Idler pulley with integral bearing carrier insert and method

Abstract

An idler pulley with an integral bearing carrier insert comprising: a pulley body having a peripheral surface for accepting and retaining an endless belt; and a tubular bearing carrier insert forming a central hub along a perpendicular axis of the idler pulley body, the hub having an inner circumferential surface and an outer circumferential surface.

1 - 23 . (canceled)  
     
     
         24 . A method for manufacturing a moldable polymeric idler pulley having an integrally formed metal or ceramic bearing insert and a bearing member, said method comprising the steps of: 
 (a) providing a mold having a cavity, the inner surface of said cavity being shaped to form an outer surface of a pulley body having a desired configuration and dimension;    (b) providing a tubular metal bearing carrier insert having an outer circumferential surface and an inner circumferential surface, said tubular bearing insert defining a central hub along a perpendicular axis of said idler, said outer circumferential surface of said insert having an outer surface shaped to enhance interlocking between said central hub and said pulley body and said hub further including a stepped profile or detents to locate said bearing member;    (c) inserting said tubular metal bearing carrier insert within said cavity;    (d) closing said mold;    (e) introducing a free-flowing moldable polymeric material into said cavity such that said free-flowing moldable polymeric material fills said cavity around said outer circumferential surface of said insert leaving said open interior space of said insert free of said free-flowing moldable polymeric material;    (f) subjecting said mold containing said free-flowing material and said tubular metal bearing carrier insert to conditions of heat and pressure to form an idler pulley with an integral bearing carrier insert;    (g) cooling said mold to provide a molded idler pulley with integral bearing carrier insert formed along a perpendicular axis of said idler pulley body;    (h) opening said mold; and    (i) recovering said molded idler pulley having said metal or ceramic bearing carrier insert integrally formed therein,    wherein said bearing member is fitted within said central hub during said step (c) or after step (i).    
     
     
         25 - 26 . (canceled)  
     
     
         27 . The method of  claim 24  wherein said moldable polymeric material is a polyamide, phenolic resin, epoxy resin, polyester, polyurethane, high density polyolefin, or a blend thereof.  
     
     
         28 . The method of  claim 27  wherein said polymeric material is a polyamide.  
     
     
         29 . The method of  claim 27  wherein said polymeric material is a polyphathalamide.  
     
     
         30 . The method of  claim 28  wherein said polyamide is a nylon selected from the group consisting of nylon-6; nylon 6,6; nylon 4,6; nylon 6,10; nylon 9; nylon 11; or nylon 12.  
     
     
         31 . The method of  claim 30  wherein said nylon is nylon 6, nylon 6,6 or nylon 4,6.  
     
     
         32 . The method of  claim 24  wherein said moldable polymeric material includes at least one of a modifier selected from the group consisting of polytetrafluoroethylene, ultra high molecular weight polyethylene, silicon, molybdum disulfide, graphite and rubber; a filler selected from the group consisting of glass beads, carbon black, calcium carbonate, wollastonite, mica, clay and talc; a reinforcing agent selected from the group consisting of glass fiber, long glass fiber, aramid fiber, steel fiber and carbon fiber; and an adhesion promoter sulfur, silica, acrylates, vinyl acetates and low molecular weight polyamides.  
     
     
         33 . The method of  claim 24  wherein said outer circumferential surface of said pulley body is coated with a metallic coating.  
     
     
         34 . The method of  claim 33  wherein said metallic coating is steel or aluminum.  
     
     
         35 . The method of  claim 24  wherein said tubular bearing carrier insert is manufactured from a metal.  
     
     
         36 . The method of  claim 35  wherein said metal is selected from the group consisting of steel, aluminum, zinc, brass or a combination thereof.  
     
     
         37 . The method of  claim 35  wherein said tubular bearing carrier insert is manufactured from steel.  
     
     
         38 . The method of  claim 37  wherein said steel tubular bearing carrier insert is coated with zinc or brass.  
     
     
         39 . The method of  claim 24  wherein said bearing member includes an outer bearing race surface fitted within said central hub such that said outer race surface of said bearing member is circumferentially adjacent the inner circumferential surface of said hub.