Belt drive

Abstract

A kit for a drive system includes a wheel and a belt. The wheel includes a first flange, a second flange and a circumferential groove therebetween with first and second interior surfaces revolved around an axial centerline. A number of protrusions are formed on the first and second interior surfaces. The belt includes an outer surface extending along a length and having a first width. First and second side surfaces of the belt extend from the outer surface along the length. Between the first and second side surfaces, an inner surface extends along the length and has a second width. A number of sockets are formed in the first and second side surfaces along the length. A drive system includes a wheel and a belt having one or more sockets in receipt of one or more protrusions of the wheel.

Description

BELT DRIVESUMMARY[OOOIJThe disclosure describes a drive system. The drive system includes a wheel and a belt. The wheel includes a first flange, a second flange and a circumferential groove therebetween having first and second interior surfaces revolved around an axial centerline. A number of protrusions are formed on at least one of the first and second interior surfaces. The belt includes an outer surface extending along a length and having a first width. First and second side surfaces extend from the outer surface along the length. Between the first and second surfaces, an inner surface extends along the length and has a second width. Formed in at least one of the first and second side surfaces along the length, a number of sockets are in receipt of a subset of the protrusions.

[0002] The disclosure also describes kit for a drive system. The kit includes a wheel and a belt. The wheel includes a first flange and a second flange joined to the first flange to form a circumferential groove therebetween with first and second interior surfaces revolved around an axial centerline. A number of male engagement members are formed on the first and second interior surfaces. The belt includes an outer surface extending along a length and having a first width. First and second side surfaces extend from the outer surface along the length. Between the first and second side surfaces, an inner surface extends along the length and has a second width. A number of female engagement members are formed in the first and second side surfaces along the length.

[0003] Further, the disclosure describes a wheel. The wheel includes a first flange and a second flange joined to the first flange to form a circumferential groove therebetween having first and second interior surfaces revolved around an axial centerline. A number of protrusions are formed on the first and second interior surfaces.

[0004] Further still, the disclosure describes a belt. The belt includes an outer surface extending along a length of the belt and having a first width, first and second side surfaces projecting from the outer surface and extending along the length and, between the first and second surfaces, an inner surface extending along the lengthand having a second width. A number of sockets are formed in the first and second side surfaces along the length.

[0005] Further still, the disclosure describes a method for manufacturing a V-belt pulley kit. The method includes injecting a construction material into a first mold, allowing the construction material to harden, removing, from the first mold, a produced wheel having a groove separating first and second flanges. A layer of construction material is provided into a ring mold, pressure is applied, the providing and applying are repeated and a belt is removed from the mold.

[0006] Further still, the disclosure describes a method for manufacturing a V-belt pulley. The method includes stamping first and second dishes out of metal, fastening the first and second dishes together to form flanges and a groove therebetween having first and second interior surfaces configured to contact or mate with first and second side surfaces of a belt and forming a plurality of protrusions on the first and second interior surfaces.BRIEF DESCRIPTION OF THE FIGURES

[0007] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, example constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those of skill in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.

[0008] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:

[0009] FIG. 1 illustrates a perspective view of an example drive assembly.

[0010] FIG.2 illustrates a side view of an example wheel suitable for use in association with disclosed belts, drive systems and drive system kits.

[0011] FIG. 3 illustrates a front view of the example wheel of FIG. 2.

[0012] FIG. 4 illustrates a perspective view of the example wheel of FIGS.2 & 3.

[0013] FIG.5 illustrates a side view of a segment of an example belt suitable for use in association with disclosed wheels, drive systems and drive system kits.

[0014] FIG. 6 illustrates a bottom or inside view of a segment of the example belt of FIG. 5.

[0015] FIG. 7 illustrates a first sectional view of the example belt of FIGS 5 & 6 taken along the plane A-A of FIG.5.

[0016] FIG.8 illustrates a second sectional view of the example belt of FIGS.5-7 taken along the plane B-B of FIG.5.

[0017] FIG. 9 illustrates a side view of a segment of another example belt suitable for use in association with disclosed wheels, drive systems and drive system kits.

[0018] FIG. 10 illustrates a bottom or inside view of a segment of the example belt of FIG. 9.

[0019] FIG.11 illustrates a first sectional view of the example belt of FIGS.9 & 10 taken along the plane C-C of FIG.9.

[0020] FIG. 12 illustrates a second sectional view of the example belt of FIGS. 9-11 taken along the plane D-D of FIG. 9.

[0021] FIG. 13 illustrates a perspective view of another example drive assembly.

[0022] FIG. 14 illustrates a front view of yet another example wheel.

[0023] FIG. 15 illustrates a perspective view of the example wheel of FIG. 14.

[0024] FIG. 16 illustrates a detailed view of protrusions of the example wheel of FIGS.14 & 15.

[0025] FIG. 17 illustrates a perspective view of yet another example drive assembly.

[0026] FIG. 18 illustrates a front view of yet another example wheel.

[0027] FIG. 19 illustrates a side view of a segment of an example belt suitable for use in association with disclosed wheels, drive systems and drive system kits and in particular with the wheel of FIG. 18 and the drive system of FIG. 17.

[0028] FIG. 20 illustrates a bottom or inside view of a segment of the example belt of FIG. 19.DETAILED DESCRIPTION

[0029] The following detailed description illustrates embodiments of the present disclosure and manners by which they can be implemented. Although the best mode of carrying out the present disclosure has been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.

[0030] It should be noted that the terms "first", "second", and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another. Further, the terms "a" and "an" herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

[0031] Known techniques for transferring power between pulleys are expensive or suffer from slippage between components.

