacing each bearing element 26 equally around the raceway 30. The inner ring 24 further includes an inner surface 31 in frictional engagement with a shaft 35 for conjoint rotation therewith. During assembly, the inner ring 24 must be friction fit over the shaft 35. In operation, the friction caused by rotation of the shaft 35 is reduced on the outer ring 22 via spinning of the bearing elements 26 within the raceway 30. While the shaft 35 is free to rotate, radial movement of the shaft 35 is prevented by the outer ring 22. [0018] Looking now to Figures 2A through 2C, an unassembled prior art tapered bearing assembly 20 is illustrated. As shown, the bearing elements 26 are placed into the cage 36 from an inside surface cage surface 38. The cage 36 and bearing elements 26 are then placed over the inner ring 24 until the bearing elements 26 are retrained in the raceway 30 between flanges 32, 34. The inner ring 24 is attached to the shaft 35 for conjoint rotation therewith. The outer ring 22 is then placed over the inner ring 24, cage 36, and bearing elements 26. The outer ring 22 is further coupled to a housing 40, which could include a transfer case, transmission, wheel bearing housing, or any other part.

[0019] Turning now to the tapered bearing assembly 100 of the present disclosure, a simplified construction is illustrated in Figure 3. The tapered bearing assembly 100 includes an outer ring 102 and an inner ring 104 disposed within the outer ring 102 and axially aligned along an axis A. The rings 102, 104 are radially spaced apart by a plurality of bearing elements 106. The outer ring 102 includes and outer surface 108 and an inner surface 110. The outer surface 108 defines an outer diameter (OD) of the assembly 100.

The inner surface 110 is conically shaped and defines an inner raceway 112 sunken into the inner surface 100. The inner raceway 112 is disposed between a front flange 114 and a rear flange 116. The front flange 114 is axially wider than the front flange 116 for bearing a greater load. The bearing elements 106 are conically shaped and are seated within the inner raceway 112. The bearing elements 106 are retained against the outer ring 102 in an annular cage 118. The cage 118 is also conically shaped and defines a plurality of holding pockets 120 circumferentially spaced and extending through the cage 118. Each holding pocket 120 is sized in the axial direction to fit a length L of the bearing elements 106 and is sized in the circumferential direction to fit only a portion of the diameter or width W of the bearing elements 106. As shown, the bearing elements 106 only extend partially into the pockets 120 from a radially outward direction such that they are primarily located radially outwardly from the cage 118. As such, the bearing elements 106 are caged to the outer ring 102. The cage 118 further includes a cage flange 122 extending radially outwardly towards the rear flange 116 of the outer ring 102. The inner ring 104 includes an outer surface 124 presenting a conical shape for contacting each bearing element 106 opposite the outer ring 102. As best shown in Figures 4A, 4B, and 4C, the inner ring 104 is attached to or integrated with a shaft 126 for conjoint rotation therewith. While the inner ring 104 could include an inner surface 128 defining an inner diameter (ID) sized to fit over the shaft 126, it is preferable that the inner ring 104 is machined directly into the shaft 126 during production of the shaft 126. As such in the preferred arrangement, the inner ring 104 is integral with the shaft 126 for a more simple assembly. As best illustrated in Figure 4 A, the outer surface 124 may further include a layer 125 of hardened material. In other words, the shaft 126 and inner ring 104 may be integrally formed of one material, such as steel, and the outer surface 124 may include a layer 125 of steel that has undergone a hardening process. The hardening processes could include tempering and/or cold working processes. In one arrangement, the layer 125 could include a larger percentage of martensite and/or austenite than that of the shaft 126 and/or other portions of the inner ring 104. In certain applications, the layer 125 of hardened material can allow longer operational life of the wear surface without detracting from the ductility of the shaft 126 and/or other portions of the inner ring 104. It should also be appreciated that the inner ring 104 could alternatively include a raceway spaced between flanges, similarly to the configuration of the inner ring in Figure 1. As such, the inner ring 104 may be integral with the shaft 126 and further define flanges and a raceway.

[0020] In operation, the conical surface of the raceway 112, the conical surface of the each bearing element 106, and the conical surface of the outer surface 124 of the inner ring 104 are each oriented such that they share the same conical apex. Rotation of the shaft 126 causes conjoint rotation of the inner ring 104. The bearing elements 106 reduce friction between the inner ring 104 and outer ring 102 such that rotation of the shaft 126 has minimal influence on the outer ring 102. Despite rotationally isolating the shaft 126 and inner ring 104 from the outer ring 102, the shaft 126 and inner ring 104 is still allowed to exert axial pressure on the outer ring 102. Likewise, the outer ring 102 can be attached to a housing 130 to prevent radial movement of the shaft 126 with respect thereto. By-way of non-limiting examples, the housing 130 could be a transfer case, transmission, wheel bearing housing, or other automotive assemblies.

[0021] A process 200 of constructing a tapered roller bearing assembly is presented in Figure 5 in accordance with the present disclosure. The process begins by providing 210 an outer ring, an inner ring, a plurality of bearing elements, a cage, and a shaft. The bearings elements are placed 220 within pockets defined by the cage from a radially outward direction, each pocket circumferentially spacing and radially retaining the bearing elements. The cage and bearing elements are then retained 230 within a raceway defined by an inner surface of the outer ring, front and rear flanges are spaced on either side of the raceway to axially retain the bearing elements. The outer ring, cage, and bearing elements are then placed 240 over the inner ring. The outer ring, the cage, the bearing elements, and the inner ring are then attached 250 to the shaft and the outer ring is then attached 260 to a housing. In addition, before providing parts 210, the inner ring can be machined or otherwise formed 270 into the shaft. In addition, the process 200 may also include hardening 280 an outer surface of the inner ring and forming 290 an outer ring including a raceway located between two flanges. The step of hardening 280 an outer surface of the inner ring can include tempering, cold working, heat treating, other types of work hardening, etc. The step of hardening 280 an outer surface of the inner ring can also include placing the outer surface through a process until it has a greater percentage of martensite and/or austenite than that of the shaft and/or other portions of the inner ring.

[0022] It should be appreciated that the foregoing description of the embodiments has been provided for purposes of illustration. In other words, the subject disclosure it is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varies in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of disclosure.