Cast fluoropolymer film for bushings

1. A method comprising

casting first and second friction reducing layers on first and second sides of a polyimide carrier;

casting first and second intermediate layers adjacent to and in direct contact with the first and second friction reducing layers, wherein the first and second intermediate layers consists of

a fluoropolymer, the fluoropolymer selected from polytetrafluoroethylene (PTFE), fluorinated ethylene-propylene (FEP), polyvinylidenfluoride (PVDF), polychlorotrifluoroethylene (PCTFE), ethylene chlorotrifluoroethylene (ECTFE), ethylene tetrafluoroethylene (ETFE), perfluoroalkoxypolymer (PFA), and any combination thereof, and

a filler, the filler selected from the group consisting of a friction reducing filler, a pigment, a scent producing filler, a noise producing filler, and a combination thereof;

casting first and second adhesive layers, wherein the first and second adhesive layers includes a melt-processible fluoropolymer, the first and second adhesive layers overlying the first and second intermediate layers to form first and second multilayer cast films;

layering first and second load bearing substrates from a feed spool, the first and second load bearing substrates comprising a continuous metal sheet, onto first and second multilayer cast films;

laminating the first and second multilayer cast films to first and second load bearing substrates with each load bearing substrate closer to the corresponding adhesive layer than to the corresponding friction reducing layer to form first and second composites, wherein a thickness of each of the load bearing substrates is greater than a thickness of each of first and second adhesive layers and the thickness of each of the load bearing substrates is greater than a thickness of each of the first and second friction reducing layers;

removing the polyimide carrier from the first and second multilayer cast films and the loadbearing substrates; and

applying a first and second coating layers onto the first and second friction reducing layers, wherein the first and second coating layers are opposite to the loadbearing substrate, wherein the first and second coating layers comprise a lubricant; and

shaping the composites.

2. The method of claim 1 , wherein casting the first and second friction reducing layers includes applying a polymer dispersion to first and second major surfaces of the carrier, drying the polymer dispersion to form a polymer layer, and sintering the polymer layer.

3. The method of claim 2 , wherein applying, drying, and sintering the first and second friction reducing layers substantially simultaneously.

4. The method of claim 1 , further comprising casting an additional polymer layer overlying each friction reducing layer prior to casting the adhesive layers.

5. The method of claim 1 , wherein the adhesive layer includes a polymer selected from the group consisting of a fluoropolymer, an epoxy resin, a polyimide resin, an acrylate, a polyether/polyamide copolymer, ethylene vinyl acetate, and any combination thereof.

6. The method of claim 1 , wherein shaping the composite includes rolling and flanging.

7. The method of claim 1 , wherein shaping the composite includes rolling and flanging.

8. A method comprising

casting first and second friction reducing layers on first and second sides of a polyimide carrier;

casting first and second adhesive layers to form first and second multilayer cast films, the first and second adhesive layers overlying the first and second friction reducing layers, wherein the first and second adhesive layers includes a melt-processible fluoropolymer consisting of

an ethylene tetrafluoroethylene copolymer (ETFE), a fluorinated ethylene propylene copolymer (FEP), a perfluoroalkoxy (PFA), or any combination thereof, and

a functional group selected from —C═O, —C—O—R, —COH, —COOH, —COOR, —CF2=CF—OR, or any combination thereof, where R is a cyclic or linear organic group containing between 1 and 20 carbon atoms;

layering first and second load bearing substrates from a feed spool, the first and second load bearing substrates comprising a continuous metal sheet, onto first and second multilayer cast film;

laminating the first and second multilayer cast films to first and second load bearing substrates with each load bearing substrate closer to the corresponding adhesive layer than to the corresponding friction reducing layer to form first and second composites, wherein a thickness of each of the load bearing substrates is greater than a thickness of each of first and second adhesive layers and the thickness of each of the load bearing substrates is greater than a thickness of each of the first and second friction reducing layers;

removing the polyimide carrier from the first and second multilayer cast films and the loadbearing substrates; and

applying a first and second coating layers onto the first and second friction reducing layers, wherein the first and second coating layers are opposite to the loadbearing substrate, wherein the first and second coating layers comprise a lubricant; and

shaping the composites.

9. The method of claim 8 , wherein casting the first and second friction reducing layers includes applying a polymer dispersion to first and second major surfaces of the carrier, drying the polymer dispersion to form a polymer layer, and sintering the polymer layer.

10. The method of claim 9 , wherein applying, drying, and sintering the first and second friction reducing layers substantially simultaneously.

11. The method of claim 8 , further comprising casting an additional polymer layer overlying each friction reducing layer prior to casting the adhesive layers.

12. The method of claim 8 , wherein the adhesive layer includes a polymer selected from the group consisting of a fluoropolymer, an epoxy resin, a polyimide resin, an acrylate, a polyether/polyamide copolymer, ethylene vinyl acetate, and any combination thereof.