Integrated magnetic/foil bearing and methods for supporting a shaft journal using the same

1 . An integrated bearing system for supporting a rotatable shaft journal, the system comprising:

a foil bearing; and

a magnetic field generating device that produces a magnetic bearing capability to the rotatable haft journal,

wherein the foil bearing is integrated into the magnetic field generating device, leaving an air gap between the shaft journal and the foil bearing; and

wherein under normal operating conditions, the magnetic field generating device and the foil bearing each provide a portion of the support to the shaft journal.

2 . The system as provided in claim 1 , wherein the foil bearing includes a corrugated bumped foil portion, having a pitch between a plurality of bump crests and bump troughs, that is disposed on an underside of an outer foil portion.

3 . The system as recited in claim 2 , wherein the pitch between the plurality of bump crests and bump troughs is uniform.

4 . The system as recited in claim 2 , wherein the pitch between the plurality of bump crests and bump troughs is non-uniform.

5 . The system as recited in claim 1 , wherein the system further comprises:

an outer housing; and

a plurality of foil bearing supports that are structured and arranged about the outer housing and oriented radially inwardly therefrom for supporting the foil bearing.

6 . The system as recited in claim 5 , wherein one or more of the plurality of foil bearing supports is used as a pole for the magnetic field generating device by wrapping a plurality of coil windings around said one or more foil bearing supports.

7 . The system as recited in claim 5 , wherein the outer housing can be used as a pole for the magnetic field generating device by wrapping a plurality of coil windings around said outer housing between adjacent foil bearing supports.

8 . The system as recited in claim 1 , wherein the foil bearing is a third generation-type foil bearing.

9 . The system as recited in claim 1 , wherein the foil bearing is made of a non-ferromagnetic material with high electrical resistivity.

10 . The system as recited in claim 1 , wherein the magnetic field generating device provides a greater portion of support to the shaft journal when said shaft journal is not rotating or is operating at lower rotating speeds.

11 . The system as recited in claim 1 , wherein the foil bearing provides a greater portion of support to the shaft journal when said shaft journal is operating at higher rotating speeds.

12 . The system as recited in claim 1 , wherein the foil bearing comprises one or more circumferentially-split rings that provide a desirable surface area.

13 . The system as recited in claim 1 , wherein the shaft journal is made of a laminated, ferromagnetic material that has been annealed.

14 . The system as recited in claim 13 , wherein the shaft journal is coated with a thin layer of a non-conductive, anti-corrosive, low friction, high hardness, anti-galling finish.

15 . The system as recited in claim 14 , wherein the thin layer is applied by vacuum plasma deposition, electroplating, high-velocity impact (sputtering) or flame spray techniques.

16 . The system as recited in claim 1 , wherein the magnetic field generating device includes a permanent magnet or an electromagnet.

17 . The system as recited in claim 1 , wherein the foil bearing and the magnetic field generating device are structured and arranged concentrically and coaxially along the length of the shaft journal.

18 . The system as recited in claim 17 , wherein the foil bearing and the magnetic field generating device are structured and arranged with unequal axial lengths along the length of the shaft journal so that the axial length of said foil bearing is longer or shorter than the axial length of said magnetic field generating device.

19 . A method of supporting a rotatable shaft journal, the method comprising the steps of:

providing a magnetic field generating device that provides a magnetic bearing capability;

integrating a foil bearing with the magnetic field generating device, wherein the foil bearing is integrated into the magnetic field generating device, leaving an air gap between the shaft journal and said foil bearing; and

structuring and arranging the magnetic field generating device and the foil bearing so that each provides a portion of the support to the shaft journal concurrently under normal operating conditions.

20 . An integrated bearing system for supporting a shaft journal, the system comprising:

a foil bearing; and

a magnetic field generating device,

wherein the foil bearing is integrated into the magnetic field generating device, leaving an air gap between the shaft journal and the foil bearing; and

wherein the magnetic field generating device and the foil bearing are structured and arranged to provide high force densities concurrently to support to the shaft journal.

21 . The system as provided in claim 20 , wherein the foil bearing includes a corrugated bumped foil portion, having a pitch between a plurality of bump crests and bump troughs, that is disposed on an underside of an outer foil portion.

22 . The system as recited in claim 20 , wherein the system further comprises:

an outer housing; and

a plurality of foil bearing supports that are structured and arranged about the outer housing and oriented radially inwardly therefrom for supporting the foil bearing.

23 . The system as recited in claim 22 , wherein one or more of the plurality of foil bearing supports is used as a pole for the magnetic field generating device by wrapping a plurality of coil windings around said one or more foil bearing supports.

24 . The system as recited in claim 22 , wherein the outer housing can be used as a pole for the magnetic field generating device by wrapping a plurality of coil windings around said outer housing between adjacent foil bearing supports.

25 . The system as recited in claim 20 , wherein the foil bearing is a third generation-type foil bearing.

26 . The system as recited in claim 20 , wherein the foil bearing is made of a non-ferromagnetic material with high electrical resistivity.

27 . The system as recited in claim 20 , wherein the magnetic field generating device provides a greater portion of support to the shaft journal when said shaft journal is not rotating or is operating at lower rotating speeds.

28 . The system as recited in claim 20 , wherein the foil bearing provides a greater portion of support to the shaft journal when said shaft journal is operating at higher rotating speeds.

29 . The system as recited in claim 20 , wherein the foil bearing comprises one or more circumferentially-split rings that provide a desirable surface area.

30 . The system as recited in claim 20 , wherein the magnetic field generating device includes a permanent magnet or an electromagnet.

31 . The system as recited in claim 20 , wherein the foil bearing and the magnetic field generating device are structured and arranged concentrically and coaxially along the length of the shaft journal.

32 . The system as recited in claim 20 , wherein the foil bearing and the magnetic field generating device are structured and arranged with unequal axial lengths along the length of the shaft journal so that the axial length of said foil bearing is longer or shorter than the axial length of said magnetic field generating device.

33 . A method of supporting a rotatable shaft journal, the method comprising the steps of:

providing a magnetic field generating device that provides a magnetic bearing capability;

integrating an foil bearing with the magnetic field generating device, wherein the foil bearing is integrated into the magnetic field generating device coaxially and concentrically about an axis or rotation of the shaft journal, leaving an air gap between the shaft journal and an outermost surface of the foil bearing; and

structuring and arranging the magnetic field generating device and the foil bearing to provide high force densities concurrently to support said shaft journal.