Low-mass roller or pulley

A low-mass roller, comprising:

• first and second tubular shells formed of a thin metal and having substantially equal inside diameters at first respective ends thereof, said first respective ends of said first and second tubular shells joined in nested relationship over each side of a weld ring disposed between said first respective ends and welded thereto to form a single cylindrical outer shell of said low-mass roller, said outer shell defining a longitudinal axis therethrough;
• a continuous body, molded of polymeric material in situ within said outer shell, defining a tubular space therethrough for receiving an axle therewithin and along said longitudinal axids;
• wherein each said first and second tubular shell includes a respective second end opposite said first respective end such that an inward-extending lip formed in each said second respective end of said first and second tubular shells defines a circular alignment opening with at least a portion of the interior surface of each said first and second tubular shell having a positive slope from said second end to said first end with respect to the longitudinal axis;
• and
• said first and second tubular shells are assembled after formation of said continuous body.

A low-mass roller, comprising:

• first and second tubular shells formed of a thin metal and having substantially equal inside diameters at first respective ends thereof;
• a weld ring formed of said thin metal and having an outer diameter dimensioned to allow nesting of a portion of said weld ring within each said first respective end of said first and second tubular shells when said shells are assembled on and welded to said weld ring to form a single cylindrical outer shell of said low-mass roller, said outer shell defining a longitudinal axis therethrough;
• and
• a continuous body defining a tubular space for receiving an axle along said longitudinal axis, said continuous body molded of a polymeric material in situ within said outer shell and substantially conformal therewith, and having and outer diameter that increases from the distal end inward and having on at least a portion of the exterior surface thereof a positive slope with respect to the longitudinal axis.

A low-mass roller, comprising:

• a cylindrical body having an exterior surface, first and second open ends and defining an interior tubular space along a longitudinal axis therethrough for receiving an axle therein, said cylindrical body formed of polymeric material cylindical body having a diameter at said first and second ends that is smaller than a diameter thereof at at least one intermediate location along the longitudinal axis thereof with at least a portion of the exterior surface from the first end to the intermediate location and the second end to the intermediate location has a positive slope with respect to the longitudinal axis;
• and
• an outer shell formed of metal proximately and conformally covering said exterior surface of and having a formed circular opening surrounding each said first and second ends of said cylindrical body, wherein said cylindrical body, said outer shell and said circular openings are concentric with said longitudinal axis, said outer shell disposed about said cylindrical body after formation of said cylindrical body;
• wherein the outer shell further comprises an assembly of first and second thin-walled tubular shells having inside diameters, at first respective ends thereof, equal within a predetermined tolerance wherein said first respective ends are joined together and welded;
• wherein said assembly further comprises a weld ring having an outside diameter smaller than said inside diameters of each said first respective end of said first and second thin-walled tubular shells by a predetermined value, said weld ring disposed between and nested within said first respective ends of first and second thin-walled tubular shells such that said shells are held in alignment during said welding;
• wherein said weld ring further comprises a circular band having said outside diameter and having a circumferential ring disposed around said outside diameter of said circular band, said ring extending orthogonally from said band by a height greater by a predetermined distance than the thickness of said thin metal of said first and second thin-walled tubular shells.

A low-mass roller, comprising:

• a cylindrical body having an exterior surface, first and second open ends and defining an interior tubular space along a longitudinal axis therethrough for receiving an axle therein, said cylindrical body formed of polymeric material said cylindrical body having a diameter at said first and second ends that is smaller than a diameter thereof at least one intermediate location along the longitudinal axis thereof with at least a portion of the exterior surface from the first end to the intermediate location and the second end to the intermediate location has a positive slope with respect to the longitudinal axis;
• and
• an outer shell formed of metal proximately and conformally covering said exterior surface of and having a formed circular opening surrounding each said first and second ends of said cylindrical body, wherein said cylindrical body, said outer shell and said circular openings are concentric with said longitudinal axis, said outer shell disposed about said cylindrical body after formation of said cylindrical body;
• wherein said outer shell further comprises an assembly of first and second thin-walled tubular shells having inside diameters, at first respective ends thereof, equal within a predetermined tolerance wherein said first respective ends are joined together and welded;
• wherein said outer shell further comprises a weld ring having an outside diameter smaller than said inside diameters of each said first respective end of said first and second thin-walled tubular shells by a predetermined value, said weld ring disposed between and nested within said first respective ends of first and second thin-walled tubular shells such that said shells are held in alignment.

