# US 2018/0023679 A1 · Two-piece molded pulley having radial bearing distortion-reducing characteristics > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2018/0023679 A1 - Document ID: US20180023679A1 - Status: Published application - Kind: A1 - Application number: 15/216,837 - Filed: 2016-07-22 - Published: 2018-01-25 - Earliest claimed: 2016-07-22 - Assignees: Ford Global Technologies, LLC - Applicants: Ford Global Technologies, LLC - Inventors: Jim M. Basile; Scott Willis; Joseph Alan Skrobowski - Web page: https://patentgrep.com/patent/US20180023679A1 ## CPC - F16H 55/36: Pulleys (with features essential for adjustment F16H55/52) - F16C 19/06: with a single row or balls - F16C 33/586: {outside the space between the races, e.g. end faces or bore of inner ring} - F16C 35/067: Fixing them in a housing (with interposition of an element F16C35/07) - F16H 55/566: {only adjustable when pulley is stationary} - F16C 2361/00: Apparatus or articles in engineering in general - F16C 2361/63: Gears with belts and pulleys - F16H: GEARING - F16C: SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS ## 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. ## Claims ### Claim 1 A pulley for use with a pulley belt, the pulley comprising: a pulley main housing including a central axis, a pulley face having a periphery, a belt running surface extending perpendicularly from said periphery, and a bearing pocket formed in said face coaxial with said axis; a bearing disposed within said pocket; and an outer pulley shell attached to said pulley main housing, whereby said bearing is axially constrained between said housing and said shell. ### Claim 2 (depends on 1) The pulley for use with a pulley belt of claim 1, wherein said pulley main housing and said outer pulley shell are formed from a material selected from the group consisting of a molded polymerized material and a metal. ### Claim 3 (depends on 2) The pulley for use with a pulley belt of claim 2, wherein said pulley main housing and said outer pulley shell are attached by ultrasonic welding. ### Claim 4 (depends on 1) The pulley for use with a pulley belt of claim 1, wherein said bearing includes an inner race having a side wall and an outer race having a side wall. ### Claim 5 (depends on 4) The pulley for use with a pulley belt of claim 4, wherein at least one of said inner race and said outer race includes a raised surface formed on said side wall. ### Claim 6 (depends on 5) The pulley for use with a pulley belt of claim 5, wherein said raised surface is selected from the group consisting of knurling and raised dots. ### Claim 7 (depends on 1) The pulley for use with a pulley belt of claim 1, wherein each of said pulley main housing and said outer pulley shell includes a bearing shield that is positioned adjacent said bearing when assembled. ### Claim 8 A pulley for use with a pulley belt, the pulley comprising: a pulley main housing including a central axis, a pulley face having a periphery, a belt running surface extending perpendicularly from said periphery, and a bearing pocket formed in said face coaxial with said axis; a bearing disposed within said pocket, said bearing having a side wall having an axially raised surface; and an outer pulley shell attached to said pulley main housing. ### Claim 9 (depends on 8) The pulley for use with a pulley belt of claim 8, wherein said bearing is axially constrained between said housing and said shell. ### Claim 10 (depends on 9) The pulley for use with a pulley belt of claim 9, wherein said pulley main housing and said outer pulley shell are formed from a material selected from the group consisting of a molded polymerized material and a metal. ### Claim 11 (depends on 10) The pulley for use with a pulley belt of claim 10, wherein said pulley main housing and said outer pulley shell are attached by ultrasonic welding. ### Claim 12 (depends on 8) The pulley for use with a pulley belt of claim 8, wherein said bearing includes an inner race having a side wall and an outer race having a side wall. ### Claim 13 (depends on 12) The pulley for use with a pulley belt of claim 12, wherein at least one of said inner race and said outer race includes a raised surface formed on said side wall. ### Claim 14 (depends on 13) The pulley for use with a pulley belt of claim 13, wherein said raised surface is selected from the group consisting of knurling and raised dots. ### Claim 15 (depends on 8) The pulley for use with a pulley belt of claim 8, wherein each of said pulley main housing and said outer pulley shell includes a bearing shield that is positioned adjacent said bearing when assembled. ### Claim 16 A method for forming a pulley for use with a pulley belt, the method comprising the steps of: forming a pulley main housing having a bearing pocket and an outer pulley shell, inserting a bearing into said bearing pocket, said bearing having a side wall with a raised surface; positioning said shell over said housing; and welding said shell and said housing together, whereby said bearing is axially constrained between said housing and said shell. ### Claim 17 (depends on 16) The method for forming a pulley for use with a pulley belt of claim 16, whereby, upon assembly, said raised surface of said bearing axially grips said pulley main housing and said outer pulley shell. ### Claim 18 (depends on 16) The method for forming a pulley for use with a pulley belt of claim 16, wherein said raised surface is selected from the group consisting of knurling and raised dots. ### Claim 19 (depends on 16) The method for forming a pulley for use with a pulley belt of claim 16, wherein said pulley main housing and said outer pulley shell are a molded polymerized material. ### Claim 20 (depends on 19) The method for forming a pulley for use with a pulley belt of claim 19, wherein said step of welding is ultrasonic welding.