[0032] Embodiments of the disclosure provide wheels, belts, drive systems and kits therefore and substantially eliminate, or at least partially address, problems in the prior art, enabling transfer of power between pulleys at a reduced cost and without slippage between components. Disclosed wheels, belts, drive systems and kits may find use in a variety of applications including but not limited to timing belt mechanisms or synchronous movement mechanisms.

[0033] Additional aspects, advantages, features and objects of the disclosure will be made apparent from the drawings and the detailed description of the illustrative embodiments construed in conjunction with the appended claims that follow.

[0034] It will be appreciated that features of the disclosure are susceptible to being combined in various combinations without departing from the scope of the disclosure as defined by the appended claims.

[0035] FIG. 1 illustrates a perspective view of an example drive assembly 100 which includes a wheel, pulley or sheave 110 and a belt 150.

[0036] FIGS. 2-4 illustrate features of an example wheel, pulley or sheave 110. Wheel 110 includes a first flange 111 and a second flange 112 joined to the first flange to form a circumferential groove 113 therebetween having first 114 and second 115 interior surfaces revolved around an axial centerline 116. While provided with first and second joined flanges, wheel 110 may be formed as two or more pieces coupled together oras a single integral unit. Supporting flanges 111 and 112 and extending therebetween, hub or web 119 has an axial centerline 116. Web 119 may include one or more openings at or near centerline 116 for coupling with a shaft to turn or to be turned by wheel 110.

[0037] First flange 111 includes a first outer edge distanced from axial centerline 116 by a first radius of curvature. Second flange 112 includes a second outer edge distanced from axial centerline 116 by a second radius of curvature and spaced from the first circular outer edge at least by groove 113. In an example, the two radii of curvature are equal.

[0038] The angle defined between the first 114 and second 115 interior surfaces of groove 113 may take any of a variety of measurements suitable for accommodating a belt having relatively angled side surfaces. First and second interior surfaces 114 and 115 may take any of a variety of profiles and may be continuous, near-continuous or disjoint where they come together at the centerline of groove 113 and may or may not have profiles that mirror one another.

[0039] Wheel 110 may take any of a variety of dimensions suitable for engaging with an associated belt including but not limited to customized dimensions, standardized dimensions and combinations of these. For example, wheel 110 may have a diameter of 7.0 in., a groove width of 0.637 in. at the top, a total groove height of 0.550 in. and an angle of 38 degrees between the first and second interior surfaces 114 and 115.

[0040] A number of projections, protuberances, posts, protrusions or other male engagement features 117 are formed on first and second interior surfaces 114 and 115. Protrusions 117 may be arranged at a fixed radius around axial centerline 116 or such that they are equidistant or approximately equidistant therefrom. Protrusions 117 may take any of a variety of shapes suitable for selectively engaging sockets of a belt. In an example, protrusions 117 are elongated in the radial direction (perpendicular to axial centerline 116). The height of protrusions 117 may extend any of a variety of suitable distances above the first and second interior surfaces 114 and 115 that enable engagement with sockets of a belt. In an example, protrusions 117 extend 0.0478 in. above the first and second interior surfaces 114 and 115.

[0041] Referring to FIGS 2-4, protrusions 117 formed on first interior surface 114 may be aligned with protrusions 117 formed in second interior surface 115. In an example,protrusions 117 are aligned such that lines exist which both connect centers of opposing protrusions and parallel axial centerline 116. In another example, protrusions 117 formed on first interior surface 114 may be offset or staggered from the protrusions 117 formed on second interior surface 115 such that no line both connecting centers of opposing protrusions 117 and paralleling axial centerline 116 exists.

[0042] Further, some protrusions 117 of first interior surface 114 may be aligned with some protrusions 117 of second interior surface 115 while other protrusions 117 of first interior surface 114 are offset or staggered from protrusions 117 of second interior surface 115. In yet another example, protrusions 117 may be omitted from one of interior surfaces 114 and 115.

[0043] Wheel 110 further includes one or more perforations or openings 118 formed through the first and second interior surfaces 114 and 115 of groove 113 to respective first and second exterior surfaces of the wheel. Openings 118 may be desirable for shedding debris such as wear debris, and, in biking or motorsports applications, dirt or mud. In an example, openings 118 are provided at a distance from axial centerline 116 of wheel 110 that is smaller than the radii at which protrusions 117 are provided. In another example, openings 118 are provided closer to the bottom, vertex or nadir of groove 113 than protrusions 117. Openings 118 may be formed to any of a variety of diameters suitable for shedding debris from groove 113. Referring to FIG. 2, while the number of openings 118 has been depicted as forty, any suitable number of openings may be provided to shed debris from groove 113.

[0044] While illustrated as a circular shape, in particular, at FIG. 2, wheel 110 may take any of a variety of shapes suitable for rotation while engaging a belt. Wheel 110 may be formed from any of a variety of rigid, durable, corrosion-resistant materials including but not limited to metals and composites. In an example, wheel 110 is formed from glass-filled nylon by injection molding.

[0045] FIGS. 5-8 illustrate features of an example belt 150 suitable for use in association with wheel 110. Belt 150 includes an outer surface 151 extending along a length and having a first width. First 152 and second 153 side surfaces extend from outer surface 151 along the length. Between the first and second side surfaces, an inner surface 154 extends along the length and has a second width. Belt 150 may further include a number of reinforcing cords 177 to increase tensile strength. Anynumber of reinforcing cords 177 may be provided to suitably increase the tensile strength of belt 150 for the intended application. The length of belt 150 may be fixed as with two ends or may be endless as with a loop. While a cross-section of belt 150 may take any of a variety of shapes tapering between outer surface 151 and inner surface 154, in the example of FIGS.8 & 9, cross-section may be generally trapezoidal as with a V-belt.

