High capacity all metal V-belts for transmitting drive between continuously variable pulleys are known in the art. Belts constructed of endless metal bands or chain links have rigid bridging transverse load blocks which engage pulley faces to transmit traction drive under contact pressure imposed radially by belt tension. Typical rigid load blocks employed with multiple laminated individual band layers in a "compression" drive are disclosed in Van Doorne et al, U.S. Patent No. 3,720,113. Similar alternative rigid load blocks are disclosed in the CVT belt of U.S. Patent No. 4 ,911,682, and in chain belt Patents 4,993,999 and 5,026,332.

Such load blocks engage eleven degree (11°) pulley faces (22° included angle) with oil environment and typical f r iction coefficients which provide free release on leaving each pulley. The transverse rigid load blocks carried by the belt engage the pulley faces with a contact pressure imposed by belt tension amplified by a factor of 5.24 times the radial load (1/sine 11°). This provides the equivalent of a corresponding increase in traction coefficient in determining required back tension to prevent drive slippage under load. Notwithstanding such amplified contact pressure, substantial back tension is required which subtracts from the useful drive torque capacity.

BRIEF DESCRIPTION OF THE PRESENT INVENTION

Instead of solid transverse load blocks having spanning contact with the pulley faces, the present invention employs pairs

of transverse drive transmitting "toggle" elements having central abutting contact with each other radially outward of end engagement with the pulley faces. Required clearance for radially outward toggle element deflection provides f ree release of driving engagement upon release of radial load in leaving each pulley, even with extremely small pulley face angles, while radially inward pressure of the belt on the bridging pair of elements during engagement provides a toggle effect in generating additional driving contact pressure against the pulley faces. The self-releasing toggle principle has been successfully tested with 5° pulley faces (10° included angle) with no resistance to free release. Since pulley face pressure imposed by belt tension radial load is amplified as a function of the sine of the face angle, a greatly increased contact pressure can be realized, apart from the toggle effect, by reducing the pulley angle, e.g., by a factor of 11.47 in the case of 5° pulley face angle as compared to 5.24 for 11°.

Thus, the pulley angle plus toggle effect serve a purpose equivalent to increasing the coefficient of friction by a factor corresponding to the amplification of contact pressure. The result in increased drive capacity without slipping through the use of a decreased pulley angle, apart from toggle effect, is subject to def initive calculation by determining the minimum relative back tension required to prevent slippage under the formula:

^τ l = ^e fa

In this formula, "T^ is drive tension; "T2" is minimum nonslip back tension; "e" is base of hyperbolic logarithm; "f" is

coefficient of friction: and "a" is angle in radians subtending the arc of contact. The effective traction coefficient for applying such formula to V-pulley faces is equal to f/sine of side pulley angle.

An alternative application of the toggle drive element principle is disclosed which will provide belt clamping during pulley engagement, as well as free release at the exit, in a tension drive system. A pair of wedge elements provide central reaction contact radially outward of the belt and clamping engagement with the belt when actuated by toggle element contact with the pulley, which may also have 5° faces as discussed above. Each of the toggle elements is modified to provide an inwardly open V, matching the wedge angle, effective to press the respective wedge elements into clamping engagement with the belt.

A further modification employs a single double faced wedge element oppositely engaged by the respective toggle elements.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a diagrammatic view of two-piece toggle load block engaging 5° pulley faces;

Fig. 2 is a diagrammatic view of two-piece toggle load block releasing pulley faces;

Fig. 3 is a fragmentary sectional view of prior art pulley engaged by rigid transverse load blocks;

Fig. 4 is a fragmentary end view of plural load blocks of Fig. 3 mounted on a plurality of laminated bands;

Fig. 5 is a schematic perspective view of prior art adjustable conical pulleys employing belt of Figs. 3 and 4;

Fig. 6 is a view corresponding to Fig. 3 employing two-piece toggle load blocks of the present invention in place of rigid one- piece load blocks of Fig. 3;

Fig. 7 is a sectional view of a prior art chain link belt employing single piece rigid transverse load blocks;

Fig. 8 is a view of two-piece load blocks of present invention to replace rigid one-piece load blocks of Fig. 7;

Fig. 9 is a graphic representation of comparative minimum belt back tension required for nonslip operation for different pulley angles.

