High torque retention joint in a tensioner

Abstract

A method of manufacturing a tensioner ( 10 ) by mounting an end member ( 38 ) on an end of a hollow tensioner shaft ( 24 ) includes a step of providing an end member ( 38 ) of sheet material with an opening ( 76 ) having a plurality of annularly spaced inwardly extending pointed projections ( 78 ). A hollow shaft ( 24 ) has an outwardly extending shoulder ( 82 ) at an end portion thereof. A relative axial movement between the end member ( 38 ) and the hollow shaft ( 24 ) is effected so that the end member ( 38 ) abuts against the shoulder ( 82 ) of the hollow shaft ( 24 ). The hollow shaft ( 24 ) is deformed at the end portion radially outward to embed the projections ( 78 ) into the hollow shaft ( 24 ) to thereby form a joint ( 32 ) therebetween.

What is claimed is: 
     
       1. A tensioner comprising a fixed structure, a pivoting structure mounted on said fixed structure for pivotal movement about a pivotal axis, a pulley mounted on said pivoting structure for rotational movement about a rotational axis parallel to said pivotal axis, a spring operatively connected between said fixed structure and said pivoting structure resiliently biasing the pivoting structure in one direction, said fixed structure including a hollow shaft and an end member formed of sheet metal of predetermined thickness fixed to an end portion of said hollow shaft, said hollow shaft receiving a bolt for fixedly attaching the tensioner to a mounting structure, said end member engaging said mounting structure for regulating a position of said tensioner relative to said mounting structure,
 said end member including an opening having a plurality of annularly spaced inwardly extending pointed projections and a mounting knob positioned to engage within an associated mating recess of said mounting structure, 
 said end portion of said hollow shaft having an outwardly extending shoulder and a shaft end section adjacent said shoulder, said end portion including a circumferential groove formed in said shaft end section and positioned between said shoulder and said shaft end section, said circumferential groove having a first diameter and said shaft end section having a second diameter greater than said first diameter, said end member abutting against said shoulder, said end portion being deformed radially outwardly embedding the pointed projections into said hollow shaft, said circumferential groove providing a deformation path as said end portion of said hollow shaft deforms radially outwardly. 
 
     
     
       2. A tensioner as claimed in  claim 1  wherein said plurality of pointed projections each has a rounded edge facing said shoulder. 
     
     
       3. A tensioner as claimed in  claim 2  wherein said hollow shaft is deformed to occupy spaces between said plurality of pointed projections. 
     
     
       4. A tensioner as claimed in  claim 3  wherein said hollow shaft is deformed to overlap said end member and clamp said end member against said shoulder. 
     
     
       5. A tensioner as claimed in  claim 1  wherein said end member is hardened to be relatively harder than said hollow shaft. 
     
     
       6. A tensioner as claimed in  claim 1  wherein said hollow shaft has a hardness of between Rockwell B 65-85 and said end member has a hardness of between Rockwell C 36-46. 
     
     
       7. A tensioner comprising a fixed structure, a pivoting structure mounted on said fixed structure for pivotal movement about a pivotal axis, a drive member mounted on said pivoting structure for rotational movement about a rotational axis parallel to said pivotal axis, a spring operatively connected between said fixed structure and said pivoting structure resiliently biasing said pivoting structure in one direction, said fixed structure including a hollow shaft and an end member fixed to an end portion of said hollow shaft, said hollow shaft including a longitudinally extending aperture that is adapted for receiving a bolt for fixedly attaching the tensioner to a mounting structure, said end member engaging said mounting structure for regulating a position of said tensioner relative to said mounting structure,
 said end member including an opening,   said end portion of said hollow shaft having an outwardly extending shoulder and a shaft end section adjacent said shoulder, said end member abutting against said shoulder, said longitudinally extending aperture being deformed radially outwardly such that said hollow shaft is received in a radially outward direction into said opening,   wherein said drive member is adapted to support an endless power transmission element, and   wherein said longitudinally extending aperture includes a cylindrical portion and a frustoconical portion that diverges outwardly from said cylindrical portion,   wherein said opening of said end member includes a plurality of annularly spaced inwardly extending projections,   wherein said longitudinally extending aperture is deformed radially outwardly such that said hollow shaft is received in a radially outward direction into said inwardly extending projections,   wherein said end member includes a mounting knob that is adapted to engage within an associated mating recess in said mounting structure; and   wherein said end portion of said hollow shaft includes a circumferential groove formed in said shaft end section and positioned between said shoulder and said shaft end section, said circumferential groove having a first diameter and said shaft end section having a second diameter greater than said first diameter, said circumferential groove providing a deformation path as said end portion of said hollow shaft deforms radially outwardly.