Two-piece molded pulley having radial bearing distortion-reducing characteristics

Abstract

A two piece pulley is provided in which the pulley main housing and the outer pulley shell are molded without the bearing in place, thus eliminating an over-molding process. The pulley main housing is molded with a bear slip fit pocket. At least one of the bearing races of the bearing assembly includes an axially-protruding raised surface such as knurls or bumps. Each of the pulley main housing and the outer shell includes a bearing shield. On assembly, the bearing is slipped into the pocket on the pulley main housing and the outer shell is then ultrasonically welded to the main housing, thereby compressing the pulley material axially into the raised surface of the bearing race, locking the outer race of the bearing to the pulley in an axial direction. The raised surface on the bearing race allows the bearing assembly to grip the pulley in an axial direction.

Dependencies are inferred from the claim text.