Abstract:
A roller structure and a manufacturing method thereof are introduced. The roller structure includes a roller rotatable about an axial portion; a bush with an end disposed to an end of the axial portion and has a first stop portion positioned proximate to one side of the roller and another end having an engaging portion coupled to a load; and a second stop portion disposed to the other end of the axial portion and positioned proximate to the other side of the roller such that the roller rotates between the first stop portion and the second stop portion. Hence, the roller structure and the manufacturing method thereof provide a modularized roller structure for carrying a load, effectuate modularized assembly and production, enhance assembly efficiency, attain structural streamlining, and cut costs.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation-in-part patent application of U.S. application Ser. No. 14/940,222 filed on Nov. 13, 2015, the entire contents of which are hereby incorporated by reference for which priority is claimed under 35 U.S.C. §120. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to roller structures and manufacturing methods thereof and, more particularly, to a roller structure and a manufacturing method thereof, characterized in that a load is mounted on and thus carried by the roller structure. 
       BACKGROUND OF THE INVENTION 
       [0003]    Rollers enable heavy objects, such as a frame or sliding doors, drawers and shelves of a cabinet, to be easily moved. Rollers work efficiently, because of the relatively small friction between each rotating roller and its rail or a surface. However, there is still room for improvement in conventional roller structures and manufacturing methods thereof. For example, an assembly structure of a conventional roller is structurally intricate, and the assembly operation or process is complicated, thereby compromising its production efficiency. In addition, the conventional roller structures seldom match the other components in wide use, such as pivots, for modularization, and in consequence roller manufacturers have to manufacture the components and perform the subsequent time-consuming assembly process independently. 
         [0004]    Accordingly, it is imperative to provide a roller structure and a manufacturing method thereof with a view to overcoming the aforesaid drawbacks of the prior art. 
       SUMMARY OF THE INVENTION 
       [0005]    In view of the aforesaid drawbacks of the prior art, the inventor of the present invention conceived room for improvement in the prior art and thus conducted extensive researches and experiments according to the inventor&#39;s years of experience in the related industry, and finally developed a roller structure and a manufacturing method thereof as disclosed in the present invention to thereby provide a modularized roller structure for carrying a load, effectuate modularized assembly and production, enhance assembly efficiency, attain structural streamlining, and cut costs. 
         [0006]    It is an objective of the present invention to provide a roller structure and a manufacturing method thereof to thereby provide a modularized roller structure for carrying a load, effectuate modularized assembly and production, enhance assembly efficiency, attain structural streamlining, and cut costs. 
         [0007]    In order to achieve the above and other objectives, the present invention provides a roller structure, comprising: a roller rotatable about an axial portion, an end of a bush is disposed to an end of the axial portion, and another end of the bush having an engaging portion coupled to a load; and a second stop portion disposed at another end of the axial portion and positioned proximate to a side of the roller such that the roller rotates between the second stop portion and the engaging portion. 
         [0008]    As regards the roller structure, the bush has a first stop portion positioned proximate to another side of the roller. 
         [0009]    As regards the roller structure, the roller comprises an axial hole which the axial portion is disposed in to enable the roller to rotate about the axial portion. 
         [0010]    As regards the roller structure, the bush formed integrally with or coupled to the axial portion. 
         [0011]    As regards the roller structure, the second stop portion formed integrally with or coupled to the axial portion. 
         [0012]    As regards the roller structure, the second stop portion is formed by injection molding. 
         [0013]    As regards the roller structure, the second stop portion is in the form of a stop component fitted around the axial portion, and the axial portion has a third stop portion for limiting movement of the stop component. 
         [0014]    The roller structure comprises a connection component coupled to the axial portion, wherein the second stop portion is provided in the form of a stop component whose movement is limited by the connection component. 
         [0015]    As regards the roller structure, the stop component is provided in the form of a hollow-core component penetrable by the connection component. 
         [0016]    As regards the roller structure, a receiving chamber concentric with the axial portion is disposed on one or two sides of the roller and adapted to receive one of the first stop portion, the second stop portion and the third stop portion. 
         [0017]    As regards the roller structure, a limiting portion is disposed on a side of the roller such that the second stop portion is confined to between the limiting portion and the roller. 
         [0018]    As regards the roller structure, the first stop portion of the bush separates the roller and the load. 
         [0019]    As regards the roller structure, the roller comprises one of an inner ring, a rolling component and a sliding component for fitting around the axial portion. 
         [0020]    As regards the roller structure, a rolling surface of the roller is striped. 
         [0021]    As regards the roller structure, the roller is made of a single-ingredient material, such as a metal, a plastic or a rubber, or a multiple-ingredient material. 
         [0022]    As regards the roller structure, the second stop portion penetrates the axial portion, or the second stop portion penetrates the axial portion and the bush, or the axial portion penetrates the second stop portion. 