[0046] Belt 150 may take any of a variety of dimensions suitable for engaging with an associated wheel including but not limited to customized dimensions, standardized dimensions and combinations of these. For example, belt 150 has a width of 0.38 in. at outer surface 151 , a height of 0.31 in. between outer surface 151 and inner surface 154 and an angle of 38 degrees between first and second side surfaces 152 and 153. In another example, belt 150 has a width of 0.63 in. at outer surface 151 and a height of 0.53 in. between outer surface 151 and inner surface 154. In another example, belt 150 has a width of 1 .00 in. at outer surface 151 and a height of 0.88 in. between outer surface 151 and inner surface 154.

[0047] A series of notches, sockets or other female engagement features 155 are formed in first and second side surfaces 152 and 153 along the length. Sockets 155 may take any of a variety of shapes suitable for receiving protrusions of a wheel or pulley groove. In an example, sockets 155 are elongate. In another example, sockets 155 extend through inner surface 154 such that they are open on at least two sides: one side surface 152 or 153 and inner surface 154. In another example, each socket 155 extends into or through only one side surface 152 or 153 and inner surface 154 while remaining offset from outer surface 151 . In this way, the socket extends from inner surface 154 only partially along side surface 152 or 153 towards outer surface 151 and does not extend through or into outer surface 151. With sockets 155 offset from outer surface 151, reinforcing cords 157 may be preserved and / or uninterrupted so that strength provided to belt 150 by the reinforcing cords may be maintained.

[0048] The depth of sockets 155 may extend any of a variety of suitable distances into the first and second side surfaces 152 and 153 that enable engagement with protrusions 117 of wheel 110. In an example, the depth extends 0.0478 in. into the first and second side surfaces 152 and 153.

[0049] Referring to FIGS 6-8, sockets 155 formed in first side surface 152 may be aligned along the length with sockets 155 formed in second side surface 153. Alternatively, sockets 155 formed in first side surface 152 may be offset or staggered from sockets 155 formed in second side surface 153. This arrangement preserves more transverse cross-sectional area of the belt while providing for engagement with protrusions such as 117. Further, some sockets 155 of first side surface 152 may be aligned with some sockets 155 of second side surface 153 while other sockets 155 of first side surface 152 are offset or staggered from sockets 155 of second side surface 153. In yet another example, sockets 155 may be omitted from one of side surfaces 152 and 153.

[0050] The first and second interior surfaces 114 and 115 of groove 113 are configured to contact or mate with first and second side surfaces 152 and 153 of belt 150 to support the same within groove 113 and leaving a small space between belt inner surface 154 and the bottom, vertex or nadir of groove 113. In an example, this space has a triangular or near-triangular cross-section.

[0051] The spacing between the first and second outer edges of wheel 110 may be greater than the width of belt outer surface 151. Protrusions 117 of wheel 110 are configured to engage sockets 155 to yield a drive system 100 (FIG. 1). Protrusions 117 are configured for insertion into sockets 155 and sockets 155 are configured to receive protrusions 117. In an example, protrusions 117 are configured to slide in and out of open ends of sockets 155. During normal operation, a subset of protrusions 117 will engage a subset of sockets 155 in a given moment while wheel 110 rotates and progressively engages protrusions 117 with sockets 155 as belt 150 articulates around wheel 110. For example, approximately half of protrusions of a wheel may be engaged with less than half of the sockets of a belt.

[0052] In an example, the spacing between or pitch of sockets 155 matches spacing between or pitch of protrusions 117 such that the pitch between consecutive pairs of the sockets is approximately equal to the pitch between consecutive pairs of protrusions formed in first and second interior surfaces of wheel 110. In another example, the pitch between protrusions 117 is a rational multiple of pitch between sockets 155. For example, the pitch between protrusions 117 may be twice the pitch between sockets 175. Distance between consecutive sockets 155 and / or consecutive protrusions 117 may be decreased for higher torque applications. In another example,the pitch between protrusions 117 on respective first and second interior surfaces 114 and 115 matches the pitch between sockets 155 in respective first and second side surfaces 152 and 153.

[0053] FIGS. 9-12 illustrate features of another example belt 170 suitable for use in association with wheel 110. Belt 170 includes an outer surface 171 extending along a length and having a first width. First 172 and second 173 side surfaces extend from the outer surface along the length. Between the first and second side surfaces, an inner surface 174 extends along the length and has a second width. The length of belt 170 may be fixed as with two ends or may be endless as with a loop. While a crosssection of belt 170 may take any of a variety of shapes tapering between outer surface 171 and inner surface 174, in the example of FIGS. 11 & 12, cross-section may be generally trapezoidal as with a V-belt.

[0054] Belt 170 may take any of a variety of dimensions suitable for engaging with an associated wheel including but not limited to customized dimensions, standardized dimensions and combinations of these. For example, belt 170 has a width of 0.38 in. at outer surface 151 , a height of 0.31 in. between outer surface 171 and inner surface 174 and an angle of 38 degrees between first and second side surfaces 172 and 173. In another example, belt 170 has a width of 0.63 in. at outer surface 171 and a height of 0.53 in. between outer surface 171 and inner surface 174.

[0055] A series of notches, sockets or other female engagement features 175 are formed in the first and second side surfaces 172 and 173 along the length. Sockets 175 may take any of a variety of shapes suitable for receiving protrusions of a wheel or pulley groove. In an example, sockets 175 are elongate. In another example, sockets 175 extend through inner surface 174 such that they are open on at least two sides: one side surface 172 or 173 and inner surface 174. In another example, each socket 175 extends into or through only one side surface 172 or 173 and inner surface 174 while remaining offset from outer surface 171. In this way, the socket extends from inner surface 174 only partially along side surface 172 or 173 towards outer surface 171 and does not extend through or into outer surface 171. The depth of sockets 175 may extend any of a variety of suitable distances below first and second side surfaces 172 and 173 that enable engagement with protrusions 117 of wheel 110. For example, the depth may extend .0478 in. below first and second side surfaces 172 and 173.

