Pulley and hub assembly
BACKGROUND OF THE INVENTION 
     This invention relates to a novel polymeric pulley for driving the cooling fan of an internal combustion engine, and to the combination of the polymeric pulley with a housed bearing assembly. 
     In recent years, fans for internal combustion engines have been considerably improved and lightened in weight, being formed of special polymeric structures weighing only a fraction of prior cooling fans. As such, rotation of the fans can be quickly initiated, stopped and regulated for optimum cooling and power usage. However, the pulley and hub drive mechanism for such fans has continued to be of heavy structure, typically of cast iron weighing well over seven pounds. This pulley and hub drive is normally, although not always, connected to a thermostatically controlled clutch for the fan. A lower mass pulley would help reduce belt wear, due to its lower moment of inertia, during speed changes. It would also permit faster engine acceleration. Reduction in mass would also add to the load carrying capacity of the vehicle. 
     Moreover, the typical structure is expensive to manufacture. The cast iron pulley and integral bearing housing are largely specially made for the particular model engine accommodated, involving costly casting and machining operations and requiring large inventory management. Each pulley requires a number of different machining operations and balancing. It would be advantageous to substitute this heavy construction with a lightweight assembly requiring little or no machining or balancing. Conceivably, use of polymeric materials in place of cast iron would help to secure these advantages. 
     Plastic or polymeric pulleys have been known heretofore. Many of these are for low duty usage, being simply solid polymeric members or, if intended for somewhat heavier duty, are composite assemblies with special metal components incorporated. Polymer and metal containing pulleys of various types are set forth in U.S. Pat. Nos. 2,760,378, 3,367,199, 3,651,705, 3,696,685, 3,772,928, 3,788,155, 4,034,616, 4,177,685, 4,326,849, 4,364,736, 4,366,609, 4,468,210, 4,473,363, 4,548,592, 4,571,226 and 4,652,474. 
     SUMMARY OF THE INVENTION 
     The novel pulley and its combination with its bearing assembly provides an effective engine cooling fan pulley arrangement capable of accommodating the intermittent high stress loads repeatedly applied in response to engine temperature variations. The novel assembly reduces the mass of prior fan drives by several pounds, being only a small fraction of the weight of previous devices. It thereby can result in longer belt life and elimination of the need for balancing. The novel device employs a polymeric pulley member clamped in compression between the steel clutch plate and a steel flange on the bearing housing, for optimum resistance to stress. The novel apparatus eliminates the requirement of a close adapter fitting which prior art pulleys needed to adapt the clutch to the pulley. The overall length of the combined pulley and bearing is also shortened, thereby providing a potential saving of space. Secondary machining operations, moreover, are not needed for the interfit between the bearing and pulley, thereby lowering production costs. Rather, the pulley has integrally formed guide means, preferably in the form of internal, radially and axially extending ribs, to locate the bearing relative to the pulley, both radially and axially. It also has integrally formed pilot surface area for alignment with the clutch. 
     The pulley and bearing assembly enables the same bearing to interfit with pulleys having differing outer drive peripheries, e.g. for driving by V-belts, poly belts, or toothed belts. The bearing fits within a special chamber of the pulley formed by the peripheral rim of the pulley and an axial end thereof. 
     The bearing elements within the bearing assembly are spaced apart by novel spacing means including a compressible-expansible wave washer allowing length variation control, and predetermined axial thrust load. It has special lubrication distribution to enable lubricant to effectively be applied to the individual bearings, and causing centrifugal force to move the grease to appropriate locations. 
     These and other objects, advantages, features and variations of the inventive apparatus will be apparent upon studying the following specification in conjunction with the drawings, setting forth the preferred version thereof. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an elevational sectional view of the novel pulley in one form, in combination with its bearing and shown mounted on a shaft of a bracket; 
     FIG. 2 is an end elevational view of the apparatus in FIG. 1, viewed from the left end of FIG. 1; 
     FIG. 3 is a sectional elevational view through the pulley, forming part of the apparatus of FIG. 1; 
     FIG. 4 is an end elevational view of the pulley in FIG. 3 viewed from the right end of FIG. 3, and having section line III--III showing where FIG. 3 is taken; 
     FIG. 5 is an end elevational view of the pulley in FIG. 3 taken from the left end of FIG. 3; and 
     FIG. 6 is a sectional elevational view of a second embodiment of bearing assembly for combination with a pulley of this invention. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The assembly 10 (FIG. 1) is illustrated in the form of a V-belt pulley and bearing assembly for the cooling fan of an internal combustion engine. The depicted apparatus includes a conventional mounting bracket 12 having a main body with a pair of upstanding spaced ears 12&#39; (FIG. 2) for securement to the engine and a stub shaft 14, commonly called a &#34;base&#34;, on which the bearing and pulley assembly are mounted. The bearing is shown retained by an end plate 16 and stud 18 (shown in phantom). 
     Pulley 30 and bearing assembly 50 interfit with each other as described hereinafter. 