         [0023]    As regards the roller structure, the second stop portion penetrates the axial portion and is coupled to the axial portion by a riveting mechanism, an expansion mechanism, a welding mechanism, an engaging mechanism, a fastening mechanism, an adhesion mechanism or a magnetic attraction mechanism, or the second stop portion penetrates the axial portion and the bush and is coupled to the bush by a riveting mechanism, an expansion mechanism, a welding mechanism, an engaging mechanism, a fastening mechanism, an adhesion mechanism or a magnetic attraction mechanism. 
         [0024]    As regards the roller structure, the engaging portion of the bush is positioned proximate to a side of the load such that the bush and the load are coupled together by a connection component. 
         [0025]    The roller structure comprises a frame which the engaging portion of the bush and the load are coupled to. 
         [0026]    As regards the roller structure, the frame is slender or plate-shaped. 
         [0027]    As regards the roller structure, the frame is coupled to the load by a riveting mechanism, an expansion mechanism, a welding mechanism, an engaging mechanism, a fastening mechanism, an adhesion mechanism or a magnetic attraction mechanism. 
         [0028]    As regards the roller structure, the roller and the axial portion are coupled to the bush and the second stop portion to form a module and then the engaging portion of the bush is coupled to the load. 
         [0029]    As regards the roller structure, the roller and the axial portion are coupled to the second stop portion to form a module so as for the bush to be coupled to the load to form a module and eventually for the axial portion to be coupled to the bush. 
         [0030]    As regards the roller structure, the engaging portion of the bush is coupled to the load by a riveting mechanism, an expansion mechanism, a welding mechanism, an engaging mechanism, a fastening mechanism, an adhesion mechanism or a magnetic attraction mechanism. 
         [0031]    As regards the roller structure, the engaging portion of the bush has a feeding space which a material of the load is injected into via a die such that the engaging portion is coupled to the load. 
         [0032]    As regards the roller structure, a diameter of the engaging portion is larger or smaller than a diameter of the roller. 
         [0033]    As regards the roller structure, the feeding space faces the roller or faces away from the roller. 
         [0034]    As regards the roller structure, the engaging portion coupled to the load via pressing the second stop portion, pressing the roller, pressing the engaging portion or pressing the first stop portion. 
         [0035]    As regards the roller structure, the engaging portion coupled to the frame via pressing the second stop portion, pressing the roller or pressing the engaging portion. 
         [0036]    The present invention further provides a manufacturing method of the roller structure, and the manufacturing method includes the step of forming the second stop portion positioned proximate to a side of the roller by using a die in performing a pressing process on a pressed portion at another end of the axial portion. 
         [0037]    As regards the manufacturing method, the engaging portion of the bush is coupled to the load by a riveting mechanism, an expansion mechanism, a welding mechanism, an engaging mechanism, a fastening mechanism or a magnetic attraction mechanism. 
         [0038]    As regards the manufacturing method, the engaging portion of the bush has a feeding space which a material of the load is injected into via a die such that the engaging portion is coupled to the load; or the engaging portion of the bush is transformed via a die to have a feeding space, the feeding space receives a material of the load to couple the engaging portion to the load. 
         [0039]    As regards the manufacturing method, the feeding space faces the roller or faces away from the roller. 
         [0040]    As regards the manufacturing method, a diameter of the engaging portion is larger or smaller than a diameter of the roller. 
         [0041]    As regards the manufacturing method, the engaging portion coupled to the load via pressing the second stop portion, pressing the roller, pressing the engaging portion or pressing the first stop portion. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0042]    Objectives, features, and advantages of the present invention are hereunder illustrated with specific embodiments in conjunction with the accompanying drawings, in which: 
           [0043]      FIG. 1  is an exploded view of a roller structure according to the first preferred embodiment of the present invention; 
           [0044]      FIG. 2  is a perspective view of the roller structure according to the first preferred embodiment of the present invention; 
           [0045]      FIG. 3  is a cross-sectional view  1  of the roller structure according to the first preferred embodiment of the present invention; 
           [0046]      FIG. 4  is a cross-sectional view  2  of the roller structure according to the first preferred embodiment of the present invention; 
           [0047]      FIG. 5  is a cross-sectional view of the roller structure according to the second preferred embodiment of the present invention; 
           [0048]      FIG. 6  is a cross-sectional view of the roller structure according to the third preferred embodiment of the present invention; 
           [0049]      FIG. 7  is a cross-sectional view of the roller structure according to the third preferred embodiment of the present invention; 
           [0050]      FIG. 8  is a cross-sectional view of the roller structure according to the third preferred embodiment of the present invention; 
           [0051]      FIG. 9  is a cross-sectional view of the roller structure according to the third preferred embodiment of the present invention; 
           [0052]      FIG. 10  is a cross-sectional view of the roller structure according to the fourth preferred embodiment of the present invention; 