A low-mass roller, comprising:

• a cylindrical body having an exterior surface, first and second open ends and defining an interior tubular space along a longitudinal axis therethrough for receiving an axle therein, said cylindrical body formed of polymeric material said cylindrical body having a diameter at said first and second ends that is smaller than a diameter thereof at least one intermediate location along the longitudinal axis thereof with at least a portion of the exterior surface from the first end to the intermediate location and the second end to the intermediate location has a positive slope with respect to the longitudinal axis;
• and
• an outer shell formed of metal proximately and conformally covering said exterior surface of and having a formed circular opening surrounding each said first and second ends of said cylindrical body, wherein said cylindrical body, said outer shell and said circular openings are concentric with said longitudinal axis, said outer shell disposed about said cylindrical body after formation of said cylindrical body;
• wherein the outer shell further comprises an assembly of first and second thin-walled tubular shells having inside diameters, at first respective ends thereof, equal within a predetermined tolerance wherein said first respective ends are joined together and welded;
• wherein said assembly further comprises a weld ring having an outside diameter smaller than said inside diameters of each said first respective and of said first and second thin-walled tubular shells by a predetermined value, said weld ring disposed between and nested within said first respective ends of first and second thin-walled tubular shells such that said shells are held in alignment during said welding;
• wherein said weld ring further comprises a circular band having said outside diameter and having a circumferential ring disposed around said outside diameter of said circular band, said ring extending orthogonally from said band by a height greater by a predetermined distance than the thickness of said thin metal of said first and second thin-walled tubular shells;
• wherein said circular band is formed of the same thin metal as said first and second thin-walled tubular shells.

A low-mass roller, comprising:

• a cylindrical body having an exterior surface, first and second open ends and defining an interior tubular space along a longitudinal axis therethrough for receiving an axle therein, said cylindrical body formed of polymeric material said cylindrical body having a diameter at said first and second ends that is smaller than a diameter thereof at least one intermediate location along the longitudinal axis thereof with at least a portion of the exterior surface from the first end to the intermediate location and the second end to the intermediate location has a positive slope with respect to the longitudinal axis;
• and
• an outer shell formed of metal proximately and conformally covering said exterior surface of and having a formed circular opening surrounding each said first and second ends of said cylindrical body, wherein said cylindrical body, said outer shell and said circular openings are concentric with said longitudinal axis, said outer shell disposed about said cylindrical body after formation of said cylindrical body
• wherein said outer shell is formed by an assembly of drawn first and second thin-walled tubular shells having inside diameters, at first respective ends thereof, equal within a predetermined tolerance wherein said first respective ends are joined together and welded;
• wherein said assembly further comprises a weld ring having an outside diameter smaller than said inside diameters of each said first respective end of said first and second thin-walled tubular shells by a predetermined value, said weld ring disposed between and nested within said first respective ends of first and second thin-walled tubular shells such that said shells are held in alignment during said welding.

A low-mass roller, comprising;

• a cylindrical body having an exterior surface, first and second open ends and defining an interior tubular space along a longitudinal axis therethrough for receiving an axle therein, said cylindrical body formed of polymeric material said cylindrical body having a diameter at said first and second ends that is smaller than a diameter thereof at least one intermediate location along the longitudinal axis thereof with at least a portion of the exterior surface from the first end to the intermediate location and the second end to the intermediate location has a positive slope with respect to the longitudinal axis;
• and
• an outer shell formed of metal proximately and conformally covering said exterior surface of and having a formed circular opening surrounding each said first and second ends of said cylindrical body, wherein said cylindrical body, said outer shell and said circular openings are concentric with said longitudinal axis, said outer shell disposed about said cylindrical body after formation of said cylindrical body
• wherein said outer shell is formed by an assembly of drawn first and second thin-walled tubular shells having inside diameters, at first respective ends thereof, equal within a predetermined tolerance wherein said first respective ends we joined together and welded;
• wherein said assembly further comprises a weld ring having an outside diameter smaller than said inside diameters of each said first respective end of said first and second thin-walled tubular shells by a predetermined value, said weld ring disposed between and nested within said first respective ends of first and second thin-walled tubular shells such that said shells are held in alignment during said welding;
• wherein said weld ring further comprises a circular band having said outside diameter and having a circumferential ring disposed around said outside diameter of said circular band, said ring extending orthogonally from said band by a height greater by a predetermined distance than the thickness of said thin metal of said first and second thin-walled tubular shells.

A low-mass roller, comprising:

• a cylindrical body having an exterior surface, first and second open ends and defining an interior tubular space along a longitudinal axis therethrough for receiving an axle therein, said cylindrical body formed of polymeric material said cylindrical body having a diameter at said first and second ends that is smaller than a diameter thereof at least one intermediate location along the longitudinal axis thereof with at least a portion of the exterior surface from the first end to the intermediate location and the second end to the intermediate location has a positive slope with respect to the longitudinal axis and
• an outer shell formed of metal proximately and conformally covering said exterior surface of and having a formed circular opening surrounding each said first and second ends of said cylindrical body, wherein said cylindrical body, said outer shell and said circular openings are concentric with said longitudinal axis, said outer shell disposed about said cylindrical body after formation of said cylindrical body
• wherein said outer shell is formed by an assembly of drawn first and second thin-walled tubular shells having inside diameters, at first respective ends thereof, equal within a predetermined tolerance wherein said first respective ends are joined together and welded;
• wherein said assembly further comprises a weld ring having an outside diameter smaller than said inside diameters of each said first respective end of said first and second thin-walled tubular shells by a predetermined value, said weld ring disposed between and nested within said first respective ends of first and second thin-walled tubular shells such that said shells are held in alignment during said welding;
• wherein said weld ring further comprises a circular band formed of the same thin metal as said first and second thin-walled tubular shells.