Fig. 10 is a sectional view correspond ing to Fig. 6 , illustrating a modification to provide tension drive belt clamping action during pulley arc engagement;

Fig. 11 is a view of belt section taken along the line 11-11 of Fig. 10;

Fig. 12 is a sectional view taken along the line 12-12 of Fig. 10;

Fig. 13 is an enlarged fragmentary view taken in the area of Fig. 12;

Fig. 14 is a view similar to Fig. 12 illustrating a modification;

Fig. 15 illustrates a further modification, corresponding to Fig. 10, employing a single piece wedge element; and

Fig. 16 is a fragmentary view of an alternative resilient band retention means.

DETAIIED INSCRIPTION OF PREFERRED EMBODIMENT

With reference to Figs. 1 and 2, the principle of the present toggle load block drive engagement and release is illustrated with 5° pulley face angles. Radial inward loading on the inner load block legs by tension belt creates wedging engagement with 5° pulley faces producing normal reaction forces equal to 11.47 times radial loading in order to provide an equal radial component (ratio=l/sine 5° ) . The opposing force couples produced by said radial and reaction forces on the respective toggle elements are resisted by compress ive engagement of the outer load block legs which, together with reaction at the pulley faces, provide balancing force couples adding to the effective driving contact pressure between load block elements and pulley faces.

Upon leaving each pulley, radial loading incident to curvature in tension belt is eliminated by the transition to tangential exit and the direction of radial contact with toggle elements is reversed as shown in Fig. 2. Clearance between inner legs 11, together with elimination of opposing force couples cause release of reaction load block/pulley contact without resistance to pulley disengagement. Releasing deflection, shown with exaggeration in Fig. 2, is accommodated by clearance angles above pulley contact together with central clearance.

With reference to Figs. 3, 4 and 5, prior art metal belt drive of the Van Doorne type is illustrated with variable diameter pulleys to produce a continuously variable transmission. The construction of the belt requires no hinged joints or pins. It consists of a series of thin V-shaped hardened steel blocks. These

are stacked together to provide a driving surface which mates with the pulley faces at varying diameters. The blocks are constrained by two multiple layer endless steel bands which slip into slots in the sides of the blocks. The bands are not fastened to the blocks but retain their position by centering on a slight crown in the surface of each block at the contact point.

In contrast with other belt drives , the system relies on compression of the block elements to transmit power rather than relying on tension in the band. Since the blocks are not connected to each other or to the bands, force must be transmitted from one pulley to the other by pusihing the blocks in a path described by the bands.

With reference to Fig. 6, the present invention substitutes a pair of toggle elements 11 for each single piece solid load block 12 of the prior art metal belt drive. Pulley faces 13 are provided with reduced 5° angle faces (10° included) which provide a sine ratio of 11.47:1. A single laminated belt 14 with a plurality of individual layers replaces the pair of prior art laminated bands shown in Fig. 3. Radial load imposed by tension in the laminated belt 14 is applied on the lower legs 15 of toggle elements 11 and, if slightly crowned, will concentrate radial pressure at the center and serve to centralize belt 14 relative to toggle elements 11 during running operation of the drive. Reaction loading on the toggle elements at 16 will equal 11.47 times radial loading as a sine function of the 5° angle and additional reaction loading at the pulley face engagement will result from the counter-torque imposed on the respective toggle elements 11 resisted by reaction contact at 16 and interengagement 17 of upper legs 18.

By constructing each pair of toggle elements 11 with slightly different length in the upper legs 18 and alternating the respective long and short legs of each pair circumferentially, slight staggered overlap in the abutting ends of adjacent. pairs will serve to maintain alignment of each pair during running operation.

