| JPH03149445 | CONTINUOUSLY VARIABLE TRANSMISSION |
| WO/1981/003051 | TRACTION SURFACE COOLING SYSTEM FOR TORQUE TRANSMISSIONS |
SIMISTER MATTHEW P (US)
DAWE DANIEL J (US)
LOHR CHARLES B (US)
OBRZUT TIMOTHY M (US)
NICHOLS JON M (US)
SIMISTER MATTHEW P (US)
DAWE DANIEL J (US)
LOHR CHARLES B (US)
OBRZUT TIMOTHY M (US)
| WO1999020918A1 | 1999-04-29 |
| US2931235A | 1960-04-05 | |||
| US20050113202A1 | 2005-05-26 |
WHAT WE CLAIM IS:
1. A continuously variable transmission comprising: a plurality of balls arranged radially about a longitudinal axis, each ball configured to have a tiltable axis of rotation; a leg operably coupled to each of the balls, the leg configured to tilt the axis of rotation of the ball; a stator interfacial member slidingly coupled to the leg; and a stator support member coupled to the stator interfacial member.
2. The transmission of Claim 1, wherein the stator interfacial member comprises a plurality of guide slots arranged angularly about, and extending radially from the longitudinal axis.
3. A transmission comprising: a torque driver rotatable about a longitudinal axis, the torque driver configured to receive a power input; a torsion plate operably coupled to the torque driver, the torsion plate having a splined inner bore and a plurality of triangular extensions extending radially from the splined inner bore; a load cam ring operably coupled to the torsion plate; a load cam roller retainer assembly operably coupled to the load cam ring; a traction ring operably coupled to the load cam roller retainer assembly; and a plurality of balls arranged radially about a longitudinal axis, each ball having a tiltable axis of rotation, each ball operably coupled to the traction ring.
4. A power input device comprising: a torque driver rotatable about a longitudinal axis, the torque driver configured to receive a power input; a torsion plate coupled to the torque driver, the torsion plate having a splined inner bore and a plurality of triangular extensions extending radially from the splined inner bore; a load cam ring coupled to the torsion plate; a load cam roller retainer subassembly coupled to the load cam ring; and a traction ring coupled to the load cam roller retainer subassembly.
5. An assembly for an axial force generator, the assembly comprising: a first slotted ring configured to receive a plurality of load cam rollers; a second slotted ring configured to receive the load cam rollers; and a spring configured to be retained in the first and/or second slotted ring.
6. The assembly of Claim 5, further comprising a load cam ring having a plurality of ramps, the load cam ring operably coupled to the spring,
7. The assembly of Claim 6, further comprising a traction ring operably coupled to the spring, the traction ring having a plurality of ramps.
8. The assembly of Claim 6, wherein the load cam ring comprises a groove configured to engage the spring.
9. The assembly of Claim 7, wherein the traction ring comprises a groove configured to engage the spring.
10. The assembly of Claim 5, wherein the first and the second slotted ring each comprise a shoulder configured to couple to the spring.
11. A torsion plate comprising: a substantially disc-shaped body having a splined inner bore; a plurality of structural ribs coupled to the disc-shaped body, the structural ribs extending radially from the spline inner bore; and a plurality of splines coupled to the outer periphery of the disc shaped body.
12. The torsion plate of Claim 1 1, wherein the disc-shaped body is made at least in part from a plastic material,
13. A carrier for a continuously variable transmission having a plurality of planet subassemblies, each planet subassembly having a ball configured to rotate about a tiltable axis, the carrier comprising: a stator interfacial member configured to be operably coupled to a planet subassembly; a stator support member operably coupled to the stator interfacial member; and a stator torque reaction member operably coupled to the stator support member.
14. The carrier of Claim 13, wherein the stator interfacial member is configured to be slidingly coupled to the planet subassembly.
15. The carrier of Claim 13, wherein the stator interfacial member is configured to be slidingly coupled to the stator support member.
16. The carrier of Claim 13, wherein the stator torque reaction member is configured to be rigidly coupled to the stator support member.
17. The carrier of Claim 13, wherein the stator torque reaction member is configured to be rigidly coupled to the stator interfacial member.
18. A transmission comprising: a plurality of balls, each ball operably coupled to at least one leg; a stator interfacial member coupled to each leg; a stator support member coupled to the stator interfacial member; and a stator torque reaction member coupled to the stator support member.
19. The transmission of Claim 18, wherein the stator interfacial member is slidingly coupled to each leg.
20. The transmission of Claim 18, wherein the stator interfacial member is slidingly coupled to the stator support member,
21. The transmission of Claim 18, wherein the leg and the stator interfacial member are integral components.
22. A transmission comprising: a plurality of planet assemblies arranged angularly about a longitudinal axis of the transmission, each planet assembly having a leg; a stator interfacial member coaxial with the longitudinal axis, the stator interfacial member having a plurality of radial grooves configured to slidingly support the leg; and a stator support member coupled to the stator interfacial member, the stator support member coaxial with the longitudinal axis.
23. The transmission of Claim 22, further comprising a stator torque reaction insert coupled to the stator support member, the stator torque reaction insert concentric to the stator support member.
24. A stator assembly for a continuously variable transmission, the stator assembly comprising: a stator torque reaction insert having a plurality of torque reaction shoulders; a stator support member coupled to the stator torque reaction insert, the stator support member extending radially outward from the stator torque reaction insert, the stator support member having a first face and a second face; and a stator interfacial member coupled to the stator support member, the stator interfacial member substantially supported by the first face of the stator support member, the stator interfacial member having a plurality of radial grooves.
25. The stator assembly of Claim 24, wherein the stator support member comprises a plurality of interlocking holes.
26. The stator assembly of Claim 25, wherein the stator interfacial member comprises a plurality of interlocking tabs configured to couple to the plurality of interlocking holes.
27. A stator support member for a continuously variable transmission (CVT), the stator support member comprising: a substantially disc-shaped body having an inner bore, a first face and a second face; a plurality of spacer support extensions arranged angularly on the first face; a plurality of guide support slots, each guide support slot arranged substantially between each of the spacer support extensions; a plurality of interlocking holes formed in each of the guide support slots; and a plurality of capture extensions formed on the outer periphery of the discshaped body.
28. The stator support member of Claim 27, further comprising a piloting shoulder formed in proximity to the inner bore on the first face.
29. The stator support member of Claim 27, further comprising a plurality of structural ribs formed on the second face.
30. The stator support member of Claim 27, wherein each of the capture extensions are substantially aligned with each of the spacer support extensions.
31. The stator support member of Claim 27, wherein the inner bore has a hexagonal shape.
32. A stator interfacial member for a continuously variable transmission, the stator interfacial member comprising: a substantially disc-shaped body having a central bore, a first face, and a second face; a plurality of sliding guide slots extending radially from the central bore, the guide slots arranged substantially on the first face; a plurality of interlocking tabs extending from the second face; a capture ring formed around the outer circumference of the disc-shaped body; and a plurality of capture cavities formed on the capture ring.
33. The stator interfacial member of Claim 32, wherein the capture ring is aligned substantially on the second face.
34. The stator interfacial member of Claim 32, wherein the interlocking tabs are formed on each of the sliding guide slots,
35. A planet assembly for a continuously variable transmission (CVT) having a shift cam and a carrier assembly, the planet assembly comprising: a ball having a through bore; a ball axle coupled to the through bore; and a leg coupled to the ball axle, the leg having a first end configured to slidingly engage the shift cam, the leg further having a face configured to slidingly engage the carrier assembly.
36. The planet assembly of Claim 35, wherein the first end has a width that is smaller than a width of the face.
37. The planet assembly of Claim 36, wherein the face has a length in the range of about 7mm to 12.5mm.
38. A leg for a continuously variable transmission (CVT) having a carrier assembly, the leg comprising: an elongated body having a first end and a second end; an axle bore formed on the first end; a shift cam guide surface formed on the second end, the shift cam guide surface configured to slidingly engage a shift cam of the CVT; and a sliding interface formed between the first end and the second end, the sliding interface configured to slidingly engage the carrier assembly.
39. The leg of Claim 38, wherein the sliding interface has a length in the range of about 7mm to 12.5mm.
40. The leg of Claim 38, wherein the shift cam guide surface has a width of about 3.5mm.
41. The leg of Claim 38, wherein the sliding interface has a width of about 8mm.
42. A transmission comprising: a plurality of planet assemblies arranged angularly about, and on a plane perpendicular to, a longitudinal axis of the transmission, each planet assembly having a leg; a plurality of stator interfacial inserts arranged angularly about the longitudinal axis, wherein each leg is configured to slidingly couple to each of the stator interfacial inserts; and a stator support member mounted coaxially with the longitudinal axis, the stator support member configured to couple to each of the stator interfacial inserts.
43. The transmission of Claim 42, further comprising an axle arranged along the longitudinal axis and coupled to the stator support member.
44. A stator support member for a continuously variable transmission (CVT), the stator support member comprising: a generally cylindrical body having a central bore; a plurality of insert support slots arranged angularly about, and extending radially from, the central bore; a plurality of stator support extensions arranged coaxial with the plurality of insert support slots, the stator support extensions arranged angularly about the central bore; and wherein each of the stator support extensions has a fastening hole and a dowel pin hole.
45. The stator support member of Claim 44, wherein the central bore comprises a plurality of torque reaction shoulders.
46. The stator support member of Claim 44, wherein each of the stator support extensions comprise a plurality of cutouts.
47. A stator interfacial insert for a continuously variable transmission, the stator interfacial insert comprising: a generally rectangular body having a back, a first side extension, and a second side extension; a stator interlock tab formed on the back; a sliding guide surface located between the first and second side extensions; and
48. The stator interfacial insert of Claim 47, further comprising a leg clearance recess formed on an end of the rectangular body between the first and second side extensions.
49. The stator interfacial insert of Claim 47, wherein the generally rectangular body is made at least partly from a plastic material.
50. A transmission comprising: a plurality of planet assemblies arranged angularly about a longitudinal axis, each planet assembly having a leg; a stator support member coaxial with the plurality of planet assemblies, the stator support member operably coupled to each of the planet assemblies; a stator torque reaction insert coupled to the stator support member at a radially inward location; and wherein the stator support member comprises a substantially bowl-shaped body having a central bore, the central bore configured to couple to the stator torque reaction insert, the bowl-shaped body having a fastening flange located on an outer periphery of the bowl-shaped body, the bowl-shaped body further having a plurality of guide support slots configured to slidingly couple to each of the planet assemblies.
51. The transmission of Claim 50, wherein the leg is made at least in part from a plastic.
52. The transmission of Claim 50, wherein the stator support member further comprises a plurality of structural ribs formed on an exterior face of the bowl-shaped body.
53. A stator support member for a continuously variable transmission (CVT), the stator support member comprising: a body having a central bore, an interior cavity, and an exterior surface; a plurality of guide support slots arranged angularly about, and extending radially from, the central bore, the guide support slots formed on the interior cavity; a fastening flange coupled to the outer periphery of the body; and a plurality of cutouts coupled to each of the guide support slots.
54. The stator support member of Claim 53, wherein each of the cutouts are configured to provide clearance to a planet assembly of the CVT.
55. The stator support member of Claim 53, wherein the central bore comprises a plurality of torque reaction shoulders.
56. The stator support member of Claim 53, further comprising a plurality of structural ribs formed on the exterior surface.
57. A planet assembly for a continuously variable transmission (CVT) having a shift cam and a carrier assembly, the planet assembly comprising: a ball having a through bore; a ball axle received in the through bore; and a leg coupled to the ball axle, the leg having a first end configured to slidingly engage the shift cam, the leg having a face configured to sHdingiy engage the carrier assembly, the leg having an axle bore formed on a second end, the leg having a bearing support extension extending from the axle bore.
58. The planet assembly of Claim 57, wherein the leg is made at least in part from a plastic.
59. A shift cam for a continuously variable transmission (CVT), the shift cam comprising: a plurality of leg contact surfaces arranged angularly about, and extending radially from, a longitudinal axis of the CVT, each of the leg contact surfaces having a convex profile with respect to a first plane and a substantially flat profile with respect to a second plane; and a shift nut engagement shoulder formed radially inward of each of the leg contact surfaces.
60. The shift cam of Claim 59, further comprising a plurality of alignment extensions coupled to each of the leg contact surfaces, each alignment extension substantially flanking each of the leg contact surfaces.