[0056] Referring to FIGS 9-12, as with belt 150, sockets 175 formed in first side surface 172 may be aligned along the length with sockets 175 formed in the second side surface 173. Alternatively, sockets 175 formed in first side surface 172 may be offset or staggered from sockets 175 formed in the second side surface 172 to preserves more transverse cross-sectional area of the belt while providing for engagement with protrusions such as 117. Further, some sockets 175 of first side surface 172 may be aligned with some sockets 175 of second side surface 173 while other sockets 175 of first side surface 172 are offset or staggered from sockets 175 of second side surface 173. In yet another example, sockets 155 may be omitted from one of side surfaces 172 and 173.

[0057] Belt 170, further includes one or more cogs 176 formed at inner surface 174 enabling belt 170 to consistently engage a wheel having a relatively small diameter as compared with the belt thickness between outer surface 171 and inner surface 174.

[0058] First 172 and second 173 side surfaces of belt 170 are configured to contact or mate with first and second interior surfaces 114 and 115 of groove 113. The spacing between the first and second outer edges of wheel 110 may be greater than the width of belt outer surface 171. Protrusions 117 of wheel 110 are configured to engage sockets 175 to yield a drive system. In an example, protrusions 117 are configured to slide in and out of open ends of sockets 175. During normal operation, a subset of protrusions 117 will engage a subset of sockets 175 in a given moment while wheel 110 rotates and progressively engages protrusions 117 with sockets 175. For example, approximately half of the protrusions of a wheel may be engaged with less than half of the sockets of a belt.

[0059] In an example, the pitch between sockets 175 matches pitch between protrusions 117 such that the pitch between consecutive pairs of sockets 175 is approximately equal to pitch between consecutive pairs of protrusions 117 formed on first and second interior surfaces 114 and 115 of wheel 110. In another example, the pitch between protrusions 117 is a rational multiple of the pitch between sockets 175. For example, the pitch between protrusions 117 may be twice the pitch between sockets 175. Distance between consecutive sockets 175 and / or consecutive protrusions 117 may be decreased for higher torque applications. In another example, the pitch between protrusions 117 on respective first and second interior surfaces 114and 115 matches pitch between sockets 175 in respective first and second side surfaces 172 and 173.

[0060] Belts 150 and / or 170 may be formed from any of a variety of flexible yet durable, materials including but not limited to rubbers and plastics.

[0061] Drive system 100 has been described with belt 150 or 170 received in groove 113 of wheel 110 such that protrusions 117 are engaged sockets 155 or 175. However, drive system 100 may alternatively be provided as a kit including one or more wheels 110, one or more belts 150 and / or 170 with one or more other components, such as one or more tensioners, all mutually disengaged and / or disassembled. Further, wheel 110 may be suitable for use with belts other than belts 150 and 170 and belts 150 and 170 may be suitable for use with wheels other than wheel 110.

[0062] FIG. 13 illustrates a perspective view of another example drive assembly 200 including a belt 250 and another example wheel, pulley or sheave 210. Belt 250 of drive assembly 200 may be equivalent to or have the same or similar features to those of cogless belt 150 and / or cogged belt 170 and may or may not include cogs.

[0063] FIGS. 14 & 15 illustrate features of wheel 210 which includes a first flange 211 and a second flange 212 joined to the first flange to form a circumferential groove 213 therebetween having first 214 and second 215 interior surfaces revolved around an axial centerline 216. While provided with first and second joined flanges 211 and 212, wheel 210 may be formed as two or more pieces coupled together or as a single integral unit. Supporting flanges 211 and 212 and extending therebetween, hub or web 219 has an axial centerline 216. Web 219 may include one or more openings at or near centerline 216 for coupling with a shaft to turn or to be turned by wheel 210.

[0064] First flange 211 includes a first outer edge distanced from axial centerline 216 by a first radius of curvature. Second flange 212 includes a second outer edge distanced from axial centerline 216 by a second radius of curvature and spaced from the first circular outer edge at least by groove 213. In an example, the two radii of curvature are equal.

[0065] The angle defined between first 214 and second 215 interior surfaces of groove 213 may take any of a variety of measurements suitable for accommodating a belt having relatively angled side surfaces. First and second interior surfaces 214 and 215 may take any of a variety of profiles and may be continuous, near-continuous or disjointwhere they come together at the centerline of groove 213 and may or may not have profiles that mirror one another.

[0066] Wheel 210 may take any of a variety of dimensions suitable for engaging with an associated belt including but not limited to customized dimensions, standardized dimensions and combinations of these. For example, wheel 210 may have a diameter of 7.0 in., a groove width of 0.637 in. at the top, a total groove height of 0.550 in. and an angle of 38 degrees between the first and second interior surfaces 214 and 215.

[0067] Projections, protuberances, posts, protrusions or other male engagement features 217 are formed on first and second interior surfaces 214 and 215. Protrusions 217 may be arranged at a fixed radius around axial centerline 216 or such that they are equidistant or approximately equidistant therefrom.

[0068] Consistent with wheel 110, protrusions 217 formed on first interior surface 214 of wheel 210 may be aligned with protrusions 217 formed in second interior surface 215. Alternatively, protrusions 217 are aligned such that a line connecting centers of the protrusions parallels axial centerline 216. In another example, protrusions 217 formed on first interior surface 214 may be offset or staggered from the protrusions 217 formed on second interior surface 215 such that a line connecting centers of protrusions 217 forms an angle with axial centerline 216. Further, some protrusions 217 of first interior surface 214 may be aligned with some protrusions 217 of second interior surface 215 while other protrusions 217 of first interior surface 214 are offset or staggered from protrusions 217 of second interior surface 215. In yet another example, protrusions 217 may be omitted from one of interior surfaces 214 and 215.

