Belt drive system

A self-aligning pulley and drive belt system comprising:

• a drive belt, the drive belt comprising a plurality of longitudinally spaced inner lugs each having a an alignment groove dividing the lug into first and second lug segments, the alignment groove having an alignment groove depth;
• and
• at least one pulley configured to engage the inner surface of the drive belt, the at least one pulley comprising:
• a frame configured to rotate about a rotation axis, the frame having a circular outer rim with opposing sides;
• a plurality of circumferential teeth extending radially and axially from the rim, each tooth having a tooth width parallel to the rotation axis, and each tooth being configured to be received between adjacent inner lugs of the drive belt;
• and
• an alignment flange extending radially between adjacent circumferential teeth, the alignment flange being configured to be received in the alignment groove, and the alignment flange extending radially an alignment flange distance that extends a distal end of the alignment flange into the alignment groove a distance no greater than the alignment groove depth.

A pulley and drive belt system for a bicycle, the bicycle comprising a crank set configured for attachment to a first pulley and a rear wheel hub configured for connection to a second pulley, the pulley and drive belt system comprising:

• a drive belt, the drive belt comprising a plurality of longitudinally spaced inner lugs each having a an alignment groove dividing each lug into first and second lug segments;
• a first pulley configured to engage the inner surface of the drive belt, the first pulley comprising:
• a frame configured for connection to the bicycle crank set for rotation about a rotation axis, the frame having a circular outer rim with opposing sides;
• a plurality of circumferential teeth extending radially and axially of the rim, the teeth extending axially a tooth width at least equal to a width of the drive belt, and each tooth being configured to be received between adjacent inner lugs of the drive belt;
• a second pulley configured to engage the inner surface of the drive belt, the second pulley comprising:
• a frame configured for connection to the bicycle wheel hub for rotation about a rotation axis, the frame having a circular outer rim with opposing sides;
• a plurality of circumferential teeth extending radially and axially of the rim, the teeth extending axially a tooth width at least equal to a width of the drive belt, and each tooth being configured to be received between adjacent inner lugs of the drive belt;
• and
• at least one of the first and second pulleys further comprising an alignment flange extending between adjacent circumferential teeth, the alignment flange being configured to be received in the alignment groove.

A bicycle comprising:

• a crank set;
• a rear wheel hub;
• and
• a pulley and drive belt system operatively associated with the crank set and the rear wheel hub, the pulley and drive belt system comprising:
• a drive belt, the drive belt comprising a plurality of longitudinally spaced inner lugs each having a an alignment groove dividing each lug into first and second lug segments;
• a first pulley configured to engage the inner surface of the drive belt, the first pulley comprising:
• a frame configured for connection to the bicycle crank set for rotation about a rotation axis, the frame having a circular outer rim with opposing sides;
• a plurality of circumferential teeth extending radially and axially of the rim, the teeth extending axially a tooth width at least equal to a width of the drive belt, and each tooth being configured to be received between adjacent inner lugs of the drive belt;
• a second pulley configured to engage the inner surface of the drive belt, the second pulley comprising:
• a frame configured for connection to the bicycle wheel hub for rotation about a rotation axis, the frame having a circular outer rim with opposing sides;
• a plurality of circumferential teeth extending radially and axially of the rim, the teeth extending axially a tooth width at least equal to a width of the drive belt, and each tooth being configured to be received between adjacent inner lugs of the drive belt;
• and
• at least one of the first and second pulleys further comprising an alignment flange extending between adjacent circumferential teeth, the alignment flange being configured to be received in the alignment groove.

A pulley for use with a drive belt, the drive belt comprising a plurality of longitudinally spaced inner lugs each having a an alignment groove dividing each lug into first and second lug segments, the pulley comprising:

• a frame configured to rotate about a rotation axis, the frame having a circular outer rim with opposing sides;
• a plurality of circumferential teeth extending radially and axially of the rim, each tooth having a tooth width at least equal to a width of the drive belt, and each tooth being configured to be received between adjacent inner lugs of the drive belt;
• and
• an alignment flange extending between adjacent circumferential teeth, the alignment flange being configured to be received in the alignment groove, the alignment flange extending radially no further than the circumferential teeth from the rotation axis.

A kit for a bicycle comprising at least two of the following belt and first and second pulleys:

• a drive belt, the drive belt comprising a plurality of longitudinally spaced inner lugs each having a an alignment groove dividing each lug into first and second lug segments, alignment groove having an alignment groove depth;
• and
• a first and a second pulley, each of the first and second pulleys being configured to engage an inner surface of the drive belt, at least one of the first and second pulleys comprising:
• a frame configured to rotate about a rotation axis, the frame having a circular outer rim with opposing sides;
• a plurality of circumferential teeth extending radially and axially of the rim, each tooth having a width parallel to the rotation axis, and each tooth being configured to be received between adjacent inner lugs of the drive belt;
• and
• an alignment flange extending radially between adjacent circumferential teeth, the alignment flange being configured to be received in the alignment groove, and the alignment flange extending no further radially than the circumferential teeth from the rotation axis, the circumferential teeth, the alignment flange and the alignment groove being configured so that with the alignment flange received in the alignment groove, the drive belt rides on the circumferential teeth.