61. A transmission comprising : a plurality of planet assemblies arranged angularly about a longitudinal axis, each planet assembly having a leg; a stator interfacial member operably coupled to each of the planet assemblies, the stator interfacial member coaxial with the plurality of planet assemblies; a stator support member coupled to the stator interfacial member, the stator support member comprising: a substantially bowl-shaped body having a central bore; a fastening flange located on an outer periphery of the bowl-shaped body; and a plurality of interlocking tabs located on an interior surface of the bowl-shaped body, the interlocking tabs configured to couple to the stator interfacial member.
62. The transmission of Claim 61, further comprising a stator torque reaction insert coupled to the central bore of the stator support member.
63. A stator support member for a continuously variable transmission having a stator interfacial member, the stator support member comprising: a substantially bowl-shaped body having a central bore; a fastening flange located on an outer periphery of the bowl-shaped body; and a plurality of interlock tabs located on an interior surface of the bowl- shaped body.
64. The stator support member of Claim 63, wherein the interlock tabs configured to couple to the stator interfacial member.
65. A stator interfacial member for a continuously variable transmission (CVT), the stator interfacial member comprising: a substantially disc-shaped body having an inner bore, a first face, and a second face; a plurality of guide slots arranged angularly about, and extending radially from the inner bore, the plurality of guide slots formed on the first face; a plurality of interlock tabs substantially aligned with each of the guide slots, the interlock tabs formed on the second face; and a plurality of stator support member extensions coupled to each of the guide slots, the stator support member extensions located on an outer periphery of the disc-shaped body.
66. The stator interfacial member of Claim 65, further comprising a plurality of leg clearance slots coupled to each of the guide slots, the leg clearance slots located radially inward of the stator support member extensions.
67. A transmission comprising: a plurality of planet assemblies arranged angularly about a longitudinal axis of the transmission, each planet assembly having a leg; an axle arranged along the longitudinal axis; a first stator support member slidingly coupled to each of the planet assemblies, the first stator support member having a first central bore, the first central bore coupled to the axle; a second stator support member sliding coupled to each of the planet assemblies, the second stator support member having a second central bore, wherein the second central bore has a diameter larger than a diameter of the first central bore; and a plurality of stator spacers coupled to the first and second stator support members, the stator spacers arranged angularly about the longitudinal axis.
68. The transmission of Claim 67, wherein the stator spacers have a first end and a second end, wherein the first and second ends have substantially triangular cross- sections.
69. The transmission of Claim 67, wherein the stator spacers have a substantially diamond-shaped cross-section located between the first and second ends.
70. The transmission of Claim 67, further comprising a substantially cylindrical idler operably coupled to the planet assemblies.
71. The transmission of Claim 67, wherein the second central bore is adapted to provide clearance to the idler upon assembly.
72. A stator support member for a continuously variable transmission (CVT), the stator support member comprising: a generally disc-shaped body having a central bore; a plurality of support extensions arranged angularly about the central bore, each of the support extensions having a substantially triangular shape, each of the support extensions located radially outward of the central bore; a plurality of stator spacer cavities coupled to the support extensions, the stator spacer cavities having a substantially triangular shape; and a plurality of guide slots formed on the disc-shaped body, each guide slot extending radially from the central bore, each guide slot substantially angularly aligned with each of the support extensions.
73. The stator support member of Claim 72, wherein the central bore is configured to couple to an axle of the CVT.
74. A stator spacer for a continuously variable transmission, the stator spacer comprising: an elongated body having a first end and a second end; a clearance neck formed between the first end and the second end; wherein each of the first and second ends has a substantially triangular cross-section; and wherein at least a portion of the clearance neck has a substantially diamond-shaped cross-section.
75. An idler assembly for a continuously variable transmission (CVT), the idler assembly comprising: a substantially cylindrical idler having a central bore, the central bore defining a longitudinal axis, the idler configured to rotate about the longitudinal axis; first and second shift cams operably coupled respectively to a first and a second end of the idler, the first and second shift cams configured to be substantially non-rotatable about the longitudinal axis; a first shift nut coupled to the first shift cam, the first shift nut having a threaded bore and a shift cam engagement shoulder extending radially from the threaded bore; and a second shift nut coupled to the second shift cam, the second shift nut comprising a second threaded bore and a second shift cam engagement shoulder extending radially from the second threaded bore.
76. The idler assembly of Claim 75, further comprising a bearing coupled to the idler, the bearing comprising a flexible cage.
77. A method of manufacturing an idler assembly for a continuously variable transmission (CVT) having an axle arranged along a longitudinal axis, the method comprising: providing a shift nut clearance slot in the axle; providing a substantially cylindrical idler having a central bore; operably coupling the idler to a first shift cam on a first end of the idler and to a second shift cam on a second end of the idler thereby yielding a subassembly including the idler, the first shift cam, and the second shift cam; placing a shift nut in the shift nut clearance slot, the shift nut having a shift cam engagement shoulder extending radially from a threaded bore; installing the subassembly of the idler, the first shift cam, and the second shift cam on the axle such that said subassembly substantially surrounds the shift nut; and coupling a shift rod to the threaded bore of the shift nut thereby coupling the shift nut engagement shoulder to the first or second shift cam.
78. The method of Claim 77, wherein placing the shift nut in the shift nut clearance slot comprises providing the shift nut with a plurality of flats configured to operably couple to the shift nut clearance slot.
79. A hub shell for a continuously variable transmission (CVT), the hub shell comprising: a generally hollow cylindrical body having a substantially closed end and a central bore; first and a second spoke flanges coupled to an outer periphery of the hollow cylindrical body; a plurality of brake splines coupled to the substantially closed end; a locking chamfer coupled to the substantially closed end, the locking chamfer located radially outward of, and coaxial with the plurality of brake splines; and a plurality of splines coupled to the substantially closed end, the splines located on an interior surface of the cylindrical body.
80. The hub shell of Claim 79, wherein the brake splines are arranged angularly about, and extend radially from, the central bore.
81. A brake adapter kit for a continuously variable transmission (CVT) having a hub shell, the brake adapter kit comprising: a brake adapter ring having a brake alignment surface, the brake adapter ring having a locking chamfer configure to engage the hub shell; a roller brake adapter configured to couple to the brake adapter ring and to the hub shell; and wherein once assembled the roller brake adapter is rigidly coupled to the hub shell.
82. The brake adapter kit of Claim 81, wherein the brake adapter ring comprises a plurality of tool engagement holes.
83. A brake adapter kit for a continuously variable transmission (CVT) having a hub shell, the brake adapter kit comprising: a brake adapter ring having a brake alignment surface, the brake adapter ring having a locking chamfer configure to engage the hub shell; a disc brake adapter configured to couple to the brake adapter ring and to the hub shell; and wherein once assembled the disc brake adapter is rigidly coupled to the hub shell.
84. The brake adapter kit of Claim 83, wherein the brake adapter ring comprises a plurality of tool engagement holes.
85. A transmission comprising: a plurality of planet assemblies arranged angularly about a longitudinal axis of the transmission, each planet assembly having a leg; a stator interfacial cap coupled to each leg; a stator support member coaxial with the plurality of planet assemblies, the stator support member having a plurality of guide grooves arranged angularly about, and extending radially from, the longitudinal axis; and wherein each of the stator interfacial caps is configured to engage slidingly to the stator support member.
86. The transmission of Claim 85, further comprising a stator torque reaction insert coupled to the stator support member, the stator torque reaction insert radially inward of the stator support member.
87. The transmission of Claim 85, wherein the stator interfacial cap comprises a sliding interface surface.
88. The transmission of Claim 87, wherein the stator interfacial cap comprises a first and a second side extending from the sliding interface surface, the first and the second side configured to substantially flank the leg.
89. A planet assembly for a continuously variable transmission, the planet assembly comprising: a ball having a through bore; an axle operably received in the through bore, the axle configured to provide a tiltable axis of rotation for the ball; a leg coupled to the axle, the leg having an elongated body with a first end and a second end, wherein the leg couples to the axle in proximity to the first end; and a stator interfacial cap coupled to the leg, the stator interfacial cap having a sliding interfacial surface.
90. The planet assembly of Claim 89, wherein the stator interfacial cap is made at least in part from a plastic.
91. The planet assembly of Claim 89, wherein the stator interfacial cap comprises a first and a second side, each side extending from the sliding interfacial surface, the first and the second side configured to substantially flank the leg. |
CONTINUOUSLY VARIABLE TRANSMISSION
BACKGROUND OF THE INVENTION Field of the Invention
[0001] The field of the invention relates generally to transmissions, and more particularly to continuously variable transmissions (CVTs). Description of the Related Art
[0002] There are well-known ways to achieve continuously variable ratios of input speed to output speed. The mechanism for adjusting an input speed from an output speed in a CVT is known as a variator. In a belt-type CVT, the variator consists of two adjustable pulleys having a belt between them. The variator in a single cavity toroidal- type CVT has two partially toroidal transmission discs rotating about an axle and two or more disc-shaped power rollers rotating on respective axes that are perpendicular to the axle and clamped between the input and output transmission discs.
[0003] Embodiments of the invention disclosed here are of the spherical -type variator utilizing spherical speed adjusters (also known as power adjusters, balls, sphere gears or rollers) that each has a tiltable axis of rotation; the speed adjusters are distributed in a plane about a longitudinal axis of a CVT. The speed adjusters are contacted on one side by an input disc and on the other side by an output disc, one or both of which apply a clamping contact force to the rollers for transmission of torque. The input disc applies input torque at an input rotational speed to the speed adjusters. As the speed adjusters rotate about their own axes, the speed adjusters transmit the torque to the output disc. The input speed to output speed ratio is a function of the radii of the contact points of the input and output discs to the axes of the speed adjusters. Tilting the axes of the speed adjusters with respect to the axis of the variator adjusts the speed ratio. Summary of The Invention
[0004] The systems and methods herein described have several features, no single one of which is solely responsible for its desirable attributes. Without limiting the scope as expressed by the claims that follow, its more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled "Detailed Description of Certain Inventive Embodiments" one will
understand how the features of the system and methods provide several advantages over traditional systems and methods.
[0005] One aspect of the invention relates to a continuously variable transmission having a group of balls that are arranged radially about a longitudinal axis. Each ball is configured to have a tillable axis of rotation. In one embodiment, a leg is operably coupled to each of the balls. The leg can be configured to tilt the axis of rotation of the ball. The transmission can include a stator interfacial member slidingly coupled to the leg. The transmission can also include a stator support member coupled to the stator interfacial member.
[0006] Another aspect of the invention concerns a transmission having a torque driver rotatable about a longitudinal axis. The torque driver can be configured to receive a power input. The transmission can include a torsion plate operably coupled to the torque driver. The torsion plate can have a spĪned inner bore and a group of triangular extensions extending radially from the splined inner bore. In one embodiment, the transmission includes a load cam ring operably coupled to the torsion plate. The transmission can include a load cam roller retainer assembly operably coupled to the load cam ring. The transmission includes a traction ring operably coupled to the load cam roller retainer assembly. The transmission also includes a group of balls arranged radially about a longitudinal axis. Each ball has a tiltable axis of rotation. Each ball can be operably coupled to the traction ring.
[0007] Yet another aspect of the invention involves a power input device that includes a torque driver rotatable about a longitudinal axis. The torque driver can be configured to receive a power input. In one embodiment, the power input device includes a torsion plate coupled to the torque driver. The torsion plate can have a splined inner bore and a number of triangular extensions extending radially from the splined inner bore. The power input device can include a load cam ring coupled to the torsion plate. In one embodiment, the power input device includes a load cam roller retainer subassembly coupled to the load cam ring. The power input device can also include a traction ring coupled to the load cam roller retainer subassembly.
[0008] One aspect of the invention concerns an assembly for an axial force generator that includes a first slotted ring configured to receive a number of load cam
rollers. In one embodiment, the assembly includes a second slotted ring configured to receive the load cam rollers. The assembly can also include a spring configured to be retained in the first and/or second slotted ring.
[0009] Another aspect of the invention relates to a torsion plate having a substantially disc-shaped body with a splined inner bore. In one embodiment, the torsion plate has a number of structural ribs coupled to the disc-shaped body. The structural ribs extend radially from the spline inner bore. The torsion plate can also have a set of splines coupled to the outer periphery of the disc shaped body.