A low-mass roller, comprising:

• a cylindrical body having an exterior surface, first and second open ends and defining an interior tubular space along a longitudinal axis therethrough for receiving an axle therein, said cylindrical body formed of polymeric material said cylindrical body having a diameter at said first and second ends that is smaller than a diameter thereof at least one intermediate location along the longitudinal axis thereof with at least a portion of the exterior surface from the first end to the intermediate location and the second end to the intermediate location has a positive slope with respect to the longitudinal axis;
• and
• an outer shell formed of metal proximately and conformally covering said exterior surface of and having a formed circular opening surrounding each said first and second ends of said cylindrical body, wherein said cylindrical body, said outer shell and said circular openings are concentric with said longitudinal axis, said outer shell disposed about said cylindrical body after formation of said cylindrical body;
• wherein said outer shell is formed by an assembly of stamped first and second thin-walled tubular shells having inside diameters, at first respective ends thereof, equal within a predetermined tolerance wherein said first respective ends are joined together and welded;
• wherein said assembly further comprises a weld ring having an outside diameter smaller than said inside diameters of each said first respective end of said first and second thin-walled tubular shells by a predetermined value, said weld ring disposed between and nested within said first respective ends of first and second thin-walled tubular shells such that said shells are held in alignment during said welding.

A low-mass roller, comprising:

• a cylindrical body having an exterior surface, first and second open ends and defining an interior tubular space along a longitudinal axis therethrough for receiving an axle therein, said cylindrical body formed of polymeric material said cylindrical body having a diameter at said first and second ends that is smaller than a diameter thereof at least one intermediate location along the longitudinal axis thereof with at least a portion of the exterior surface from the first end to the intermediate location and the second end to the intermediate location has a positive slope with respect to the longitudinal axis;
• and
• an outer shell formed of metal proximately and conformally covering said exterior surface of and having a formed circular opening surrounding each said first and second ends of said cylindrical body, wherein said cylindrical body, said outer shell and said circular openings are concentric with said longitudinal axis, said outer shell disposed about said cylindrical body after formation of said cylindrical body;
• wherein said outer shell is formed by an assembly of stamped first and second thin-walled tubular shells having inside diameters, at first respective ends thereof, equal within a predetermined tolerance wherein said first respective ends are joined together and welded;
• wherein said assembly further comprises weld ring having an outside diameter smaller than said inside diameters of each said first respective end of said first and second thin-walled tubular shells by a predetermined value, said weld ring disposed between and nested within said first respective ends of first and second thin-walled tubular shells such that said shells are held in alignment during said welding;
• wherein said weld ring further comprises a circular band having said outside diameter and having a circumferential ring disposed around said outside diameter of said circular band, said ring extending orthogonally from said band by a height greater by a predetermined distance than the thickness of said thin metal of said first and second thin-walled tubular shells.

A low-mass roller, comprising;

• a cylindrical body having an exterior surface, first and second open ends and defining an interior tubular space along a longitudinal axis therethrough for receiving an axle therein, said cylindrical body formed of polymeric material said cylindrical body having a diameter at said first and second ends that is smaller than a diameter thereof at least one intermediate location along the longitudinal axis thereof with at least a portion of the exterior surface from the first end to the intermediate location and the second end to the intermediate location has a positive slope with respect to the longitudinal axis;
• and
• an outer shell formed of metal proximately and conformally covering said exterior surface of and having a formed circular opening surrounding each said first and second ends of said cylindrical body, wherein said cylindrical body, said outer shell and said circular openings are concentric with said longitudinal axis, said outer shell disposed about said cylindrical body after formation of said cylindrical body;
• wherein said outer shell is formed by an assembly of stamped first end second thin-walled tubular shells having inside diameters, at first respective ends thereof, equal within a predetermined tolerance wherein said first respective ends are joined together and welded;
• wherein said assembly further comprises a weld ring having an outside diameter smaller than said inside diameters of each said first respective end of said first and second thin-walled tubular shells by a predetermined value, said weld ring disposed between and nested within said first respective ends of first and second thin-walled tubular shells such that said shells are held in alignment during said welding;
• wherein said weld ring further comprises a circular band formed of the same thin metal as said first and second thin-walled tubular shells.