[0069] Protrusions 217 may take a shape suitable for selectively engaging sockets of a belt but different from protrusions 117. In an example, protrusions 217 are elongated in the radial direction (perpendicular to axial centerline 216). Referring to the detailed view of FIG. 16, each protrusion 217 may take a trapezoidal shape. Further, each protrusion may have a length extending in the radial direction from an inner end to an outer end and a width perpendicular thereto which is greater at the outer end than at the inner end. In an example, the width of each protrusion tapers from the outer end towards the inner end.

[0070] In use with a belt, the wider outer end of the trapezoid may be aligned with the outer surface of the belt and the narrower inner end of the trapezoid may be alignedwith the bottom of the belt. A trapezoidal shaped protrusion may prevent interference between the protrusion and corresponding female engagement feature as belt engagement begins. Resistance to the compression of the belt inner surface, an effect which increases with decreasing wheel size, may be reduced or eliminated. Further, collision of the protrusion with the belt inner surface or side surfaces may be avoided. The sides of the trapezoid spanning the inner and outer ends may be shaped to provide for maximally uniform force on the power-transmitting side of the protrusions. In an example, the shape of the sides is non-linear.

[0071] The height of protrusions 217 may extend any of a variety of suitable distances above the first and second interior surfaces 214 and 215 that enable engagement with sockets of a belt. In an example, the protrusions extend 0.0478 in. above the first and second interior surfaces 214 and 215. Each protrusion may have a height perpendicular to the length and width which is constant or monotonic and / or does not taper, increase or decrease with the radial length. Alternatively, the height may decrease towards axial centerline 216.

[0072] As with wheel 110, wheel 210 may include one or more perforations or openings formed through the first and second interior surfaces 214 and 215 of groove 213 to respective first and second exterior surfaces of the wheel which may be desirable for shedding debris such as wear debris, and, in biking or motorsports applications, dirt or mud.

[0073] FIG. 17 illustrates a perspective view of yet another example drive assembly 300 including a wheel, pulley or sheave 310 and a belt 350.

[0074] FIG. 18 illustrates features of wheel 310. As with wheels 110, and 210, wheel 310 includes a first flange 311 and a second flange 312 joined to the first flange to form a circumferential groove 313 therebetween having first 314 and second 315 interior surfaces revolved around an axial centerline 316. Wheel 310 may be formed as two or more pieces coupled together or as a single integral unit. Supporting flanges 311 and 312 and extending therebetween, hub or web 319 has an axial centerline 316. Web 319 may include one or more openings at or near centerline 316 for coupling with a shaft to turn or to be turned by wheel 310.

[0075] First flange 311 includes a first outer edge distanced from axial centerline 316 by a first radius of curvature. Second flange 312 includes a second outer edgedistanced from axial centerline 316 by a second radius of curvature and spaced from the first circular outer edge at least by groove 313. The two radii of curvature may be equal.

[0076] The angle defined between the first 314 and second 315 interior surfaces of groove 313 may take any of a variety of measurements suitable for accommodating a belt having relatively angled side surfaces. First and second interior surfaces 314 and 315 may take any of a variety of profiles and may be continuous, near-continuous or disjoint where they come together at the centerline of groove 313 and may or may not have profiles that mirror one another.

[0077] Wheel 310 may take any of a variety of dimensions suitable for engaging with an associated belt including but not limited to customized dimensions, standardized dimensions and combinations of these. For example, wheel 310 may have a diameter of 7.0 in., a groove width of 0.637 in. at the top, a total groove height of 0.550 in. and an angle of 38 degrees between the first and second interior surfaces 314 and 315.[0078JA number of projections, protuberances, posts, protrusions or other male engagement features 317 are formed on first and second interior surfaces 314 and 315. Protrusions 317 may be arranged at a fixed radius around axial centerline 316 or such that they are equidistant or approximately equidistant therefrom. Protrusions 317 may take any of a variety of shapes suitable for selectively engaging sockets of a belt. In an example, protrusions 317 are circular domes. The height of protrusions 317 may extend any of a variety of suitable distances above the first and second interior surfaces 314 and 315 that enable engagement with sockets of a belt. In an example, the protrusions extend 0.0478 in. above the first and second interior surfaces 314 and 315.

[0079] Referring to FIG 18, protrusions 317 formed on first interior surface 314 may be offset or staggered from the protrusions 317 formed on second interior surface 315 such that a line connecting centers of protrusions 317 forms an angle with axial centerline 316.

[0080] As with wheel 110, wheel 310 may include one or more perforations or openings formed through the first and second interior surfaces 314 and 315 of groove 313 to respective first and second exterior surfaces of the wheel which may be desirable forshedding debris such as wear debris, and, in biking or motorsports applications, dirt or mud.

[0081] While illustrated as a circular shape, in particular, at FIG. 17, wheel 310 may take any of a variety of shapes suitable for rotation while engaging a belt. Wheel 310 may also be formed from any of a variety of rigid, durable, corrosion-resistant materials including but not limited to metals and composites. In an example, wheel 310 is formed from glass-filled nylon by injection molding.

[0082] FIGS. 19 & 20 illustrate features of an example belt 350 suitable for use in association with wheel 310. Belt 350 includes an outer surface 351 extending along a length and having a first width. First 352 and second 353 side surfaces extend from outer surface 351 along the length. Between first and second side surfaces 352 and 353, an inner surface 354 extends along the length and has a second width. The length of belt 350 may be fixed as with two ends or may be endless as with a loop. While a cross-section of belt 350 may take any of a variety of shapes tapering between outer surface 351 and inner surface 354, in an example, a cross-section may be generally trapezoidal as with the belts 150, 170 as shown in FIGS. 7, 8, 11 & 12.