[0010] Yet one more aspect of the invention addresses a carrier for a continuously variable transmission having a group of planet subassemblies. Each planet subassembly has a ball configured to rotate about a tiltable axis. In one embodiment, the carrier includes a stator interfacial member configured to be operably coupled to a planet subassembly. The carrier can include a stator support member operably coupled to the stator interfacial member. The carrier can also include a stator torque reaction member operably coupled to the stator support member.
[0011] In another aspect, the invention concerns a transmission having a group of balls. Each ball is operably coupled to at least one leg. The transmission includes a stator interfacial member coupled to each leg. In one embodiment, the transmission includes a stator support member coupled to the stator interfacial member. The transmission also includes a stator torque reaction member coupled to the stator support member.
[0012] Another aspect of the invention relates to a transmission having a group of planet assemblies arranged angularly about a longitudinal axis of the transmission. Each planet assembly has a leg. In one embodiment, the transmission includes a stator interfacial member coaxial with the longitudinal axis. The stator interfacial member has a number of radial grooves configured to slidingly support the leg. The transmission also includes a stator support member coupled to the stator interfacial member. The stator support member is coaxial with the longitudinal axis.
[0013] One aspect of the invention relates to a stator assembly for a continuously variable transmission. The stator assembly includes a stator torque reaction insert having a number of torque reaction shoulders. In one embodiment, the stator
assembly has a stator support member coupled to the stator torque reaction insert. The stator support member extends radially outward from the stator torque reaction insert. The stator support member can have a first face and a second face. The stator assembly can also include a stator interfacial member coupled to the stator support member. The stator interfacial member is substantially supported by the first face of the stator support member. The stator interfacial member has a number of radial grooves.
[0014] Another aspect of the invention addresses a stator support member for a continuously variable transmission (CVT). The stator support member can include a substantially disc-shaped body having an inner bore, a first face and a second face. The stator support member can also have a group of spacer support extensions arranged angularly on the first face. In one embodiment, the stator support member includes a number of guide support slots. Each guide support slot is arranged substantially between each of the spacer support extensions. The stator support member has a number of interlocking holes formed in each of the guide support slots. The stator support member also has a number of capture extensions formed on the outer periphery of the disc-shaped body.
[0015] One more aspect of the invention concerns a stator interfacial member for a continuously variable transmission. The stator interfacial member includes a substantially disc-shaped body having a central bore, a first face, and a second face, In one embodiment, the stator interfacial member includes a number of sliding guide slots that extend radially from the central bore. The guide slots can be arranged substantially on the first face. The stator interfacial member can include a set of interlocking tabs extending from the second face. The stator interfacial member has a capture ring formed around the outer circumference of the disc-shaped body. The stator interfacial member also has a group of capture cavities formed on the capture ring.
[0016] Yet another aspect of the invention involves a planet assembly for a continuously variable transmission (CVT) having a shift cam and a carrier assembly. The planet assembly has a ball with a through bore. In one embodiment, the planet assembly has a ball axle coupled to the through bore. The planet assembly also has a leg coupled to the ball axle. The leg has a first end configured to slidingly engage the shift cam. The leg further has a face configured to slidingly engage the carrier assembly.
[0017] Another aspect of the invention relates to a leg for a continuously variable transmission (CVT) having a carrier assembly. The leg includes an elongated body having a first end and a second end. In one embodiment, the leg has an axle bore formed on the first end. The leg can have a shift cam guide surface formed on the second end. The shift cam guide surface can be configured to slidingly engage a shift cam of the CVT. The leg can also have a sliding interface formed between the first end and the second end. The sliding interface can be configured to slidingly engage the carrier assembly.
[0018] Yet another aspect of the invention involves a transmission. In one embodiment, the transmission includes a group of planet assemblies arranged angularly about, and on a plane perpendicular to, a longitudinal axis of the transmission. Each planet assembly has a leg. The transmission can include a set of stator interfacial inserts arranged angularly about the longitudinal axis. Each leg is configured to slidingly couple to each of the stator interfacial inserts. The transmission can also include a stator support member mounted coaxial Iy with the longitudinal axis. The stator support member can be configured to couple to each of the stator interfacial inserts.
[0019] In another aspect, the invention concerns a stator support member for a continuously variable transmission (CVT). The stator support member includes a generally cylindrical body having a central bore. In one embodiment, the stator support member has a number of insert support slots arranged angularly about, and extending radially from, the central bore. The stator support member can include a number of stator support extensions arranged coaxial with the insert support slots. The stator support extensions are arranged angularly about the central bore. Each of the stator support extensions has a fastening hole and a dowel pin hole.
[0020] Another aspect of the invention relates to a planet assembly for a continuously variable transmission (CVT) having a shift cam and a carrier assembly. The planet assembly includes a ball having a through bore. In one embodiment, the planet assembly includes a ball axle received in the through bore. The planet assembly can also include a leg coupled to the ball axle. The leg has a first end configured to slidingly engage the shift cam. The leg has a face configured to slidingly engage the carrier
assembly. The leg has an axle bore formed on a second end. The leg has a bearing support extension extending from the axle bore.
[0021J One aspect of the invention relates to a shift cam for a continuously variable transmission (CVT). The shift cam has a number of leg contact surfaces arranged angularly about, and extending radially from, a longitudinal axis of the CVT. Each of the leg contact surfaces has a convex profile with respect to a first plane and a substantially flat profile with respect to a second plane. The shift cam also has a shift nut engagement shoulder formed radially inward of each of the leg contact surfaces.
[0022] Another aspect of the invention addresses a transmission having a group of planet assemblies arranged angularly about a longitudinal axis. Each planet assembly has a leg. The transmission can have a stator interfacial member operably coupled to each of the planet assemblies. The stator interfacial member can be coaxial with the group of planet assemblies. In one embodiment, the transmission has a stator support member coupled to the stator interfacial member. The stator support member includes a substantially bowl-shaped body having a central bore. The stator support member can have a fastening flange located on an outer periphery of the bowl-shaped body. The stator support member also includes a set of interlocking tabs located on an interior surface of the bowl-shaped body. The interlocking tabs are configured to couple to the stator interfacial member.
[0023] One more aspect of the invention concerns a stator support member for a continuously variable transmission having a stator interfacial member. In one embodiment, the stator support member has a substantially bowl-shaped body with a central bore. The stator support member includes a fastening flange located on an outer periphery of the bowl-shaped body. The stator support member also has a set of interlock tabs located on an interior surface of the bowl-shaped body.
[0024] Yet another aspect of the invention involves a stator interfacial member for a continuously variable transmission (CVT). The stator interfacial member includes a substantially disc-shaped body with an inner bore, a first face, and a second face. In one embodiment, the stator interfacial member has a number of guide slots arranged angularly about, and extending radially from the inner bore. The guide slots are formed on the first face. The stator interfacial member includes a set of interlock tabs
substantially aligned with each of the guide slots. The interlock tabs are formed on the second face. The stator interfacial member can also include a number of stator support member extensions coupled to each of the guide slots. The stator support member extensions are located on an outer periphery of the disc-shaped body.
[0025] Another aspect of the invention relates to a transmission having a group of planet assemblies arranged angularly about a longitudinal axis of the transmission. Each planet assembly has a leg. In one embodiment, the transmission includes an axle arranged along the longitudinal axis. The transmission can include a first stator support member slidingly coupled to each of the planet assemblies. The first stator support member has a first central bore. The first central bore can be coupled to the axle. The transmission includes a second stator support member sliding coupled to each of the planet assemblies. The second stator support member has a second centra! bore. The second central bore has a diameter larger than a diameter of the first central bore. The transmission can also include a set of stator spacers coupled to the first and second stator support members. The stator spacers are arranged angularly about the longitudinal axis.
[0026J Yet one more aspect of the invention addresses a stator support member for a continuously variable transmission (CVT). The stator support member has a generally disc-shaped body having a central bore. In one embodiment, the stator support member has a group of support extensions arranged angularly about the central bore. Each of the support extensions has a substantially triangular shape. Each of the support extensions is located radially outward of the central bore. The stator support member includes a number of stator spacer cavities coupled to the support extensions. The stator spacer cavities have a substantially triangular shape. The stator support member can also include a number of guide slots formed on the disc-shaped body. Each guide slot extends radially from the central bore. Each guide slot is substantially angularly aligned with each of the support extensions.
[0027] In another aspect, the invention concerns a stator spacer for a continuously variable transmission. The stator spacer includes an elongated body having a first end and a second end. In one embodiment, the stator spacer has a clearance neck formed between the first end and the second end. Each of the first and second ends has a
substantially triangular cross-section. At least a portion of the clearance neck has a substantially diamond-shaped cross-section.
[0028] Another aspect of the invention relates to an idler assembly for a continuously variable transmission (CVT). The idler assembly includes a substantially cylindrical idler having a central bore. The central bore defines a longitudinal axis. The idler is configured to rotate about the longitudinal axis. In one embodiment, the idler assembly includes first and second shift cams operably coupled respectively to a first and a second end of the idler. The first and second shift cams are configured to be substantially non-rotatable about the longitudinal axis. The idler assembly includes a first shift nut coupled to the first shift cam. The first shift nut has a threaded bore and a shift cam engagement shoulder extending radially from the threaded bore. The idler assembly also includes a second shift nut coupled to the second shift cam, the second shift nut comprising a second threaded bore and a second shift cam engagement shoulder extending radially from the second threaded bore.
[0029] One aspect of the invention relates to a method of manufacturing an idler assembly for a continuously variable transmission (CVT) having an axle arranged along a longitudinal axis, In one embodiment, the method includes providing a shift nut clearance slot in the axle. The method can include providing a substantially cylindrical idler having a central bore. The method includes operably coupling the idler to a first shift cam on a first end of the idler and to a second shift cam on a second end of the idler thereby yielding a subassembly including the idler, the first shift cam, and the second shift cam. The method includes placing a shift nut in the shift nut clearance slot. The shift nut has a shift cam engagement shoulder extending radially from a threaded bore. The method includes installing the subassembly of the idler, the first shift cam, and the second shift cam on the axle such that said subassembly substantially surrounds the shift nut. The method also includes coupling a shift rod to the threaded bore of the shift nut thereby coupling the shift nut engagement shoulder to the first or second shift cam.
[0030] Another aspect of the invention concerns a hub shell for a continuously variable transmission (CVT). The hub shell includes a generally hollow cylindrical body having a substantially closed end and a central bore. In one embodiment, the hub shell has first and a second spoke flanges coupled to an outer
periphery of the hollow cylindrical body. The hub shell includes a set of brake splines coupled to the substantially closed end. The hub shell can have a locking chamfer coupled to the substantially closed end. The locking chamfer is located radially outward of, and coaxial with the brake splines. The hub shell can also include a set of splines coupled to the substantially closed end. The splines are located on an interior surface of the cylindrical body.
[0031] Yet another aspect of the invention involves a brake adapter kit for a continuously variable transmission (CVT) having a hub shell. The brake adapter kit includes a brake adapter ring having a brake alignment surface. The brake adapter ring has a locking chamfer configure to engage the hub shell. The brake adapter kit can include a roller brake adapter configured to couple to the brake adapter ring and to the hub shell. Once assembled the roller brake adapter is rigidly coupled to the hub shell.
[0032] One aspect of the invention concerns a brake adapter kit for a continuously variable transmission (CVT) having a hub shell. The brake adapter kit includes a brake adapter ring having a brake alignment surface. The brake adapter ring has a locking chamfer configure to engage the hub shell. In one embodiment, the brake adapter kit includes a disc brake adapter configured to couple to the brake adapter ring and to the hub shell. Once assembled the disc brake adapter is rigidly coupled to the hub shell.
[0033] Another aspect of the invention relates to a transmission having a group of planet assemblies arranged angularly about a longitudinal axis of the transmission. Each planet assembly has a leg, In one embodiment, the transmission includes a stator interfacial cap coupled to each leg. The transmission includes a stator support member coaxial with the planet assemblies. The stator support member has a number of guide grooves arranged angularly about, and extending radially from, the longitudinal axis. Each of the stator interfacial caps is configured to engage slidingly to the stator support member.
