Decoupler assembly

Abstract

A decoupler assembly that includes a hub, a pulley and a mechanism for transmitting rotary power between the hub and the pulley. The mechanism includes a torsion spring and a one-way clutch. The torsion spring is configured to dampen vibration in the rotary power that is transmitted from the pulley to the hub. The one-way clutch has a wrap spring that is smaller in diameter than the torsion spring.

What is claimed is: 
     
       1. A decoupler assembly comprising:
 a hub; 
 a driver sleeve mounted about the hub, the driver sleeve defining a clutch surface; 
 a pulley that is configured to engage an endless drive element; 
 a torsion spring received between the pulley and the driver sleeve and configured to transmit rotary power in a predetermined rotational direction from the pulley to the driver sleeve; and 
 a wrap spring having a first end, a second end and a plurality of coils between the first and second ends, the first end being drivingly connected to the hub, the coils being frictionally engaged to the clutch surface and wound such that the coils tend to expand when rotary power is transmitted from the pulley to the hub in the predetermined rotational direction. 
 
     
     
       2. The decoupler assembly of  claim 1 , wherein at least a portion of the pulley is made from a polymeric material. 
     
     
       3. The decoupler assembly of  claim 1 , wherein the torsion spring is a helical torsion spring. 
     
     
       4. The decoupler assembly of  claim 1 , wherein the pulley comprises a driver wall that drivingly engages a first helical end of the torsion spring, and wherein the driver sleeve has a driver member thereon that drivingly engages a second helical end of the torsion spring. 
     
     
       5. The decoupler assembly of  claim 1 , wherein one of the pulley and the driver sleeve includes an anti-ramp slot, wherein the other one of the pulley and the driver sleeve includes an anti-ramp member that extends into the anti-ramp slot, and wherein the anti-ramp member and the anti-ramp slot cooperate to limit relative rotation between the driver sleeve and the pulley to a predetermined angular range. 
     
     
       6. The decoupler assembly of  claim 1 , wherein the wrap spring is received in a chamber that is at least partly defined by the driver sleeve and the hub, wherein a lubricant is received in the chamber. 
     
     
       7. The decoupler assembly of  claim 1 , further comprising an expansion limiter that is mounted on the torsion spring, the expansion limiter being configured to be driven by the torsion spring into contact with the pulley when a load transmitted through the torsion spring exceeds a predetermined load. 
     
     
       8. The decoupler assembly of  claim 1 , wherein the driver sleeve includes a flange portion that axially constrains an axial end of the torsion spring. 
     
     
       9. The decoupler assembly of  claim 1 , wherein the torsion spring is made from wire having a circular cross-sectional shape. 
     
     
       10. The decoupler assembly of  claim 1 , wherein the wire that forms the torsion spring has a cross-sectional shape that is constant. 
     
     
       11. The decoupler assembly of  claim 1  wherein first and second bearing members are positioned between the pulley and the hub, and support relative rotation between the pulley and the hub. 
     
     
       12. The decoupler assembly of  claim 11 , wherein the first and second bearing members are bushings which are fixedly connected to the pulley. 
     
     
       13. A method of assembling a decoupler assembly comprising:
 a) providing a hub; 
 b) coupling a driver sleeve to the hub, the driver sleeve including a radially inner surface defining a clutch surface and a driver member; 
 c) sliding a wrap spring onto the hub, and operatively connecting a first end of the wrap spring to the hub to form a subassembly comprising the hub, the wrap spring and the driver sleeve, the wrap spring being positioned in a chamber that is at least partly defined by the clutch surface of the driver sleeve and the hub, the wrap spring including a plurality of coils being frictionally engaged to the clutch surface and wound such that the coils tend to expand when rotary power is transmitted from the pulley in the predetermined rotational direction to increase engagement and to cause a rotation of the hub; 
 c) sliding a driver sleeve onto the hub over the wrap spring to form a subassembly comprising the hub, the wrap spring and the driver sleeve, wherein the driver sleeve includes a clutch surface, a driver member and an anti-ramp member the clutch surface being engaged to coils of the wrap spring; 
 d) providing a pulley; 
 e) drivingly coupling a helical torsion spring into to the pulley; 
 f) inserting the subassembly into the pulley after step e); and 
 g) rotating one of the pulley and the hub in a selected rotational sense relative to the other one of the pulley and the hub until the driver member on the driver sleeve is engaged with a second helical end of the torsion spring and a driver wall on the pulley is engaged with the first helical end of the torsion spring. 
 
     
     
       14. A method as claimed in  claim 13 , wherein step g) is carried out until a selected torque is sensed between the pulley and the hub. 
     