[0083] Belt 350 may take any of a variety of dimensions suitable for engaging with an associated wheel including but not limited to customized dimensions, standardized dimensions and combinations of these. For example, belt 350 has a width of 0.38 in. at outer surface 351 , a height of 0.31 in. between outer surface 351 and inner surface 354 and an angle of 38 degrees between first and second side surfaces 352 and 353. In another example, belt 350 has a width of 0.63 in. at outer surface 351 and a height of 0.53 in. between outer surface 351 and inner surface 354. In another example, belt 350 has a width of 1 .00 in. at outer surface 351 and a height of 0.88 in. between outer surface 351 and inner surface 354.

[0084] A series of notches, sockets or other female engagement features 355 are formed in first and second side surfaces 352 and 353 along the length. Sockets 355 may take any of a variety of shapes suitable for receiving protrusions of a wheel or pulley groove. In an example, sockets are 355 elongate. In another example, sockets 355 extend through inner surface 354 such that they are open on at least two sides: one side surface 352 or 353 and inner surface 354. In another example, each socket 355 extends into or through only one side surface 352 or 353 and inner surface 354while remaining offset from outer surface 351 . In this way, the socket extends from inner surface 354 only partially along side surface 352 or 353 towards outer surface 351 and does not extend through or into outer surface 351 . The depth of sockets 355 may extend any of a variety of suitable distances into the first and second side surfaces 352 and 353 that enable engagement with protrusions 317 of wheel 310. In an example, the depth extends 0.0478 in. into the first and second side surfaces 352 and 353. Referring to FIG. 20, sockets 355 formed in first side surface 352 may be offset or staggered from sockets 355 formed in second side surface 353. Belt 350 may be formed from any of a variety of flexible yet durable, materials including but not limited to rubbers and plastics.

[0085] The first and second interior surfaces 314 and 315 of groove 313 are configured to contact or mate with first and second side surfaces 352 and 353 of belt 350 to support the same within groove 313 and leaving a small space between belt inner surface 354 and the bottom, vertex or nadir of groove 313. In an example, this space has a triangular or near-triangular cross-section. Belt 350 may further include one or more cogs similar to those of belt 170 enabling belt 350 to consistently engage a wheel having a relatively small diameter as compared with the belt thickness.

[0086] The spacing between the first and second outer edges of wheel 310 may be greater than the width of belt outer surface 351. Protrusions 317 of wheel 310 are configured to engage sockets 355 to yield a drive system 300 (FIG. 17). Protrusions 317 are configured for insertion into sockets 355 and sockets 355 are configured to receive protrusions 317. In an example, protrusions 317 are configured to slide in and out of open ends of sockets 355. During normal operation, a subset of protrusions 317 will engage a subset of sockets 355 in a given moment while wheel 310 rotates and progressively engages protrusions 317 with sockets 355 as belt 350 articulates around wheel 310. For example, approximately half of protrusions of a wheel may be engaged with less than half of the sockets of a belt.

[0087] In an example, the pitch between sockets 355 matches pitch between protrusions 317 such that the pitch between consecutive pairs of the sockets is approximately equal to pitch between consecutive pairs of protrusions formed in first and second interior surfaces of wheel 310. In another example, the pitch between protrusions 317 is a rational multiple of pitch between sockets 355. For example, the pitch between protrusions 317 may be twice the pitch between sockets 375. Distancebetween consecutive sockets 355 and / or consecutive protrusions 317 may be decreased for higher torque applications. In another example, the pitch between protrusions 317 on respective first and second interior surfaces 314 and 315 matches the pitch between sockets 355 in respective first and second side surfaces 352 and 353.

[0088] Drive system 300 has been described with belt 350 received in groove 313 of wheel 310 such that protrusions 317 are engaged sockets 355. However, drive system 300 may alternatively be provided as a kit including wheel 310, belt 350 with one or more other components all mutually disengaged and / or disassembled. Further, wheel 310 may be suitable for use with belts other than belt 350 and belt 350 may be suitable for use with wheels other than wheel 310.

[0089] While wheels 110, 210 and 310 have been disclosed as having male engaging feature and belts 150, 170, 250 and 350 have been disclosed as having a female engagement feature, in other examples, the engagement feature of the wheel is female and the engagement feature of the belt is male or each of the wheel and belt include a plurality of engagement feature types such as both male and female. In another alternative, male engaging features on wheels 110, 210 and 210 may be rectangular with a consistent width while female engaging features in belts 150, 170, 250 and 250 may be trapezoidal to achieve the interference avoidance mentioned above with regard to protrusions 217.

[0090] Disclosed belts, drive systems and drive system kits may be manufactured according to any of a variety of manufacturing methods, processes and / or techniques. An example method includes joining or fastening together first and second dishes to yield a wheel, forming a number of protrusions and producing a belt with a number of sockets.

[0091] The first and second dishes may be provided in any of a variety of ways. In an example, the first and second dishes are stamped out of metal. The first and second dishes are fastened together to form flanges and a groove therebetween having first and second interior surfaces configured to contact or mate with first and second side surfaces of the belt. The first and second dishes may be fastened together so as to space first and second outer edges to a distance greater than the width of the beltouter surface. In an example the first and second dishes are fastened together by welding or mechanical coupling.

[0092] The protrusions are formed on the first and second interior surfaces by any of a variety of methods. In an example, the protrusions are additions coupled with the first and second interior surfaces. In another example, the protrusions are formed by bending, manipulating or pressing the material of the dishes such as when constructed from metal. The protrusions may be formed equidistant from the axial centerline of the pulley.