[0034] Yet one more aspect of the invention addresses a planet assembly for a continuously variable transmission. The planet assembly can include a ball with a through bore. The planet assembly includes an axle operably received in the through bore. The axle can be configured to provide a tiltable axis of rotation for the ball. In one
embodiment, the planet assembly includes a leg coupled to the axle. The leg has an elongated body with a first end and a second end. The leg couples to the axle in proximity to the first end. The planet assembly also includes a stator interfacial cap coupled to the leg. The stator interfacial cap has a sliding interfacial surface.
BRIEF DESCRIPTION OF THE FIGURES
[0035] Figure 1 is a perspective view of one embodiment of a bicycle having a continuously variable transmission (CVT) in accordance with inventive embodiments disclosed herein.
[0036] Figure 2 is a partially cross-sectioned, perspective view of one embodiment of a (CVT).
[0037] Figure 3 is a cross-sectional view of the CVT of Figure 2.
[0038] Figure 4 is a perspective, cross-sectional view of one embodiment of an input subassembly that can be used in the CVT of Figure 2.
[0039] Figure 5 is a perspective view of a torque driver that can be used in the input subassembly of Figure 4.
[0040] Figure 6 is a cross-sectional view of the torque driver of Figure 5.
[0041] Figure 7 is a perspective view of a torsion plate that can be used in the input subassembly of Figure 4.
[0042] Figure 8 is a cross-sectional view of the torsion plate of Figure 7.
[0043] Figure 9 is a perspective view of a load cam ring that can be used in the input subassembly of Figure 4.
[0044] Figure 10 is a cross-sectional view of the load cam ring of Figure 9.
[0045] Figure 1 1 is a perspective view of a traction ring that can be used in the input subassembly of Figure 4.
[0046] Figure 12 is an exploded, perspective, cross-sectional view of certain components of the CVT of Figure 2.
[0047] Figure 13, is a second exploded, perspective, cross- sectional view of certain of the components of Figure 12.
[0048] Figure 14 is a partial cross-section view of the components shown in Figure 12.
[0049J Figure 15A is a perspective view of one embodiment of a torsion plate that can be used in the input subassembly of Figure 4.
[0050] Figure 15B is a partially cross-sectioned perspective view of the torsion plate of Figure 15A.
[0051] Figure 16A is a cross-sectional perspective view of a torsion plate and traction ring that can be used with the CVT of Figure 2.
[0052] Figure 16B is an exploded cross-sectional perspective view of the torsion plate and traction ring of Figure 16A.
[0053] Figure 17 is a perspective view of one embodiment of an output load cam that can be used with the CVT of Figure 2.
[0054] Figure 18 is a block diagram showing one embodiment of a carrier assembly that can be used with the CVT of Figure 2.
[0055] Figure 19 is an exploded, partially-cross-sectioned, perspective view of the CVT of Figure 2 employing an embodiment of a carrier assembly.
[0056] Figure 20 is a cross-sectional view of the carrier assembly of Figure 20.
[0057] Figure 21 is an exploded, partially cross-sectioned, perspective view of one embodiment of a stator subassembly that can be used with the carrier assembly of Figure 20.
[0058] Figure 22 is a plan view of the stator subassembly of Figure 21.
[0059] Figure 23 is a second plan view of the stator subassembly of Figure 21.
[0060] Figure 24 is a cross-section of the stator subassembly of Figure 21.
[0061] Figure 25 is a perspective view of one embodiment of a stator support member that can be used with the stator subassembly of Figure 21.
[0062] Figure 26 is a second perspective view of the stator support member of Figure 26.
[0063] Figure 27 is a partially cross-sectioned, perspective view of a stator interfacial member that can be used with the stator subassembly of Figure 21.
[0064] Figure 28 is a perspective view of one embodiment of a planet subassembly that can be used in the CVT of Figure 2,
[0065] Figure 29 is a cross-sectional view of the planet subassembly of Figure 28.
[0066] Figure 30 is a perspective view of one embodiment of a leg that can be used with the planet subassembly of Figure 28,
[0067J Figure 31 is a cross-sectional view of the leg of Figure 30.
[0068] Figure 32 is a cross-sectional view of one embodiment of a leg that can be used with the pianet subassembly of Figure 28.
[0069] Figure 33 is an exploded, partially cross-sectioned, perspective view of an embodiment of a carrier assembly that can be used with the CVT of Figure 2,
[0070] Figure 34 is a cross-sectional view of the carrier assembly of Figure 33.
[0071] Figure 35 is a perspective view of one embodiment of a stator support member that can be used with the carrier assembly of Figure 33.
[0072] Figure 36 is a partially cross-sectioned, perspective view of the stator support member of Figure 35.
[0073] Figure 37 is a plan view of the stator support member of Figure 35.
[0074] Figure 38 is a second plan view of the stator support member of Figure 35.
[0075] Figure 39 is a perspective view of one embodiment of a stator interfacial insert that can be used with the carrier assembly of Figure 33.
[0076] Figure 40 is a second perspective view of the stator interfacial insert of Figure 39.
[0077] Figure 41 is a cross-sectional view of the stator interfacial insert of Figure 39.
[0078] Figure 42 is a cross-sectional view of an embodiment of a stator interfacial insert that can be used with the carrier assembly of Figure 33.
[0079] Figure 43 is a partially cross-sectioned, exploded, perspective view of an embodiment of a carrier assembly that can be used with the CVT of Figure 2.
[0080] Figure 44 is a cross-sectional view of the carrier assembly of Figure 43.
[0081] Figure 45 is a perspective view of one embodiment of a stator support member that can be used in the carrier assembly of Figure 43.
[0082] Figure 46 is a second perspective view of the stator support member of Figure 45
[0083] Figure 47 is a perspective view of one embodiment of a planet subassembly that can be used with the carrier assembly of Figure 43.
[0084] Figure 48 is a cross-sectional view of the planet subassembly of Figure 47,
[0085] Figure 49 is a partially cross-sectioned, perspective view of one embodiment of a shift cam that can be used in the CVT of Figure 2.
[0086] Figure 50 is a cross-sectional view of the shift cam of Figure 49.
[0087] Figure 51 is a partially cross-sectioned, exploded, perspective view of an embodiment of a carrier assembly that can be used in the CVT of Figure 2.
[0088] Figure 52 is a cross-sectional view of the carrier assembly of Figure 51.
[0089] Figure 53 is a perspective view of a stator support member that can be used in the carrier assembly of Figure 51.
[0090] Figure 54 is a second perspective view of the stator support member of Figure 53.
[0091] Figure 55 is a perspective view of one embodiment of a stator interfacial member that can be used in the carrier assembly of Figure 51.
[0092] Figure 56 is a second perspective view of the stator interfacial member of Figure 55.
[0093] Figure 57 is a partially cross-sectioned, exploded, perspective view of an embodiment of a carrier assembly that can be used in the CVT of Figure 2.
[0094] Figure 58 is a cross-sectional view of the carrier assembly of Figure 57.
[0095] Figure 59 is a perspective view of an embodiment of a stator support member that can be used in the carrier assembly of Figure 57.
[0096] Figure 60 is a perspective view of an embodiment of a stator support member that can be used in the carrier assembly of Figure 57.
[0097] Figure 61 is a perspective view of an embodiment of a stator spacer that can be used in the carrier assembly of Figure 57.
[0098] Figure 62 is a cross-sectional view of the stator spacer of Figure 61.
[0099] Figure 63 is a perspective view of an embodiment of a main axle that can be used in the CVT of Figure 2,
[0100] Figure 64 is a partially cross-sectioned, perspective view of a shift nut that can be used in the CVT of Figure 2.
[0101] Figure 65 A is a partially cross-sectioned, exploded, perspective view of an embodiment of an idler assembly that can be used in the CVT of Figure 2.
[0102] Figure 65B is a cross-section of the idler assembly of Figure 65A.
[0103] Figure 66 is a perspective view of an embodiment of a shift nut that can be used in the idler assembly of Figure 65 A.
[0104] Figure 67 is a perspective view of an embodiment of a hub shell that can be used in the CVT of Figure 2.
[0105] Figure 68 is a second perspective view of the hub shell of Figure 67.
[0106] Figure 69 is a cross-sectional view of the hub shell of Figure 67.
[0107] Figure 70 is a perspective view of an embodiment of a hub cover that can be used in the CVT of Figure 2.
[0108] Figure 71 is a second perspective view of the hub cover of Figure 70.
[0109] Figure 72 is a cross-sectional view of the hub cover of Figure 70.
[0110] Figure 73 is a perspective view of an embodiment of a brake adapter ring that can be used with the CVT Figure 2.
[0111] Figure 74 is a cross-sectional view of the brake adapter ring of Figure 73.
[0112] Figure 75 is a perspective view of an embodiment of a disc brake adapter that can be used with the CVT of Figure 2.
[0113] Figure 76 is a cross-section of the disc brake adapter of Figure 75.
[0114] Figure 77 is a perspective view of an embodiment of a roller brake adapter that can be used with the CVT of Figure 2.
[0115] Figure 78 is a second perspective view of the roller brake adapter of Figure 77.
[0116] Figure 79 is a cross-sectional view of the roller brake adapter of Figure 77.
[0117] Figure 80 is a partially cross-sectioned, exploded, perspective view of an embodiment of a carrier assembly that can be used with the CVT of Figure 2.
[0118] Figure 81 is a cross-sectional view of the carrier assembly of Figure 80.
[0119] Figure 82 is an exploded, perspective view of an embodiment of a planet subassembly that can be used with the carrier assembly of Figure 80.
[0120] Figure 83 is an exploded, perspective view of certain components of the planet subassembly of Figure 82.
DETAILED DESCRIPTION OF CERTAIN INVENTIVE EMBODIMENTS
[0121] The preferred embodiments will be described now with reference to the accompanying figures, wherein like numerals refer to like elements throughout. The terminology used in the descriptions below is not to be interpreted in any limited or restrictive manner simply because it is used in conjunction with detailed descriptions of certain specific embodiments of the invention. Furthermore, embodiments of the invention can include several novel features, no single one of which is solely responsible for its desirable attributes or which is essential to practicing the inventions described. The CVT embodiments described here are generally of the type disclosed in U.S. Patent Nos. 6,241,636; 6,419,608; 6,689,012; 7,01 1 ,600; 7,166,052; U.S. Patent Application Nos. 11/243,484; 11/543,31 1 ; 60/948,273; 60/864,941 ; and Patent Cooperation Treaty Patent Application PCT/US2007/023315. The entire disclosure of each of these patents and patent applications is hereby incorporated herein by reference.
[0122] As used here, the terms "operationally connected," "operationally coupled", "operationally linked", "operably connected", "operably coupled", "operably linked," and like terms, refer to a relationship (mechanical, linkage, coupling, etc.) between elements whereby operation of one element results in a corresponding, following, or simultaneous operation or actuation of a second element. It is noted that in using said terms to describe inventive embodiments, specific structures or mechanisms that link or couple the elements are typically described. However, unless otherwise specifically stated, when one of said terms is used, the term indicates that the actual linkage or coupling may take a variety of forms, which in certain instances will be readily apparent to a person of ordinary skill in the relevant technology.
[0123] For description purposes, the term "radial" is used here to indicate a direction or position that is perpendicular relative to a longitudinal axis of a transmission or variator. The term "axial" as used here refers to a direction or position along an axis that is parallel to a main or longitudinal axis of a transmission or variator. For clarity and conciseness, at times similar components labeled similarly (for example, stator assembly 200A and stator assembly 200B) will be referred to collectively by a single label (for example, stator assembly 200).
[0124] Embodiments of a continuously variable transmission (CVT), and components and subassemblies therefor, will be described now with reference to Figures 1-83. Referring now to Figure 1, in one embodiment a bicycle 1 can include a continuously variable transmission (CVT) 100 supported in a frame 2. For simplification, only the rear portion of the bicycle 1 is shown Figure 1. The frame 2 can include a set of dropouts 3 that are configured to support the CVT 100. A sprocket 4 can couple to the CVT 100, and the sprocket 4 further couples via a drive chain 5 to a crank sprocket 6. The crank sprocket 6 is typically coupled to a pedal and crank assembly 7. The CVT 100 can be coupled to a wheel 8 via a number of wheel spokes 9. For clarity, only a few of the wheel spokes 9 are shown in Figure 1 as an illustrative example. In one embodiment, the transmission ratio of the CVT 100 can be adjusted via cables and a handle grip (not shown).