By limiting the radial engagement extremity 19 of toggle elements 11 with pulley faces 13, at or inside the abutting contact extremity 20 of toggle elements 11 and providing a slight clearance angle 21 outside of engagement extremity 19, as well as slight clearance 22 between adjacent ends of lower legs 15, a free release of the toggle elements upon exiting each pulley is effected upon the transition of belt 14 from curved to straight path.

With reference to Fig. 7, a rigid load block 23 is illustrated from a prior art construction corresponding to Fig. 9 in U.S. Patent No. 5,007,883 disclosing a chain belt wherein 11° pulley face angles are employed for engagement by load block ends 24 corresponding to the 22° included angle illustrated in Fig.3. By substituting a pair of toggle elements 25, as shown in Fig. 8, having abutting interengagement at 26, extending radially outward of 5° pulley engaging surfaces 27, with clearance provided radially inward of abutting surfaces 26, and radially outward of 5° engaging surfaces 27, free release of the toggle elements upon exiting each pulley can be provided as in the case of the Fig. 6 embodiment.

In each case, a toggle effect in spreading the pulley engaging ends is provided by radial loading, which may be maximized by a central concentration of the radial loading, supplementing the high reaction loading incident to the 5° pulley angle. Accordingly,

the radio of required back tension to achieve nonslip operation may be reduced substantially to a nominal value.

With reference to Fig. 9, a comparison of relative back tension 2 required for 11° and 5° pulley angles, as a percentage of drive tension at 100%, has been graphically illustrated for a complete range of potential friction coefficients involving hardened steel pulley load block engagement running in oil environment, typically with a 0.09 friction coefficient. The graphic curves were calculated on the basis of the formula:

^τ l ^{= τ} 2 ^efa

As explained above, the coefficient of friction "f" has been amplified by the sine function of respective 11° and 5° pulley angles but with no ref ection of T2/T2 ratio increase through the supplemental toggle effect.

In the event convex pulley faces are employed to equalize lateral shifting of the belt incident to change of ratio with two diagonally opposed axially fixed pulley halves, as suggested in applicant's prior U.S. Patent 3,044,316, Col. 14, Is. 5-42, pulley contacting ends of the toggle elements are preferably beveled to maintain contact at the pitch line of the belt at the outermost radius of contact, notwithstanding a slight clearance radially inward of the pitch line at the smaller radii of contact. With such convex pulley faces, a 5° angle, 10° included, at minimum radius may be provided to preserve the benefit of high reaction traction loading at the most critical torque radius.

With reference to the compression belt of Figs. 3-6, the curves of Fig. 9 do not have direct application. The compressive

loading on the driving side of the belt requires additional belt tension to maintain the load blocks in effective driving engagement with the pulleys against compressive forces directed to disengage radial contact. The absence of positive drive connection between belt bands and load blocks with lubricated surface interengagement accommodates equalization of circumferential tension in the application of radial load on the load blocks, notwithstanding a progressive diminishing of load block compression over the arc of contact in transferring torque to the driven pulley, and progressive increase in compression over the arc of contact in transferring torque from the driving pulley to the compression drive side of the belt. If the belt is run with compressive preloading directed to avoid separation of the load blocks on the nondriving side of the belt under maximum torque conditions where maximum compression takes place on the driving side of the belt, it may be desirable to further preload the initial compression assembly of the belt to include required tensioning of the bands through axial pulley compression for maintaining nonslip driving contact of the load blocks at the respective pulleys.

Notw ithstanding such differences between tension and compression drives, it is clear that required nonslip driving contact pressure for any given torque and power requirement can be maintained with a much lower belt tension in the case of 5° pulley faces; or with corresponding increase in torque and power capacity for any given belt tension and bearing load capacity.

In final effect, the conversion of pulley face angles from prior art 11° to a much smaller angle such as 5° through the use of

the present toggle load blocks, providing free release from an otherwise locking or sticking angle, can substantially increase the torque and power capacity of a given size of variable V-pulley transmission to include an increased range of power requirements for larger and higher powered vehicles.

