Molded polymeric bearing housing and method for making same

Abstract

A molded polymeric bearing housing is formed of a moldable polymer base material in combination with a glass fiber reinforcing component. A foaming agent is added to the base material to create a fine structural foam within interior regions of the housing. A density gradient is established between regions adjacent to the surfaces of the housing and the internal regions, thereby reducing the need for reinforcing ribs particularly in a base or mounting portion of the housing. An antimicrobial agent may be added to the housing material to inhibit the growth and proliferation of fungi, molds, bacteria, and so forth. Structural features of the housing may be formed subsequent to the molding process, such as by turning operations. Metal inserts may be provided to avoid crushing of regions of the housing, such as by attachment fasteners. The housing forms a mounting base surface in a single plane coextensive with the footprint of the housing. When the housing is placed in service moisture and debris is prevented from collecting below the housing by conformity of the mounting base surface with the machine support surface. The housing may be formed in a variety of styles, including pillow block styles, tapped base pillow block styles, two and four bolt flange styles, take up frame styles, flange bracket styles and so forth.

What is claimed is:  
     
         1 . A housing for a bearing insert, the housing comprising: 
 a unitary body made of a moldable polymeric material and having a bearing insert support portion configured to receive and support the bearing insert, and a support base configured to receive and cooperate with fasteners to secure the housing to a substantially planar machine surface, the support base having a mounting surface extending substantially in a plane, wherein the polymeric material includes an antimicrobial agent for inhibiting growth of microorganisms.    
     
     
         2 . The housing of  claim 1 , wherein the body comprises a moldable structural foam material.  
     
     
         3 . A housing for a bearing insert, the housing comprising: 
 a unitary body having a bearing insert support portion configured to receive and support the bearing insert, and a support base configured to receive and cooperate with fasteners to secure the housing to a substantially planar machine surface, the support base having a mounting surface extending substantially in a plane, wherein the body comprises a moldable plastic material, fiberglass, and an antimicrobial agent.    
     
     
         4 . The housing of  claim 3 , wherein the support base includes a central portion underlying the bearing support portion and a pair of lateral flanges extending from the central portion, the mounting surface comprising a region coextensive with the lateral flanges and the central portion.  
     
     
         5 . The housing of  claim 3 , wherein the polymeric material comprises polybutylene terephthalate.  
     
     
         6 . A support housing for a bearing insert, the bearing insert including an inner race, an outer race and a plurality of bearing elements disposed therebetween, the support housing comprising: 
 a bearing insert support portion configured to receive and support the bearing insert; and    an attachment portion integral with the bearing insert support portion, the attachment portion including a plurality of apertures configured to receive fasteners for securing the support housing to a machine support surface;    wherein the bearing insert support portion and the attachment portion comprise an antimicrobial agent for inhibiting growth of microorganisms.    
     
     
         7 . The support housing of  claim 6 , wherein the bearing insert support portion and the attachment portion are made of an admixture of a moldable polymeric material and the antimicrobial agent.  
     
     
         8 . The support housing of  claim 7 , wherein the admixture further includes a fiberglass reinforcing component.  
     
     
         9 . The support housing of  claim 7 , wherein the moldable polymeric material comprises a structural foam.  
     
     
         10 . The support housing of  claim 6 , wherein the attachment portion forms a base on which the support housing is mounted when placed in service, and wherein the base includes a base mounting surface extending substantially in a plane and coextensive with the base.  
     
     
         11 . A housing for supporting a bearing insert on a substantially planar machine frame, the bearing insert including an inner race, an outer race and a plurality of bearing elements disposed therebetween, the housing comprising: 
 a bearing insert support portion configured to receive and support the bearing insert; and    a mounting portion integral with the bearing insert support portion, the mounting portion having a substantially planar mounting surface extending substantially over the entire mounting portion, whereby when the housing is mounted on the machine frame, the mounting surface contacts the machine frame with no interstice therebetween,    wherein the bearing insert support portion and the mounting portion comprise an admixture of a moldable polymeric material and an antimicrobial agent for inhibiting growth of microorganisms.    
     
     
         12 . The housing of  claim 11 , wherein the mounting portion includes a plurality of apertures extending through the mounting surface, the apertures being configured to receive fasteners for securing the housing to the machine frame.  
     
     
         13 . The housing of  claim 11 , wherein the mounting portion includes a plurality of mounting apertures for securing the housing to a machine frame, and wherein a metallic support sleeve is disposed within each of the plurality of mounting apertures.  
     
     
         14 . The housing of  claim 11 , wherein the bearing insert support portion and the mounting portion comprise an admixture of the polymeric structural foam material and a fiberglass reinforcing component.  
     
     
         15 . A housing for a bearing insert, the housing comprising: 
 a bearing insert support portion configured to receive and support the bearing insert; and    a mounting portion configured to secure the housing to an external surface,    wherein the bearing insert support portion and the mounting portion comprise a mixture of a polymeric material and an antimicrobial agent.    
     
     
         16 . The housing as recited in  claim 15 , wherein the mounting portion is integral with the bearing insert support portion.  
     
     
         17 . The housing as recited in  claim 15 , wherein the mounting portion has a substantially planar mounting surface.  
     
     
         18 . The housing as recited in  claim 16 , wherein the mixture of a polymeric material and an antimicrobial agent includes a glass fiber reinforcing material.  
     
     
         19 . The housing as recited in  claim 16 , wherein the mixture of a polymeric material and an antimicrobial agent includes a foaming agent.