[0093] The belt is produced with a first outer surface extending along a length of the belt and having a width, first and second side surfaces projecting from the first outer surface along and extending along the length and a number of sockets formed in the first and second side surfaces along the length. In an example, the belt may be produced by pouring a construction material into a mold, allowing the construction material to harden and removing the produced belt from the mold with sockets and / or cogs in place. In another example, the belt may be produced by pouring a construction material into a mold, allowing the construction material to harden, removing the produced belt from the mold and removing regions of the hardened construction material to form the sockets and / or cogs. In another example, the belt may be produced by ring molding of materials in a number layer and pressure applications. Features may be provided to the ring molds to form the female engagement members or sockets in the belt.

[0094] According to another example manufacturing method, the first and second dishes are joined together in a split pulley technique, protrusions are formed and a belt is provided. The belt may be provided by any of a variety of methods such as molding to include a first outer surface extending along a length of the belt and having a width, first and second side surfaces projecting from the first outer surface and extending along the length and a number of sockets formed in the first and second side surfaces along the length.

[0095] According to yet another example manufacturing method, a wheel or pulley having a groove separating first and second flanges may be formed with protrusions by injection molding. In a further example, molding employs a plurality of slides to form the individual protrusions. A belt is provided for use with the wheel or pulley forexample by molding to yield a first outer surface extending along a length of the belt and having a width, first and second side surfaces projecting from the first outer surface and extending along the length and a number of sockets formed in the first and second side surfaces along the length.

[0096] According to yet another example manufacturing method, a wheel or pulley having a groove separating first and second flanges may be formed without protrusions by split steel fabrication. Protrusions are added by a rotary process at an angle of attachment normal to the first and second interior walls of the groove.[0097JA belt is provided for use with the wheel or pulley for example by molding to yield a first outer surface extending along a length of the belt and having a width, first and second side surfaces projecting from the first outer surface and extending along the length and a number of sockets formed in the first and second side surfaces along the length.

[0098] According to yet another example manufacturing method, a wheel or pulley having a groove separating first and second flanges may be formed either with or without protrusions by 3D printing. A belt is provided for use with the wheel or pulley for example by molding to yield a first outer surface extending along a length of the belt and having a width, first and second side surfaces projecting from the first outer surface and extending along the length and a number of sockets formed in the first and second side surfaces along the length.

[0099] Disclosed belts, drive systems and drive system kits may be suitable for use in any of a variety of power transmission or transfer methods. In an example method of use, a first shaft coupled with a first wheel rotates causing the first wheel to rotate and articulate a belt partially wrapping the first wheel along and around the first wheel. The belt, as pulled by the first wheel, may then articulate on a second wheel which is caused to rotate by the articulation. Rotation of the second wheel may thereby rotate a second shaft so that power is transmitted or transferred between the first shaft and the second shaft.

[0100] In another example, a first pulley is rotated by a bicyclist turning a pair of pedals causing a belt partially wrapping the first pulley to articulate along and around the first pulley. The belt, as pulled by the first pulley, may then articulate on a second pulley which is caused to rotate by the articulation. Turning of the second pulley may therebyrotate a bicycle riding wheel shaft so that power is transmitted or transferred between the pedals and the riding wheel to rotate the same to drive the bicycle along a riding surface.

[0101] In yet another example, an electric bike includes a front gearbox drive motor which rotates a first pulley causing a belt partially wrapping the first pulley to articulate along and around the first pulley. The belt, as pulled by the first pulley may then articulate on a second pulley which is caused to rotate by the articulation. The second pulley may be coupled with the rear riding wheel of the bicycle to rotate the same to drive the bicycle along a riding surface.

[0102] Embodiments of the disclosure are susceptible to being used for various purposes, including, though not limited to, enabling users to transfer power, torque and / or motion between an axle or shaft and a belt without loss or slippage. Disclosed wheels, belts and drive systems may enable operation with less belt tension as a result of positive coupling between respective engagement members of the wheel and belt.

[0103] Modifications to embodiments of the disclosure described in the foregoing are possible without departing from the scope of the disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “consisting of”, “have”, “is” used to describe and claim the disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural.

Claims

CLAIMSWhat is claimed is:1 . A drive system, comprising:a wheel including:a first flange;a second flange;having first and second interior surfaces revolved around an axial centerline, a circumferential groove between the first and second flanges; and a plurality of protrusions formed on at least one of the first and second interior surfaces;a belt including:an outer surface extending along a length and having a first width; first and second side surfaces extending from the outer surface along the length;between the first and second surfaces, an inner surface extending along the length and having a second width; andformed in at least one of the first and second side surfaces along the length, a plurality of sockets in receipt of a subset of the protrusions.

2. The system as set forth in claim 1 , wherein the sockets formed in the first side surface are aligned along the length with the sockets formed in the second side surface.

3. The system as set forth in claim 1 , wherein the sockets formed in the first side surface are offset along the length from the sockets formed in the second side surface.

4. The system as set forth in claim 1 , wherein the sockets do not extend through the inner surface.

5. The system as set forth in claim 1 , wherein the sockets do not extend through the outer surface.

6. The system as set forth in claim 1 , wherein the sockets extend through neither the inner surface nor the outer surface.

7. The system as set forth in claim 1 , wherein the first and second interior surfaces of the groove contact the first and second side surfaces of the belt.

8. The system as set forth in claim 1 , wherein the wheel further includes one or more openings formed through the first and second interior surfaces of the groove to respective first and second exterior surfaces of the wheel.

9. The system as set forth in claim 1 , further comprising one or more cogs formed at the inner surface.

10. The system as set forth in claim 1 , wherein the protrusions each take a trapezoidal shape.11 . The system as set forth in claim 1 , wherein the protrusions each have a length extending in the radial direction from an inner end to an outer end and a width perpendicular thereto which is greater at the outer end than at the inner end.