With reference to Fig. 10 , toggle elements 30 and wedge elements 31 cooperate to clamp belt 32 between the lower surface 33 of each wedge element and the upper surface 34 of the inner leg 35 of each toggle element. Such upper surface may be formed with a slight crown, as illustrated in Fig. 13, matching belt curvature at its innermost radius to avoid edge stress line contact on the belt.

As shown in Fig. 11, the inner legs 35 of each pair of toggle elements may overlap with projections 36 providing an interlock against separation from the belt in the straight runs between pulleys where release action uponleaving the pulleys leaves the elements in a loose condition. Such interlock is provided with enough clearance 37 to accommodate toggle release, corresponding to the schematic view of Fig. 2, with the interlock projections of minimum extension.

With reference to Fig. 12, adjacent toggle elements are shown in respective straight, and in pulley engaging relation for minimum pulley radius.

With reference to Fig. 14 , a slight matching arc may be provided, if warranted, in the respective adjacent ramp surfaces 41' and 40' of the wedge and toggle elements in order to assure maintenance of individual wedge and toggle element pair alignment.

With reference to Fig. 15 , a modification is shown which substitutes a single double faced wedge element 31" for the pair

shown in Fig. 10. The interlock provision of Fig. 11 is not employed but an alternative retention means is provided by recess 50 in the single piece wedge 31" trapping respecitve projections 51 of the toggle elements 30". Simple clearance 52 is provided between legs 35' to accommodate toggle release action.

With reference to Fig. 16, as an alternative to the interlock shown in Figs. 11 and 15, an elastic band 52, such as an oil resistant elastomer or flat convoluted spring wire, may be employed with appropriate side edge engagement to retain the individual toggle elements against lateral displacement between pulleys. A slight staggered overlap 53 in adjacent toggle elements may be provided to maintain individual wedge and toggle element alignment.

The 30° wedge angle shown in Figs. 10 and 15 may be modified to provide more or less clamping force, relative to pulley drive, which need be only sufficient to prevent gross slippage under prevailing friction coefficient.

The convex equalizing pulley face referred to above in the BRIEF DESCRIPTION can be derived from formulae for respective pulley radii throughout the variable range:

Starting with belt length "L" for ratio extremity from maximum pulley radius "R" to minimum radius "r"; pulley center distance "C"; belt angle "a" relative to center line between pulley axes; arc of contact (180° + 2a) for large pulley and (180° - 2a) for small ; the progressive change in respective radii R' and r' between maximum and 1:1 ratios can be determined under the following formulae :

L = (2Rπ) x ( ( 180+2a)/360) + (2rτr ) x ( ( 180-2a)/360) + (2C cos a) ;

(L-(2C cos a' )/2 π = R" ( (180+2a' )/360) + r ' ( (180-2a' )/360) ; and R'-r ' = C sin a'

Solving f or progress ive values of a ¹ w ill provide corresponding ratio changes in R' and r' up to and through 1:1 ratio. Starting with a given minimum slope, e.g., 5° , at minimum pulley radius, the relative rate of radial increments at each respective radial point of progressive ratio change will define the required respective pulley face slopes to produce equalized lateral displacement. The smaller pulley radius up to 1:1 ratio will change in larger radial increments than corresponding radial reductions in the larger pulley radius, therefore requiring a greater relative pulley face angle at the corresponding larger pulley radius reaching a maximum at the maximum radius.

In a typical case involving a ratio spread of six, a face angle progressing f rom 5° to slightly greater than 7° at maximum radius can provide true lateral equalization throughout the ratio range.

It will be understood that the clamping action of this embodiment may be employed in a V-belt tension drive with any smooth surface belt and will accommodate the use of multiple independent bands nested to provide total net tensile strength for virtually any required vehicle torque capacity, with only nominal back tension and minimum shaft bearing loads.