[0125] The CVT 100 can be used in many applications including, but not limited to, human powered vehicles, light electrical vehicles hybrid human-, electric-, or internal combustion powered vehicles, industrial equipment, wind turbines, etc. Any technical application that requires modulation of mechanical power transfer between a power input and a power sink (for example, a load) can implement embodiments of the CVT 100 in its power train.
[0126] Turning now to Figures 2 and 3, in one embodiment the CVT 100 includes a hub shell 102 coupled to a hub cover 104. The hub shell 102 substantially surrounds the internal components of the CVT 100. A brake adapter kit 106 couples to the hub shell 102. The CVT 100 can include a number of planet subassemblies 108 supported in a carrier assembly 101, The planet subassemblies 108 couple to an input subassembly 1 10, which input subassembly 110 is generally depicted in detail view A). In some embodiments, the planet subassemblies 108 are operably coupled to the hub shell 102 via a traction ring 145. The traction ring 145 can be configured to engage a cam roller retainer assembly 147, which couples to an output cam ring 149. The hub shell 102 couples to the output cam ring 149 in one embodiment. A main axle 112 can be arranged along the longitudinal axis of the CVT 100 and can be coupled to, for example, the dropouts 3 with no-turn- washers 114, axle nut 116, and lock-nut 118. In one embodiment, a shift rod 120 can be arranged along a central bore of the main axle 112
and can be coupled to an idler subassembly 109 via a shift nut 1 19. The idler subassembly 109 is arranged radially inward of, and in contact with, the planet subassemblies 108. The shift rod 120 can be axially constrained in the main axle 1 12 via a shift-rod-lock nut 122. In one embodiment, the shift rod 120 couples to, for example, cables (not shown) that are operationally coupled to a handlegrip or user control interface (not shown). For descriptive purposes, the sprocket side of the CVT 100 can be referred to as the input side of the CVT 100, and the brake adapter kit 106 side of the CVT 100 can be referred to as the output side of the CVT 100.
[0127] During operation of CVT 100, an input power can be transferred to the input subassembly 1 10 via, for example, the sprocket 4, The input subassembly 110 can transfer power to the planet subassemblies 108 via a traction or friction interface between the input subassembly 1 10 and the planet subassemblies 108. The planet subassemblies 108 deliver the power to the hub shell 102 via the traction ring 145 and the output cam ring 149. A shift in the ratio of input speed to output speed, and consequently a shift in the ratio of input torque to output torque, is accomplished by tilting the rotational axis of the planet subassemblies 108. A shift in the transmission ratio involves actuating an axial or rotational movement of the shift rod 120 in the main axle 112, which facilitates the axial translation of the idler assembly 109 and thereby motivates the tilting of the rotational axis of the planet subassemblies 108.
[0128] Passing now to Figure 4, in one embodiment the input subassembly 1 10 includes a torque driver 140 coupled to a torsion plate 142. The torsion plate 142 can be attached to a load cam ring 144 with, for example, screw fasteners or rivets. In some embodiments, the torsion plate 142 can be coupled to the load cam ring 144 with a spline. In one embodiment, the load cam ring 144 couples to a load cam roller retainer subassembly 146. The load cam roller retainer subassembly 146 further couples to a traction ring 148. The load cam ring 144, the load cam roller retainer subassembly 146, and the traction ring 148 are preferably configured to produce axial force during operation of the CVT 100. In other embodiments, the load cam ring 144, the load cam roller retainer subassembly 146, and the traction ring 148 are substantially similar in function to the traction ring 145, the load cam roller retainer 147, and the output cam ring 149 that are located on the output side of the CVT 100.
[0129] Referring to Figure 5 and 6, in one embodiment the torque driver 140 can be a substantially hollow cylindrical body with a first end having a set of torsion plate engagement splines 130 and a second end having a set of sprocket engagement splines 132. In some embodiments, the torque driver 140 can include a sprocket support shoulder 134 located on the outer circumference of the cyiindrical body and axially positioned between the torsion plate engagement splines 130 and the sprocket engagement splines 132. In other embodiments, the second end can have a standard bicycle freewheel thread to allow the coupling of a threaded freewheel or threaded sprocket. A first bearing bore 136 can be provided on the inner circumference of the cylindrical body in proximity to the first end. A first bearing support shoulder 137 can be arranged on the inner circumference of the cylindrical body in proximity to the first bearing bore 136. A second bearing bore 138 can be provided on the inner circumference of the cylindrical body in proximity to the sprocket engagement splines 132. A second bearing support shoulder 139 can be arranged on the inner circumference of the cylindrical body in proximity to the second bearing bore 138. In some embodiments, the torque driver 140 includes a number of service tool engagement splines 135 formed on the inner circumference of the cylindrical body. The service tool engagement splines 135 can be arranged in proximity to the sprocket engagement splines 132 and can generally be accessible to the exterior of the CVT 100.
[0130] Turning to Figures 7 and 8, in one embodiment the torsion plate 142 includes a splined inner bore 170 and a number of triangular extensions 172 extending radially from the splined inner bore 170. In some embodiments, the triangular extensions 172 are substantially axially aligned with a first end of the splined inner bore 170 so that the splined inner bore 170 and the triangular extensions 172 form a substantially flat face on the torsion plate 142. In other embodiments, the triangular extensions 172 extend from the splined inner bore 170 so that the radially outward end of the triangular extension 172 is angled relative to the splined inner bore 170 when viewed in the plane of the page of Figure 8. In one embodiment, each of the triangular extensions 172 can be provided with a cutout 174. Each of the triangular extensions 172 can be provided with a fastening hole 176 positioned on a radially outward portion of the extension 172. The fastening holes 176 facilitate the coupling of the torsion plate 142 to the load cam ring
144. The splined inner bore 170 facilitates the coupling of the torsion plate 142 to the torque driver 140. The triangular extensions 172 provide a lightweight and torsionally stiff structure to the torsion plate 142. The torsion plate 142 can be made from steel, aluminum, magnesium, plastic, or other suitable material.
[0131] Turning to Figures 9 and 10, in one embodiment the load cam ring 144 is a substantially annular ring with a number of ramps 152 formed on a first side of the annular ring. The load cam ring 144 can include a set of preload spring grooves 154, which can be formed on the first side of the annular ring. In some embodiments, the load cam ring 144 can have a bearing support surface 158 formed on a second side of the annular ring that is oppositely located from the first side of the annular ring. In one embodiment, the load cam ring 144 can include a number of fastening lugs 156 arranged on the inner circumference of the annular ring. The fastening lugs 156 can be substantially axialiy aligned with the second side of the annular ring. In some embodiments, the fastening lugs 156 can be used to support an over-molded plastic torsion plate that is substantially similar to torsion plate 142.
[0132] Referring to Figure 11, the traction ring 148 can be a generally annular ring having a number of ramps 153 formed on one side. The traction ring 148 can be provided with a traction contact surface 1480 on the inner circumference of the annular ring that is substantially opposite the side having ramps 153. The traction contact surface 1480 is configured to contact the planet subassembly 108. A number of preload spring grooves 155 can be formed on the annular ring. In one embodiment, the preload spring grooves 155 are formed on the side having the ramps 153. In the embodiment shown in Figures 2 and 3, the traction ring 145 is substantially similar to the traction ring 148.
[0133] Referring now to Figures 12-14, in one embodiment, an axial force generator device includes, among other things, the load cam ring 144, the load cam roller retainer subassembly 146 and the traction ring 148. In one embodiment, the ramps 152 are arranged to contact a number of load cam rollers 160. The load cam rollers 160 are retained in the load cam roller retainer subassembly 146. A number of springs 162, for example two, can be retained in the load cam roller retainer subassembly 146 and can be arranged to simultaneously contact the load cam ring 144 and the traction ring 148. In
the embodiment illustrated in Figure 13, the load cam roller retainer subassembly 146 includes a first slotted ring 146A coupled to a second slotted ring 146B. In some embodiments, the first and second slotted rings 146 A, 146B are received in a band 146C. The first slotted ring 146A and the second slotted ring 146B can be provided with slots 164. The slots 164 are configured to support the load cam rollers 160. The first slotted ring 146A and the second slotted ring 146B can be coupled together with, for example, a plurality of pegs 166A and bores 166B. In some embodiments, each of the slotted rings 146A and 146B have equally as many pegs 166A as bores 166B. The arrangement of the pegs 166A and the bores 166B around the face of the slotted rings 146A and 146B can be configured to accommodate various manufacturing methods, such as plastic injection molding. For example, the arrangement of the pegs 166A and the bores 166B can allow the slotted rings 146A and 146B to be substantially identical for manufacture while retaining features for alignment during assembly. In one embodiment, the pegs 166A are arranged around half the circumference of the slotted ring 146A while the bores 166B are arranged around the other half of the circumference. The arrangement of pegs 166A and 166B are substantially similar on slotted ring 146B, so that once assembled the slotted rings 146A and 146B are aligned when joined. In some embodiments, the slotted rings 146 A and 146B are further retained around their outer circumference or periphery with the band 146C. The band 146C can be a generally annular ring made from, for example, steel or aluminum. An outer circumference of the band 146C can have a number of holes 167. The holes 167 are generally aligned with the slotted rings 146A and 146B. The holes 167 are configured to, among other things, axially retain and align the slotted rings 146 A and 146B. In some embodiments, the slotted rings 146 A and 146B can be coupled to the band 146C with standard fasteners (not shown) via fastening the holes 167. In other embodiments, the fastening holes 167 can receive mating features formed onto outer periphery of the slotted rings 146.
[0134] Still referring to Figures 12-14, a plurality of springs 162, for example two, are retained in load cam roller retainer subassembly 146 and are arranged in such a way that one end of the spring 162 couples to the load cam ring 144 and the other end of the spring 162 couples to the traction ring 148. The springs 162 can be generally arranged 180-degrees with respect to each other for configurations provided with two
springs. In one embodiment, a middle portion of the spring 162 is retained in the load cam roller retainer subassembly 146. Shoulders 177 and 173 formed on the slotted rings 146 A and 146B, respectively, can be provided to capture the middle portion of the spring 162. In some embodiments, the spring 162 can be a coil spring of the compression type. In other embodiments, the spring 162 can be a wire spring. In yet other embodiments, the spring 162 can be a flat spring. It is preferable that the ends of spring 162 have rounded or curved surfaces that have generally the same shape as reaction surfaces 170 and 171.
[0135] A preload spring groove 154 can be formed onto the load cam ring 144. Similarly, a groove 155 can be formed onto the traction ring 148. Once assembled, the preload spring grooves 154 and 155 aid to, among other things, retain the spring 162 and provide the reaction surfaces 170 and 171, respectively. Channels 174 and 175 can be formed into the slotted rings 146A and 146B to provide clearance for the spring 162.
[0136] Preferably, once assembled, the springs 162 are configured to apply a force on the load cam ring 144 and the traction ring 148 that engages the load cam rollers 160 with the load cam ring 144 and the traction ring 148. The load cam rollers 160 are positioned generally on the flat portion of the ramps 152 and 153. The interaction between the traction ring 148, the load cam ring 144, and the springs 162 causes the load cam rollers 160 to roll up the ramps 152 and 153 for some distance to produce a preload that ensures that a certain minimum level of clamping force will be available during operation of the CVT 100.
[0137] Passing now to Figures 15A-15B, a torsion plate 1420 can include a substantially disc-shaped body having a splined inner bore 1422 configured to couple to, for example, the torque driver 140. The torsion plate 1420 can be provided with a bearing support surface 1424 on the outer periphery of one side of the disc-shaped body, and the torsion plate 1420 can be provided with a set of engagement splines 1426 located on the outer periphery of a second side of the disc-shaped body. The engagement splines 1426 can be configured to engage a cam ring such as cam ring 144. In one embodiment, the torsion plate 1420 can include a number of structural ribs 1428 arranged on the discshaped body. The structural ribs 1428 can form a lattice or triangulated pattern that connects the outer periphery of the disc-shaped body to the splined inner bore 1422.