     
       15. A method as claimed in  claim 13 , wherein the driver member on the driver sleeve is resiliently bendable out of the way by the torsion spring if the driver member does not engage the second helical end of the torsion spring when the subassembly is inserted into the pulley, wherein step g) causes relative rotation between the driver sleeve and the torsion spring until the driver member resiliently returns to a driving position wherein the driver member engages the second helical end of the torsion spring. 
     
     
       16. A method as claimed in  claim 15 , wherein step c) entails sliding the driver sleeve into a seat, wherein the driver sleeve includes an anti-ramp member that is positionable in an anti-ramp slot that has a fixed angular relationship with the driver wall, wherein the anti-ramp member is resiliently bendable out of the way by the seat if the driver member is not in the anti-ramp slot when the driver sleeve is slid into the seat, wherein step g) causes relative rotation between the driver sleeve and the seat until the anti-ramp member resiliently returns to an active position in which the anti-ramp member extends into the anti-ramp slot. 
     
     
       17. A decoupler assembly comprising:
 a hub that defines a slot; 
 a driver sleeve having a flange portion and a clutch surface, the flange portion having a driver member; 
 a wrap spring disposed about the hub and radially within the driver sleeve, the wrap spring having a first end, a plurality of coils, and a second end, the first end being received in the slot, the plurality of coils being frictionally engaged to with the clutch surface; 
 a pulley having a driver wall at one axial end of the pulley; 
 a helical torsion spring disposed radially between the pulley and the driver sleeve, the helical torsion spring having a first helical end and a second helical end, the first helical end being abutted against the driver wall, the second helical end being abutted against the driver member; and 
 at least one bearing element supporting the pulley for rotation on the hub
 wherein one of an anti-ramp slot or an anti-ramp member is provided at another axial end of the pulley in a fixed angular relationship with the driver wall, wherein the anti-ramp slot has a first end and a second end, 
 
 wherein the driver sleeve includes the other of the anti-ramp member and the anti-ramp slot, wherein the anti-ramp member is resiliently biased towards an extended position and is movable to a retracted position when not exposed to the anti-ramp slot and is movable via rotation of the driver sleeve to a position to be exposed to the anti-ramp slot. 
 
     
     
       18. The decoupler assembly of claim 17, comprising a second bearing element operatively connected to the pulley having a tab connected in series with the torsion spring and the driver sleeve to impart rotatory power from the pulley to the torsion spring. 
     
     
       19. A decoupler assembly comprising:
 a hub;   a driver sleeve mounted about the hub, the driver sleeve having a radially inner surface defining a clutch surface;   a pulley having an inner surface and an outer surface, the outer surface of the pulley is configured to engage an endless drive element;   a torsion spring positioned between the inner surface of the pulley and a radially outer surface of the driver sleeve, the torsion spring configured to transmit rotary power in a predetermined rotational direction from the pulley to the driver sleeve; and   a wrap spring disposed in a chamber partly defined by the clutch surface of the driver sleeve and the hub, the wrap spring having a first end, a second end and a plurality of coils between the first and second ends, at least a portion of the coils being frictionally engaged to the clutch surface and wound such that the coils tend to expand when rotary power is transmitted from the pulley to the driver sleeve such that rotation of the wrap spring causes corresponding rotation of the hub.   
     
     
       20. A decoupler assembly comprising:
 a pulley having an outer surface and an inner surface;   a hub extending within the pulley;   a driver sleeve having a flange portion and a clutch surface, the flange portion having a driver member;   a wrap spring disposed about the hub and positioned within a chamber that is at least partly defined by the clutch surface of the driver sleeve and the hub, the wrap spring having a first end, a plurality of coils, and a second end, the plurality of coils being frictionally engaged with the clutch surface, the wrap spring being wound such that the coils tend to expand when the driver sleeve is rotated in a predetermined rotational direction to cause a rotation of the wrap spring, the wrap spring coupled to the hub such that a rotation of the wrap spring causes a corresponding rotation of the hub;   an end cap disposed in one axial end of the pulley and having tab extending therefrom;   a helical torsion spring disposed radially between the pulley and the driver sleeve, the helical torsion spring having a first helical end and a second helical end, the first helical end abutting the tab, the second helical end abutting the driver member to transmit rotary power in the predetermined rotational direction from the pulley to the driver sleeve.   
     
     
       21. A decoupler assembly comprising:
 a hub;   a driver sleeve mounted about the hub, the driver sleeve defining a clutch surface;   a pulley that is configured to engage an endless drive element;   a torsion spring received between the pulley and the driver sleeve and configured to transmit rotary power in a predetermined rotational direction from the pulley to the driver sleeve; and   a wrap spring having a first end, a second end and a plurality of coils between the first and second ends, the coils being frictionally engaged to the clutch surface and wound such that the coils tend to expand when rotary power is transmitted from the pulley to the hub in the predetermined rotational direction.