     Pulley 30 comprises a polymeric member preferably formed by injection molding and shown to include an axially elongated peripheral rim 32 and an integral axial end 34 on one end of the rim. The opposite end of the rim is open (FIG. 3) to axially receive bearing assembly 50. The outer peripheral drive surface area of rim 32 is shown to include V-belt grooves. This could be alternate drive configurations such as poly belt grooves and toothed belt grooves. Axial end panel 34 encloses one axial end of the pulley, having an integrally-formed, outer, central protrusion 38, preferably cylindrical, forming a pilot to interfit with a correspondingly shaped opening in the center of the drive clutch plate 31 (shown in phantom) or a spacer between the pulley and the clutch. Rim 32 and axial end 34 collectively define a chamber 40 of generally cylindrical configuration. Around the periphery of this cylindrical chamber is shown a plurality of radially-inwardly protruding, axially extending ribs 42 integral with the rim. The radially inner end surfaces 42&#39; of these ribs radially locate and center bearing assembly 50 when inserted. These ribs are formed in pairs (FIG. 4), each shown straddling an axially extending opening 44 in axial end 34. Bolt receiving orifices 44 have a peripheral boss extension 44&#39; therearound for extra support. There are six pairs of ribs and six openings depicted in this particular embodiment, although this number can vary. The axial ends 42&#34; of ribs 42, oriented toward the open end of chamber 40, serve as axial locator surfaces for bearing assembly 50 in a manner to be described hereinafter. 
     Bearing assembly 50 includes a metal housing 52, preferably of steel, of generally cylindrical configuration, and having between its ends an annular integral mounting flange 54 projecting outwardly from the periphery thereof. This mounting flange has a plurality of openings 54&#39; therein, of equal number with and aligned with openings 44 in pulley 30. Bolt type connectors 33 (shown in phantom) extend through these openings as well as suitable openings in the clutch mounting plate 31 and into threaded engagement with threaded orifices 54&#39; of flange 54 to cause metal plate 31 and metal mounting flange 54 to sandwich the polymeric pulley therebetween, such that the bolts place the pulley in compression. Polymeric materials have the greatest resistance to stress under compressive load. 
     When bearing assembly 50 is placed within hollow chamber 40 of the pulley, the axial inner face 54a (FIG. 1) of flange 54 abuts axial locator faces 42&#34; of ribs 42, while outer cylindrical surface 52a (FIG. 1) of bearing housing 52 engages radially inner locator surfaces 42&#39; of ribs 42 for radial location between the bearing and pulley. 
     The bearing assembly is shown to include two bearings therein, spaced from each other by appropriate spacer means. More specifically, bearings 56a and 56b include outer races 58a and 58b inner races 60a and 60b, and a plurality of round, here cylindrical, roller bearing members 62a and 62b respectively. At the axial outer ends of bearing housing 52 is a pair of bearing seals 64a and 64b. Between the two bearings and adjacent the respective bearings is a retaining snap ring 66a to prevent axial inward movement of bearing 56a or axial inward movement of bearing 56b by force on spacer 90. Engaging the axial outer ends of the inner races is locating shoulder 16&#39; on retainer plate 16, and shoulder 14&#39; on shaft 14. 
     Retainer plate 16 contains two tangs 16a, approximately 80 degrees apart, which engage like slots in the end of the shaft for antirotation of plate 16. 
     Also positioned between the two bearings is spacer means in the form of a pair of polymeric spacer rings 70a and 70b engaging the inner races around the periphery of shaft 14 as well as sandwiching therebetween a wave type washer 72 which is resiliently compressible-expansible under axial force. This axial force can thus be preset to minimize rotation of the inner cones on the shaft during operation. 
     The spacer arrangement allows the axial spacing of the bearings to be exactly achieved as well as the desired axial force load to be effected. Specifically, by controlled tightening of socket head, self locking bolt 18 against cap 16 to axially shift bearing 56a toward bearing 56b, wave spring 72 is compressed until the desired bearing end play (e.g. about 0.002 inch) position is achieved and preferably a force load of about 100 pounds obtained. 
     Extending radially through housing 52 and into the annular space 80 between the bearings is a lubricant inlet passage 82 for lubrication of the bearing elements. Spacer rings 70a and 70b are tapered diagonally away from space 80 toward the individual bearings so that lubricant injected at 82 will flow freely to the roller elements of the rear bearing 60b first, then forward to front bearing 60a. This is initially injected before installing retainer plate 16. Moreover, rotation of the assembly will cause centrifugal force to drive the lubricant back toward the roller elements during operation because of the tapered corners of annular spacer 90 (FIG. 1) between the bearings. 
     In FIG. 6 is depicted a modified form of bearing which can be used with the novel assembly and pulley. In this instance, the bearing housing 152 has, as before, an annular outer mounting flange 154 and a generally cylindrical interior. However, the spacer means between the two bearing elements, here represented only by the outer races 158a and 158b, comprises a single polymeric ring 190 between and in engagement with the outer races. In this embodiment, lubricant inlet passage 182, shown to have a zerk fitting 183, communicates with a cutout 190&#39; in spacer 190, such cutout forming a cavity communicating with diagonally outwardly oriented passages 190&#34; oriented toward the bearings for optimum flow of lubricant thereto. A snap ring 166 retains the components in position. A pair of end seals 164a and 164b retain the lubricant. 
     It is conceivable that additional variations other than those specifically enumerated may be made to the apparatus, the preferred embodiment only of which is depicted and described in detail herein, without departing from the invention. Hence, it is intended that the invention is not to be limited to this disclosed embodiment, but only by the scope of the appended claims and the reasonable equivalents thereto.