[0138] Referring to Figures 16A and 16B, a torsion plate 1600 can couple to a load cam ring 1602. The load cam ring 1602 and the torsion plate 1600 can generally be used in CVT 100 in a similar manner as the load cam ring 144 and the torsion plate 142. In one embodiment, the torsion plate 1600 can be a generally disc shaped body 1604 having a splined central bore 1606. The splined central bore 1606 can be configured to mate with the splines 130 of the torque driver 140, for example. An outer periphery of the disc shaped body 1604 can be provided with a number of splines 1608. In some embodiments, the torsion plate 1600 can include a number of structural ribs 1609 formed on a first side of the disc shaped body 1604. The structural ribs 1609 can extend radially outward from the splined central bore 1606 and can be configured in a substantially triangulated pattern, such as the pattern shown in Figure 16A. Configuring the structural ribs 1609 in this way can, among other things, improve the torsional strength and stiffness to the torsion plate 1600.
[0139] The load cam ring 1602 can include a substantially annular ring 1610 having a number of ramps 1612 formed on a first face. The ramps 1612 can be substantially similar to the ramps 152. The inner circumference of the annular ring 1610 can be provided with a number of splines 1614 that can be adapted to mate with the splines 1608. In one embodiment, the torsion plate 1600 can be made of a plastic material that is formed over the load cam ring 1602. The splines 1608 and 1614 can be configured to rigidly couple the torsion plate 1600 to the traction ring 1602. In one embodiment, the annular ring 1610 can be provided with a bearing support surface 1616 that can be substantially similar to the bearing support surface 158. In some embodiments, the annular ring 1610 can include a number of preload spring grooves 1618 that are substantially similar to the preload spring grooves 155.
[0140] Turning to Figure 17, in one embodiment the output cam ring 149 can be a generally annular ring, substantially similar to the load cam ring 144. The output cam ring 149 can include a number of preload spring slots 1492 arranged substantially similar to the preload spring slots 154. The output cam ring 149 can also be provided with ramps 1494 that are substantially similar to ramps 152, and are configured to engage the load cam rollers 160. In one embodiment, the output cam ring 149 includes lugs 1496
arranged on the inner circumference of the annular ring. The lugs 1496 are preferably adapted to couple to a mating feature on the hub shell 102.
[0141] Referring now to the functional block diagram of Figure 18, in one embodiment a carrier assembly 50 can be configured to couple to, and/or to support, a planet subassembly 52. The carrier assembly 50 can be functionally similar in some respects to the carrier assembly 101. The planet subassembly 52 can be functionally similar in some respects to the planet subassembly 108. The carrier assembly 50 includes a stator interfacial member 54 coupled to the stator support member 56. In one embodiment, the stator support member 56 is further coupled to a stator torque reaction member 58. The stator interfacial member 54 can be configured to provide a sliding interface between certain components of the planet subassembly 52 and the stator support member 56. In one embodiment, the stator interfacial member 54 is a component that attaches to the stator support member 56. In some embodiments, the stator interfacial member 54 is integral with the stator support member 56. In yet other embodiments, the stator interfacial member 54 is integral with the planet subassembly 52. The stator interfacial member 54 is preferably a low-friction interface and made from materials such as plastic, bronze, or polished metals.
[0142] The stator support member 56 can be configured to provide structural support for the carrier assembly 50, and the stator support member 56 can be adapted to react forces generated during operation of the CVT 100. The stator support member 56 positions and supports the planet subassembly 52. The stator torque reaction member 58 can be provided to transfer torque from the stator support member 56 to another component in, for example, the CVT 100 during operation of the CVT 100. In one embodiment, the stator torque reaction member 58 is a component that can be coupled to the stator support member 56 so that the stator torque reaction member 58 can be made from a different material than the stator support member 56. For example, the stator torque reaction member 58 can be made of steel and the stator support member 56 can be made of aluminum. It should be noted that the reference to steel and aluminum are exemplary only; in other embodiments, other materials can be used (such as, for example, plastics, alloys, ceramics, composites, etc.). In some embodiments, the stator torque reaction member 58 is integral with the stator support member 56. In yet other
embodiments, the stator interfacial member 54, the stator support member 56, and the stator torque reaction member 58 can be one integral component.
[0143] Turning now to Figures 19 an d 2 0, the carrier assembly 101 can include a first stator subassembly 200A coupled with a number of stator spacers 202 to a second stator subassembly 200B. The stator spacers 202 can be arranged angularly around the perimeter of the stator subassemblies 200. In one embodiment, the stator spacers 202 can be attached to the stator subassemblies 200 with common fasteners. In the embodiment shown in Figure 20, the stator spacers 202 are orbit formed on stator spacer ends 203 for coupling the stator spacers 202 and the stator subassemblies 200. The carrier assembly 101 supports and facilitates a tilting of the rotational axis of balls 240 of the planet subassemblies 108. In some embodiments, the carrier assembly 101 is configured to couple to the main axle 112. In one embodiment, for example, the carrier assembly 101 is rigidly and non-rotatably coupled to the main axle 112.
[0144] Referring to Figures 21-27, the stator subassembly 200 can include a stator torque reaction insert 204, a stator support member 206, and a stator interfacial member 208. In one embodiment, the stator torque reaction insert 204 can be rigidly attached to the stator support member 206, and the stator interfacial member 208 can be attached to the stator support member 206.
[0145] The stator torque reaction insert 204 facilitates the coupling of the carrier assembly 101 to the main axle 112. In one embodiment, the stator torque reaction insert 204 includes a number of torque reaction shoulders 210 that are adapted to engage mating surfaces on the main axle 112. The stator torque reaction insert 204 prevents, among other things, rotation of the stator subassembly 200 with respect to the main axle 112. In one embodiment, the stator torque reaction insert 204 has six torque reaction shoulders 210 that form a hexagonal body. A number of locking splines 212 can be provided on the periphery of the hexagonal body. The locking splines 212 can facilitate the rigid attachment of the stator torque reaction insert 204 to the stator support member 206.
[0146] In one embodiment, the stator support member 206 includes a substantially disc-shaped body having an inner bore adapted to couple to the stator torque reaction insert 204. In some embodiments, the stator support member 206 has an inner
bore having a hexagonal shape. The stator support member 206 can be provided with a number of spacer support extensions 214 arranged angularly on a first face of the discshaped body about the longitudinal axis of the CVT 100. The stator support extensions 214 are preferably positioned angularly about the longitudinal axis of the CVT 100 and, for example, can be placed angularly between the planet subassemblies 108 in the CVT 100. In one embodiment, each of the spacer support extensions 214 includes a stator spacer support hole 216. In some embodiments, the stator spacer support holes 216 are arranged on a radially outward periphery of the stator support extensions 214. In one embodiment, each of the stator spacer support holes 216 can be provided with a stator spacer end relief 217 (see Figure 25, for example). The stator spacer end relief 217 substantially surrounds the stator spacer support hole 216. Once assembled, the stator spacer end 203 is substantially enclosed in the stator spacer end relief 217. The arrangement of stator spacers 200 on the outward periphery of the stator support extensions 214 maximizes torsional stiffness of the carrier assembly 101. The stator support member 206 can be provided with a number of structural ribs 218 arranged on a face of the disc-shaped body. The structural ribs 218 provide strength and stiffness to the disc-shaped body. The stator support member 206 provides structural support to the carrier assembly 101 for reacting forces generated during the operation of, for example, the CVT 100.
[0147] Referring to Figures 21-27, the stator support member 206 can be further provided with a number of guide support slots 220. The guide support slots 220 are substantially arranged between the spacer support extensions 214 around the discshaped body and extend radially outward from the inner bore. The number of guide support slots 220 provided on the stator support member 206 generally, though not necessarily, corresponds to the number of planet subassemblies provided in the CVT 100. Each of the guide support slots 220 can be provided with a leg clearance relief 222A positioned on a radially inward portion of the guide support slot 220. The leg clearance reliefs 222A provide clearance for certain components of the planet subassembly 108 during operation of the CVT 100. In some embodiments, the stator support member 206 can include a piloting shoulder 224 located radially inward of the guide support slots 220 and spacer support extensions 214. The piloting shoulder 224 facilitates alignment of the
stator support member 206 to the stator interfacial member 208. In some embodiments, the stator support member 206 can have a uniform material thickness throughout the component, which aides manufacturing processes such as casting or forging.
[0148] In one embodiment, the stator interfacial member 208 is a substantially disc-shaped body having an inner bore. The stator interfacial member 208 can be provided with a number of sliding guide slots 226 arranged angularly about a longitudinal axis of the disc-shaped body. The disc-shaped body can include a number of interlocking tabs 228 formed on one side. The interlocking tabs 228 are configured to mate with a number of interlocking holes 229 on the stator support member 206. In some embodiments, a number of leg clearance reliefs 222B are formed toward the inner periphery of the guide slots 226. The stator interfacial member 208 can be provided with a capture ring 230 formed on the outer periphery of the disc-shaped body. The capture ring 230 is preferably formed on the side of the disc-shaped body with the interlocking tabs 228. The capture ring 230 can couple to a capture shoulder 231 formed on the stator support member 206. The interlocking tabs 228 and capture ring 230 facilitate a rigid coupling between the stator interfacial member 208 and the stator support member 206. A number of capture extensions 232 (see Figure 26) can be provided on the outer periphery of the stator support member 206. The capture extensions 232 are generally concentric with the capture shoulder 231 and are configured to couple to capture cavities 233 (Figure 27) of the stator interfacial member 208. In one embodiment, the stator interfacial member 208 can be a plastic component, and can be pressed onto the stator support member 206 so that the capture ring 230 and the interlocking tabs 228 engage the corresponding mating capture shoulder 231 and the interlocking holes 229. In some embodiments, the stator interfacial member 208 can be plastic injection molded onto the stator support member 206. The stator interfacial member 208 facilitates a low friction, sliding coupling between the carrier assembly 101 and the planet subassemblies 108.
[0149] Turning now to Figures 28-29, the planet subassembly 108 can include a substantially spherical ball 240, a ball axle 242, and at least one leg 244. The ball 240 can be provided with a central bore. The ball 240 is supported on the ball axle 242 with ball support bearings 249 arranged in the central bore and positioned with spacers 245A, 245B, and 245C. In other embodiments, the spacers 245A, 245B, and
245C can be integral with the ball support bearings 249. The ball axle 242 can be supported on one end with one leg 244 and on a second end with another leg 244. In some embodiments, the leg 244 can be pressed onto the bail axle 242 so that there is no relative motion between the leg 244 and the ball axle 242 during operation of the CVT 100. The legs 244 can be configured to act as levers to pivot the ball axle 242 about the center of the ball 240.
[0150] Referring to Figures 30-32, in one embodiment the leg 244 includes a sliding interface 246 and a shift cam guide end 248. The leg 244 can be provided with a ball axle support bore 250. In some embodiments, the leg 244 can include a hole 252. The hole 252 can serve to, among other things, reduce the weight of the leg 244. In one embodiment, the sliding interface 246 can have a length Ll of about 12.5mm and a width Wl of about 8mm, In some embodiments, a leg 2444 can be substantially similar in function to the leg 244. The leg 2444can be provided with a sliding interface 2466 that can be of a length L2 that can be about 7mm, for example. The shift cam guide end 2488 can have a width w2, which is generally about 3.5mm. The shift cam guide ends 248 and 2488 are preferably adapted to slide on the shift cams 260 (see Figure 20, for example). The sliding interfaces 246 and 2466 are preferably adapted to slide in the carrier assembly 101. In some embodiments, the sliding interfaces 246 and 2466 have curved profiles as shown in the plane of the page of Figure 31 or Figure 32. Each of the curved profiles of the sliding interfaces 246 and 2466 are typically conformal to a mating surface of the carrier assembly 101. The legs 244 or 2444 are preferably adapted to transfer forces from the planet subassembly 108 to the carrier assembly 101.
[0151] Passing now to Figures 33-34, an alternative carrier assembly 300 includes a number of stator interfacial inserts 302 supported in a stator support member 304. The stator interfacial inserts 302 are slidingly coupled to legs 240 of the planet subassemblies 108. The carrier assembly 300 includes a retaining ring 306 configured to couple the stator interfacial inserts 302 to the stator support member 304. In one embodiment, the carrier assembly 300 includes two stator support members 304 rigidly coupled together. Preferably, each leg 240 of the planet subassemblies 108 is provided with a corresponding stator interfacial insert 302. It should be readily apparent to a
person having ordinary skill in the relevant technology that the carrier assembly 300 is substantially similar in function to the carrier assembly 101.