12. The system as set forth in claim 11 , wherein the width tapers from the outer end towards the inner end.

13. The system as set forth in claim 11 , wherein the protrusions each have a height perpendicular to the length and width which does not taper with the length.

14. The system as set forth in claim 11 , wherein the protrusions each have a height perpendicular to the length and width which tapers with the length.

15. A kit for a drive system, comprising:a wheel including:a first flange;a second flange joined to the first flange to form a circumferential groove therebetween having first and second interior surfaces revolved around an axial centerline; anda plurality of male engagement members formed on the first and second interior surfaces;a belt including:an outer surface extending along a length and having a first width;first and second side surfaces extending from the outer surface along the length;between the first and second side surfaces, an inner surface extending along the length and having a second width; anda plurality of female engagement members formed in the first and second side surfaces along the length.

16. The kit as set forth in claim 15, wherein the female engagement members are configured to receive the male engagement members.

17. The kit as set forth in claim 15, wherein the male engagement members are configured to engage the female engagement members.

18. The kit as set forth in claim 15, wherein the male engagement members are configured to slide in and out of open ends of the female engagement members.

19. The kit as set forth in claim 15, wherein pitch of the male engagement members matches pitch of the female engagement members.

20. The kit as set forth in claim 15, wherein the male engagement members each take a trapezoidal shape.

21. The kit as set forth in claim 15, wherein the male engagement members each have a length extending in the radial direction from an inner end to an outer end and a width perpendicular thereto which is greater at the outer end than at the inner end.

22. The kit as set forth in claim 21, wherein the width tapers from the outer end towards the inner end.

23. The kit as set forth in claim 21 , wherein the male engagement members each have a height perpendicular to the length and width which does not taper with the length.

24. The kit as set forth in claim 15, wherein the sockets do not extend through the inner surface.

25. The kit as set forth in claim 15, wherein the sockets do not extend through the outer surface.

26. The kit as set forth in claim 15, wherein the sockets extend through neither the inner surface nor the outer surface.

27. The kit as set forth in claim 15, wherein the wheel further includes one or more openings formed through the first and second interior surfaces of the groove to respective first and second exterior surfaces of the wheel.

28. The kit as set forth in claim 15, further comprising one or more cogs formed at the inner surface of the belt.

29. A wheel including:a first flange;a second flange joined to the first flange to form a circumferential groove therebetween having first and second interior surfaces revolved around an axial centerline; anda plurality of protrusions formed on the first and second interior surfaces.

30. The wheel as set forth in claim 29, wherein the protrusions are configured to engage sockets formed in first and second side surfaces of a belt.

31. The wheel as set forth in claim 29, wherein the protrusions each take a trapezoidal shape.

32. The wheel as set forth in claim 29, wherein the protrusions each have a length extending in the radial direction from an inner end to an outer end and a width perpendicular thereto which is greater at the outer end than at the inner end.

33. The wheel as set forth in claim 32, wherein the width tapers from the outer end towards the inner end.

34. The wheel as set forth in claim 32, wherein the protrusions each have a height perpendicular to the length and width which does not taper with the length.

35. The wheel as set forth in claim 32, wherein the protrusions each have a height perpendicular to the length and width which tapers with the length.

36. The wheel as set forth in claim 29, further comprising one or more openings formed through the first and second interior surfaces of the groove to respective first and second exterior surfaces of the pulley.

37. A belt comprising:an outer surface extending along a length of the belt and having a first width;first and second side surfaces projecting from the outer surface and extending along the length;between the first and second surfaces, an inner surface extending along the length and having a second width; anda plurality of sockets formed in the first and second side surfaces along the length.

38. The belt as set forth in claim 37, wherein the sockets extend through the inner surface.

39. The belt as set forth in claim 37, wherein the sockets do not extend through the inner surface.

40. The belt as set forth in claim 37, wherein the sockets do not extend through the outer surface.41 . The belt as set forth in claim 37, wherein the sockets extend through neither the inner surface nor the outer surface.

42. The belt as set forth in claim 37, wherein the sockets are configured to receive protrusions formed on the first and second interior surfaces of a groove of a pulley.

43. The belt as set forth in claim 37, further comprising one or more cogs formed at the inner surface.

44. A method for manufacturing a V-belt pulley kit, comprising:injecting a construction material into a first mold;allowing the construction material to harden; andremoving, from the first mold, a produced wheel having a groove separating first and second flanges;providing a layer of construction material into a ring mold;applying pressure;repeating the providing and applying; andremoving a produced belt from the mold.

45. The method as set forth in claim 44, wherein removing the produced wheel further comprises translating a number of slides from protrusions formed on the wheel first and second flanges.

46. The method as set forth in claim 44, wherein removing the produced belt further comprises removing the produced belt with a number of sockets provided thereto.

47. The method as set forth in claim 44, further comprising removing regions of the hardened construction material to form a number of sockets.

48. A method for manufacturing a V-belt pulley, comprising:stamping first and second dishes out of metal;fastening the first and second dishes together to form flanges and a groove therebetween having first and second interior surfaces configured to contact or mate with first and second side surfaces of a belt; andforming a plurality of protrusions on the first and second interior surfaces.

49. The method as set forth in claim 48, wherein fastening the first and second dishes together further comprises fastening with a space between the first and second outer edges greater than a width of the belt outer surface between the first and second side surfaces.

50. The method as set forth in claim 48, wherein fastening together the first and second dishes further comprises fastening by welding.51 . The method as set forth in claim 48, wherein fastening together the first and second dishes further comprises fastening by mechanical coupling.

52. The method as set forth in claim 48, wherein forming the protrusions further comprises coupling the protrusions with the first and second interior surfaces.

53. The method as set forth in claim 48, wherein forming the protrusions further comprises manipulating material out of planes of the first and second dishes to form the protrusions.

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