[0152] Referring to Figures 35-38, the stator support member 304 can be a generally cylindrical body having a central bore. The stator support member 304 can include a number of insert support slots 308. The insert support slots 308 can be arranged angularly about, and extend radially from, the central bore of the cylindrical body. Preferably, though not necessarily, the stator support member 304 has at least one insert support slot 308 for each stator interfacial insert 302. Each of the insert support slots 308 can have a tab engagement hole 310 formed on a radially inward portion of the insert support slot 308. The tab engagement hole 310 can be configured to couple to a mating feature on the stator interfacial insert 302. The stator support member 304 can be provided with a number of support extensions 312. Each of the stator support extensions 312 includes a fastening hole 314 and a dowel pin hole 315; each hole is configured to receive a fastener and a dowel pin, respectively. In one embodiment, the fastening hole 314 is arranged radially inward of the dowel pin hole 315. The stator support member 304 can be provided with a number of cutouts 316 formed on one end of the cylindrical body. Preferably, the cutouts 316 reduce the weight of the stator support member 304 while retaining the strength and stiffness of the component. In one embodiment, the stator support member 304 can have a number of torque reaction shoulders 318 formed on the inner bore. The torque reaction shoulders 318 can be adapted to mate with corresponding shoulders on the main axle 112. In some embodiments, the torque reaction shoulders 318 form a square bore. In one embodiment, the stator support member 304 is provided with a retaining ring groove 320 that is configured to couple to the retaining ring 306.
[0153] Turning now to Figures 39-42, the stator interfacial insert 302 can be a generally rectangular body having a back 322 with at least two side extensions 324 attached to the back 322. A stator interlock tab 326 can be formed on the back 322. In one embodiment, the stator interlock tab 326 can be substantially circular and extend from the back 322. The stator interlock tab 326 can be configured to couple to the tab engagement hole 310 on the stator support member 304. In one embodiment, the stator interfacial insert 302 includes a retaining shoulder 328 formed on an end of the back 322
at a distal location from the stator interlock tab 326. The retaining shoulder 328 is configured to couple to the retaining ring 306. In other embodiments, a stator interfacial insert 303 is not provided with a retaining shoulder such as the retaining should 328, but can share many other similar elements with the stator interfacial insert 302.
[0154] The stator interfacial insert 302 can be provided with a sliding guide surface 330 formed between the two side extensions 324. The sliding guide surface 330 is preferably adapted to couple to a leg 240 of the planet subassembly 108. In one embodiment, the sliding guide surface 330 has a leg clearance recess 332 formed on an end of the rectangular body in proximity to the stator interlock tab 326. The stator interfacial insert 302 preferably is made from a low-friction material with sufficient compressive strength. For example, the stator interfacial insert 302 can be made out of a variety of plastics that can include Fortron 1342L4, Nylon 6/6 resin, Vespel, Rulon, PEEK, Delrin or other materials. The materials listed here are merely examples and are not intended to be an exhaustive list of acceptable materials as many different types of materials can be used in the embodiments disclosed herein.
(0155] Passing now to Figures 43-44, in one embodiment a carrier assembly 400 includes a stator support member 402 coupled a stator torque reaction insert 404, which can be substantially similar to the stator torque reaction insert 204. The stator support member 402 is adapted to slidingly couple to a number of planet subassemblies 406. Preferably, the carrier assembly 400 includes two stator support members 402 coupled to each other with common screw fasteners, rivets, or welds.
[0156] Referring to Figures 45-46, in one embodiment the stator support member 402 is a substantially bowl-shaped body having a central bore. The stator support member 402 can include a fastening flange 410 having a number of fastening holes 41 1. The fastening flange 410 can be arranged on the outer periphery of the bowl- shaped body. A number of guide support slots 412 can be formed on the interior of the bowl-shaped body. The stator support member 402 can be provided with a number of ball clearance cutouts 414 configured to substantially surround each of the planet subassemblies 406. The stator support member 402 can include a number of torque reaction shoulders 416 formed on the central bore of the bowl-shaped body. In one embodiment, the torque reaction shoulders 416 form a hexagonal pattern. The torque
reaction shoulders 416 can be adapted to couple to the stator torque reaction insert 404. The stator support member 402 can be provided with a number of structural ribs 418 arranged on the bottom of the bowl-shaped body. The structural ribs provide strength and stiffness to the stator support member 402.
[0157] Referring to Figures 47 and 48, in one embodiment the planet subassembly 406 includes a ball 420, a ball axle 422, and a leg 424. The ball 420 has a bore and is supported on the ball axle 422 with support bearings 426. In one embodiment, the support bearings 426 are positioned in on the ball axle 422 with at least one spacer 428. The leg 424 can be pressed onto an end of the ball axle 422. Each end of the ball axle 422 is coupled to a leg 424. In one embodiment, the leg 424 includes a sliding interface guide 421, a shift cam engagement surface 423, and a bearing support extension 425 surrounding a ball axle bore 427. In some embodiments, the leg 424 can include a press relief hole 429 arranged concentric with the ball axle bore 427. The sliding interface guide 421 can have a curved profile when viewed in the plane of the page of Figure 48. The sliding interface guide 421 is preferably substantially conformal with the guide support slots 412 so that the forces transferred from the leg 424 to the stator support member 402 are distributed over a large surface area of contact between the leg 424 and the stator support member 402. This arrangement minimizes stress and wear on the contacting components.
[0158] Turning to Figures 49-50, in one embodiment a shift cam 430 includes a number of leg contact surfaces 432. The leg contact surfaces 432 can have a profile that is substantially convex when viewed in the plane of the page in Figure 50, and the profile can be substantially flat when viewed in the plane of the cross-section in Figure 49. The substantially flat profile facilitates a line contact between the leg 424 and the shift cam 430. The line contact is preferable for minimizing wear and stress on the leg 424 and the shift cam 430. In one embodiment, the shift cam 430 includes a number of alignment extensions 436. The alignment extensions 436 are arranged on each side of each of the leg contact surfaces 432, so that the leg 424 is substantially flanked by the alignment extensions 436 when assembled. In some embodiments, the shift cam 430 is provided with a bearing race 438 that is adapted to support a bearing for facilitating the coupling of the shift cam 430 to, for example, the idler assembly 109. The shift cam 430
can also be provided with a shift nut engagement shoulder 440 that extends ax i ally from the leg contact surfaces 432. The shift nut engagement shoulder 440 surrounds a hollow bore 442, which is configured to provide clearance to the main axle 112, for example. The shift nut engagement shoulder 440 can couple to the shift nut 1 19, for example.
[0159] Passing now to Figures 51-56, in one embodiment a carrier assembly 500 can include a stator support member 502 coupled to a stator interfacial member 504. A stator torque reaction insert 506 can be coupled to the inner bore of the stator support member 502. The stator support member 502 can be provided with a number of torque reaction shoulders 507 (see Figure 53, for example). The torque reaction shoulders 507 are configured to engage a number of mating torque reaction shoulders 508 provided on the stator torque reaction insert 506. In one embodiment, the stator torque reaction insert 506 includes a piloting flange 510 that extends radially from the torque reaction shoulders 508. The piloting flange 510 is adapted to align and couple to the inner diameter of the stator interfacial member 504. In some embodiments, the piloting flange 510 can include a number of holes (not shown) configured to receive fasteners, such as rivets, to facilitate the coupling of the piloting flange 510 to the stator support member 502. In other embodiments, the piloting flange 510 can be welded to the stator support member 502. In yet other embodiments, the piloting flange 510 can be configured to couple to the stator support member 502 via the stator interfacial member 504. For example, the stator interfacial member 504 can be made of plastic, which can be formed around the piloting flange 510 and the stator support member 502 in such a way as to facilitate the coupling of the piloting flange 510 to the stator support member 502.
[0160] Referring now specifically to Figures 53-54, the stator support member 502 can be a generally bowl shaped body having a bottom face 512. In one embodiment, the torque reaction shoulders 507 are formed on the bottom face 512. It should be readily apparent that the torque reaction shoulders 507 can be, in some embodiments, knurls or splines (not shown) configured to facilitate the coupling of the stator support member 502 to, for example, the main axle 112. A number of interlock cavities 514 can be provided on the bottom face 512. The interlock cavities 514 are adapted to couple to mating features located on the stator interfacial member 504. In the embodiment shown in Figures 53 and 54, the interlock cavities 514 are arranged in
groups of four interlock cavities 514 per planet assembly 108, and the groups of interlock cavities 514 are distributed angularly about the torque reaction shoulders 507 on the bottom face BF. In one embodiment, each of the interlock cavities 514 has a corresponding tab 515 that extends from the interlock cavity 514 towards the interior of the bowl shaped body. The tabs 515 are configured to align and couple to mating features of the stator interfacial member 504. The stator support member 502 can also be provided with a number of ball clearance cavities 516 formed on the outer periphery of the bowl shaped body. The number of ball clearance cavities 516 preferably, though not necessarily, corresponds to the number of planet subassemblies 108 provided in, for example, the CVT 100. The stator support member 502 can include a fastening flange 518 located on the outer periphery of the bowl-shaped body. The fastening flange 518 can have a number of fastening holes 519. In one embodiment, the stator support member 502 can be a stamped sheet metal component. Once assembled, carrier 500 can include two stator support members 502 coupled together at the respective fastening flange 518 with common screw fasteners or rivets.
[0161] Referring to now specifically to Figures 55 and 56, the stator interfacial member 504 can include a disk shaped body having an inner bore. In one embodiment, the disc shaped body has a number of guide slots 520 arranged angularly about the inner bore so that each of the guide slots 520 extends radially from the inner bore to an outer periphery of the disc shaped body. In some embodiments, the guide slots 520 have a conformal profile configured to couple to the legs 240 of the planet assembly 108. The stator interfacial member 504 can include a number of interlock tabs 522 configured to mate with the interlock cavities 514 and tabs 515 of the stator support member 502. In one embodiment, interlock tabs 522 can be arranged in groups of four interlock tabs 522 located at each guide slot 520. For example, each of the guide slots 520 can be flanked on each side by at least two interlock tabs 522. In some embodiments, at least one interlock tab 522 is arranged on either side of the guide slot 520. The stator interfacial member 504 can be provided with a number of leg clearance slots 524. The leg clearance slots 524 are generally formed on the inner circumference of the disk shaped body and the leg clearance slots 524 are substantially aligned angularly with the guide slots 520. In some embodiments, the stator interfacial member 504 can
include a number of stator support member extensions 526 that are configured to engage the stator support member 502. The stator support member extensions 526 are preferably substantially aligned with, and extend from, the guide slots 520.
[0162] Referring now to Figures 57-62, in one embodiment a carrier assembly 600 can include a first stator support member 602 coupled to a second stator support member 603 via a number of stator spacers 604. The carrier assembly 600 can be adapted to cooperate with planet subassemblies 406. The first stator support member 602 can be a generally disk-shaped body having a central bore 608. The central bore 608 is configured to couple to, for example, the main axle 112. In one embodiment, the main axle 1 12 is welded to the first stator support member 602, for example. In other embodiments, the main axle 112 can be coupled to the first stator support member 602 via torque reaction shoulders that are substantially similar to torque reaction shoulders 210 (see Figure 21, for example) and the torque reaction shoulders 318 (see Figure 35, for example).
[0163] Still referring to Figures 57-62, the second stator support member 603 can be a generally disc-shaped body having a central bore 610. The central bore 610 is configured to provide clearance between the disc-shaped body and the main axle 112. In one embodiment, the radial clearance between the disc-shaped body and the main axle 1 12 is large enough to allow the idler assembly 109, for example, to be removed from the main axle 112 while the second stator support member 603 and the first stator support member 602 remain assembled. The radial clearance between the second stator support member 603 and the main axle 112 facilitates, among other things, angular alignment , between the first and second stator support members 602 and 603 that is independent from the alignment of the main axle 112 to the second stator support member 603, thereby simplifying assembly of the carrier 600 and the main axle 112.
[0164] In one embodiment, the first stator support member 602 is provided with a number of support extensions 612 and a number of guide slots 614 interposed between the support extensions 612. The guide slots 614 are arranged angularly about, and extend radially from, the central bore 608. The planet assemblies 406 are adapted to slide in the guide slots 614. The support extensions 612 substantially define the perimeter structure for a number of stator spacer cavities 616. Each of the stator spacer
cavities 616 is adapted to receive an end of the stator spacer 604. The end of the stator spacer 604 can attach to the stator spacer cavity 616 with common screw fasteners, press fit, or other suitable fastening means. Similarly, the second stator support member 603 can be provided with the support extensions 612. The support extensions 612 form sides for the guide slots 614. The guide slots 614 are arranged angularly about, and extend radially from, the central bore 610. The support extensions 612 substantially define the perimeter structure for a number of stator spacer cavities 616.
[0165] In one embodiment, the stator spacer 604 includes ends 620 and 622 connected by a clearance neck 624. The clearance neck 624 is preferably configured to maximize torsional stiffness of the stator spacers 604 while maintaining adequate clearance between the planet subassemblies 406. In one embodiment, the clearance neck 624 has a substantially diamond shaped cross-section 626 at the mid-point of the body while the ends 620 and 622 are substantially triangular in cross-section, when viewed in the plane of the page of Figure 62.
[0166] Turning to Figure 63, in one embodiment the main axle 112 can include a substantially elongated body with a shift nut clearance slot 1120 arranged in a middle portion of the elongated body. The shift nut clearance slot 1 120 is an opening in the elongated body that is aligned axially in the elongated body. The shift nut clearance slot 1 120 has a first axial end and a second axial end. A number of torque reaction shoulders 1122 can be formed in proximity to each axial end. In one embodiment, six torque reaction shoulders 1122 are formed at the first axial end, and six torque reaction shoulders 1122 are formed at the second axial end. In some embodiments, only four torque reaction shoulders 1122 are formed at each axial end. In other embodiments, as few as one torque reaction shoulder 1 122. In yet other embodiments, the torque reaction shoulders 1122 can be a knurled surface. The torque reaction shoulders 1122 are configured to couple to, for example, the carrier assembly 101. The main axle 1 12 can also include frame support flats 1 124 on each end of the elongated body. The frame support flats 1 124 are configured to couple to, for example, dropouts 3 (see Figure 1, for example).
[0167] Referring to Figure 64 now, a shift nut 119 can include a threaded bore 1190 configured to couple to the shift rod 120, for example. The shift nut 119 can
include at least two shift cam engagement faces 1192 that extend from the threaded bore 1190. The shift cam engagement faces 1192 can be substantially flat surfaces that are configured to couple to, for example, the shift cam 430. In one embodiment, the shift nut 119 can be provided with a bore 1194 that intersects the threaded bore 1190. The bore 1 194 can, among other things, reduce the weight of the shift nut 1 19.
[0168] Passing now to Figures 65A-66, in one embodiment an idler assembly 700 includes an idler 702, a first and a second shift cam 704 and 706 operably coupled to the idler with a bearing 705. In some embodiments, the bearing 705 has a flexible cage
707 that can be manipulated during assembly. In other embodiments, the bearing 705 can consist of two bearings that have independent cages. The idler assembly 700 can be coupled to, for example, the shift rod 120 with a first and a second shift nut 708 A and 708B. The shift nuts 708 can be arranged in the shift nut clearance slot 1 120 of the main axle 112 and couple to shift nut engagement shoulders 710 formed on the shift cams 704 and 706. The shift nut 708 can be provided with a threaded bore 712 adapted to couple to a threaded portion of the shift rod 720. The shift nut 708 can be configured to axially translate with a rotation of the shift rod 120, and thereby axially translating the idler assembly 700. In one embodiment, the shift nut 708 is provided with a shift cam engagement shoulder 714 formed on a first end. The shift cam engagement shoulder 714 is configured to mate with the shift nut engagement shoulders 710. The shift cam engagement shoulder 714 extends radially in one direction from the threaded bore 712 and is aligned axially with the first end of the body of the shift nut 708. In some embodiments, the shift nut 708 is provided with a set of flats 716.
[0169] During assembly, the first and the second shift nuts 708 are placed in the shift nut clearance slot 1120 and positioned to allow the idler assembly 700 to be placed onto the main axle 112. In some embodiments, the first and the second shift nuts
708 are one integral component. Once the idler assembly 700 is placed onto the main axle 112, the shift rod 120 is threaded into the first shift nut 708 A, which aligns the threaded bore 712 with the longitudinal axis of the transmission and facilitates the engagement of the shift cam engagement shoulder 714 with the shift nut engagement shoulder 710. The second shift nut 708B is threaded onto the shift rod 120 and couples to the second shift cam 706. Once assembled, the two shift nuts 708 axially guide the idler
assembly 700. The shift nuts 708 allow the idler assembly 700 to be removed from the main axle 1 12 without disassembly of the idler assembly 700.
[0170] Turning to Figures 67-69, one embodiment of the hub shell 102 will be described. The hub shell 102 can include a first spoke flange 6700A and a second spoke flange 6700B arranged on the outer periphery of the hub shell 102. The first and the second spoke flanges 6700 are provided with a number of spoke fastening holes 6702 to facilitate the coupling of the CVT 100 to a wheel of a bicycle, for example. The hub shell 102 can include a number of brake adapter splines 6704 formed on an exterior surface of the hub shell 102. The brake adapter splines 6704 are encircled with a set of threads 6706. The threads 6706 are configured to mate with a brake adapter ring 7300 (see Figure 3, for example). A second set of threads 6708 are provided on an end opposite the brake adapter splines 6704. The second set of threads 6708 are configured to mate with the hub shell cover 104. The hub shell 102 can be provided with an interior face 6710 having a central bore concentric with the brake adapter splines 6704. The central bore can include a seal bore 6712, a bearing bore 6714, and a snap ring groove 6716. Preferably, the seal bore 6712 is positioned axially outward of the bearing bore 6714. The seal bore 6712 is configured to support, for example, an axle seal. The bearing bore 6714 is configured to support, for example, a bearing. The interior face 6710 can be provided with a set of splines 6718 configured to mate with the output cam ring 149, for example.
[0171] Referring to Figures 70-72 now, one embodiment of the hub cover 104 includes a disc-shaped body 7000 having a central bore 7002, an exterior face 7004, and an interior face 7006. The interior face 7006 is preferably arranged facing the interior of the CVT 100, and the exterior face 7004 is preferably arranged facing the exterior of the CVT 100. In some embodiments, the hub cover 104 is arranged on the input side of the CVT 100. The hub cover 104 includes a threaded outer periphery 7008 configured to mate with the hub shell 102. The central bore 7002 can be provided with a bearing support surface 7010 and a seal support bore 7012. The bearing support surface 7010 and the seal support bore 7012 are coaxial with the main axle 112. The interior face 7006 can be provided with a thrust reaction surface 7014 configured to support, for example, a thrust bearing of the CVT 100. The hub cover 104 can be provided with a set
of stiffening ribs 7016 extending radially from the central bore 7002 on the interior face 7006. In some embodiments, the hub cover 104 includes a set of tool engagement splines 7018 arranged on the exterior face 7004 and surrounding the central bore 7002. The tool engagement splines 7018 facilitate, among other things, the coupling of the hub cover 104 to the hub shell 102.
[0172] Passing to Figures 73-74, in one embodiment a brake adapter ring 7300 can be a generally annular ring having a threaded perimeter 7302. A first exterior face of the annular ring can include a number of tool engagement holes 7304 configured to facilitate the coupling of the brake adapter ring 7300 to, for example, the hub shell 102. The brake adapter ring 7300 can be provided with a locking chamfer 7306 formed on the inner circumference of the annular ring. In some embodiments, the diameter of the annular ring is in the range of 1.25 to 3.25 inches.
[0173] Referring to Figures 75-76 now, in one embodiment a disc brake adapter 7500 includes a brake alignment surface 7502 and a number of torque reaction splines 7504. The brake alignment surface 7502 is substantially configured to mate with a standard disc brake for a bicycle. The torque reaction splines 7504 are configured to mate with the brake adapter splines 6704 of the hub shell 102 (see Figure 67, for example). The disc brake adapter 7500 can be provided with a seal support surface 7506 that is configured to couple to a seal of the CVT 100. A number of brake fastening holes 7508 can be provided on the disc brake adapter 7500. The disc brake adapter 7500 can include a locking chamfer 7510 configured to engage the brake adapter ring 7300. The engagement of the locking chamfer 7510 with the locking chamfer 7306 provides a rigid coupling between the disc brake adapter 7500 and the hub shell 102.
[0174] Referring now to Figures 77-79, in one embodiment a roller brake adapter 7700 can include a number of torque reaction splines 7702 that are substantially similar to torque reaction splines 7504, and are configured to couple to the brake adapter splines 6704 of the hub shell 102. The roller brake adapter 7700 can be provided with a splined extension 7704 that is configured to couple to a standard roller brake of a bicycle. The roller brake adapter 7700 can include a locking chamfer 7706 that is substantially similar to the locking chamfer 7510, and is adapted to engage the locking chamfer 7306 of the brake adapter ring 7300. The roller brake adapter 7700 can also be provided with a
seal support surface 7708 that is configured to couple to a seal of the CVT 100. Once assembled, the roller brake adapter 7700 can be coupled to, for example, the CVT 100 at substantially the same location on the hub shell 102 as the disc brake adapter 7500. The engagement of the locking chamfer 7706 with the locking chamfer 7306 provides a rigid coupling between the roller brake adapter 7700 and the hub shell 102. In one embodiment, the brake adapter kit 106 can include the brake adapter ring 7300 and the disc brake adapter 7500. In other embodiments, the brake adapter kit 106 can include the brake adapter ring 7300 and the roller brake adapter 7700.
[0175] Turning now to Figures 80 and 81, in one embodiment a carrier assembly 800 can include a first stator support member 802A coupled with a number of stator spacers 804 to a second stator support member 802B, The stator spacers 804 can be arranged angularly around the perimeter of the stator support members 802. In one embodiment, the stator support members 802 and the stator spacers 804 are substantially similar in function to the stator subassemblies 200 and the stator spacers 202, The carrier assembly 800 supports and facilitates a tilting of the rotational axis of a number of planet subassemblies 806. In some embodiments, the stator support member 802 can be coupled to a stator torque reaction insert 807 that is substantially similar to the stator torque reaction insert 204, for example. In other embodiments, the stator support member 802 is coupled directly to the main axle 112.
[0176] Turning to Figures 82 and 83, and still referring to Figures 80 and 81, in one embodiment, the planet subassembly 806 includes a first stator interfacial cap 808A coupled to a first leg 810A. The planet subassembly 806 includes a ball 812 configured to rotate about a planet axle 814. In one embodiment, the planet axle 814 is supported in the first leg 810A and in a second leg 810B. The second leg 810B can be coupled to a second stator interfacial cap 808B. Typically, each of the stator interfacial caps 808 are provided with a planet axle relief 816 that is configured to provide clearance between the planet axle 814 and the stator interfacial cap 808. The stator interfacial cap 808 preferably includes a sliding interface surface 817 that is configured to contact the stator support member 802. In one embodiment, the sliding interface surface 817 has a curved profile when viewed in the plane of the page of Figure 81. The sliding interface surface 817 is substantially similar in certain functional aspects to the sliding interface
guides 421. In some embodiments, the stator interfacial cap 808 includes sides 818 that extend from the sliding interface surface 817. The sides 818 can be arranged to substantially flank the leg 810. In some embodiments, the stator interfacial caps 808 are made of a plastic or other low-friction material. The legs 810 can be made of steel, for example. The stator interfacial cap 808 can be formed or assembled onto the legs 810 via a plastic molding process, for example. Once assembled, the stator interfacial cap 808A and the leg 810 can be substantially similar in certain functional aspects to the leg 244, 2444, or 424, for example. In some embodiments, the leg 810 can be adapted to couple to the shift cam 260 or 430, for example.
[0177] It should be noted that the description above has provided dimensions for certain components or subassemblies. The mentioned dimensions, or ranges of dimensions, are provided in order to comply as best as possible with certain legal requirements, such as best mode. However, the scope of the inventions described herein are to be determined solely by the language of the claims, and consequently, none of the mentioned dimensions is to be considered limiting on the inventive embodiments, except in so far as anyone claim makes a specified dimension, or range of thereof, a feature of the claim.
[0178] The foregoing description details certain embodiments of the invention. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the invention can be practiced in many ways. As is also stated above, it should be noted that the use of particular terminology when describing certain features or aspects of the invention should not be taken to imply that the terminology is being redefined herein to be restricted to including any specific characteristics of the features or aspects of the invention with which that terminology is associated.
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