           [0053]      FIG. 11  is a cross-sectional view of the roller structure according to the fifth preferred embodiment of the present invention; 
           [0054]      FIG. 12  is a schematic view of a manufacturing method of the roller structure according to the first preferred embodiment of the present invention; 
           [0055]      FIG. 13  is a schematic view of the manufacturing method according to the first preferred embodiment of the present invention; 
           [0056]      FIG. 14  is a schematic view of the manufacturing method according to the second preferred embodiment of the present invention; 
           [0057]      FIG. 15  is a schematic view of the manufacturing method according to the second preferred embodiment of the present invention; 
           [0058]      FIG. 16  is an exploded view of a modularized frame according to a preferred embodiment of the present invention; 
           [0059]      FIG. 17  is a cross-sectional view of the roller structure according to the preferred embodiment of the present invention; 
           [0060]      FIG. 18  is a schematic view  1  of the manufacturing method according to the preferred embodiment of the present invention; 
           [0061]      FIG. 19  is a schematic view  2  of the manufacturing method according to the preferred embodiment of the present invention; 
           [0062]      FIG. 20  is a schematic view  3  of the manufacturing method according to the preferred embodiment of the present invention; and 
           [0063]      FIG. 21  is a schematic view  4  of the manufacturing method according to the preferred embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0064]    Referring to  FIG. 1  through  FIG. 3 , the present invention provides a roller structure and a manufacturing method thereof, applicable to rollers. In a preferred embodiment of the present invention, the roller structure comprises a roller  1  and a second stop portion  4 . The roller  1  is adapted to carry a load  3  and made of a single-ingredient material, such as a metal, a plastic or a rubber, or a multiple-ingredient material. The roller  1  is a cylinder circumferentially provided with a rolling surface  11  for contact with any other object regardless of whether the roller  1  is rotating or not. The rolling surface  11  is either glossy or striped. When striped, the rolling surface  11  exhibits stripes which run longitudinally, transversely, obliquely or cross each other. The roller  1  is centrally provided with an axial portion  12  for driving the roller  1  to rotate. Preferably, the axial portion  12  is disposed in an axial hole  13  disposed centrally at the roller  1  such that the roller  1  rotates about the axial portion  12 . The roller  1  is coupled to a load  3  through the axial portion  12  and a bush  2 . Preferably, the bush  2  is a cylinder made of a single-ingredient material, such as a metal or a plastic, or a multiple-ingredient material. One end of the bush  2  is formed integrally with or coupled to one end of the axial portion  12  and enclosed with a first stop portion  21  adjacent to the roller  1 . The first stop portion  21  has a first stop surface  211  corresponding in position to a side of the roller  1 . Another end of the bush  2  has an engaging portion  22 . The bush  2  is coupled to the load  3  through the engaging portion  22 . The first stop portion  21  separates the roller  1  and the load  3  to thereby prevent the roller  1  from coming into contact with the load  3 ; hence, the roller  1  is rotatably disposed at the load  3 . The second stop portion  4  serves to limit disconnection-proof components or structures disposed in the axial direction of the roller  1  and, in a preferred embodiment, is formed integrally with or coupled to another end (facing away from the bush  2 ) of the axial portion  12  and positioned proximate to another side (facing away from the bush  2 ) of the roller  1 ; hence, the roller  1  rotates between the first stop portion  21  and the second stop portion  4  to therefore effectuate the roller structure of the present invention. In addition, referring to  FIG. 4 , in a variant embodiment of the present invention, the roller structure is dispensed with the first stop portion  21 . Referring to  FIG. 4 , an inner annular groove  18  is disposed on another side of the roller  1  to fix movably around the circumferential edge of the second stop portion  4 . 
         [0065]    Referring to  FIG. 3 ,  FIG. 4 ,  FIG. 5  and  FIG. 9 , in an embodiment of the present invention, the second stop portion  4  is preferably formed at another end of the axial portion  12  by injection molding in a manner that the second stop portion  4  has a larger diameter than the axial portion  12  so as to limit the movement of the roller  1  from another side thereof. Referring to  FIG. 6 ,  FIG. 7  or  FIG. 8 , in another embodiment of the present invention, the second stop portion  4  is provided with a stop component  41  which has a larger diameter than the axial portion  12  and functions as a hollow-core component, ring, C-ring, clip, bush or bearing for use in penetrable coupling or snug engagement such that the stop component  41  is fitted around the axial portion  12 . Preferably, the axial portion  12  has a third stop portion  14  for limiting the movement of the stop component  41 . In an embodiment of the present invention, the third stop portion  14  is formed by performing a pressing process on another end of the axial portion  12  (as shown in  FIG. 6 ) such that the stop component  41  is coupled to the axial portion  12  firmly. In a variant embodiment of the present invention, the third stop portion  14  is provided in the form of a head portion  51  of a connection component  5  such that a body portion  52  of the connection component  5  is coupled to the axial portion  12  and the bush  2  (shown in  FIG. 7  and  FIG. 8 ); hence, the movement of the stop component  41  is limited by the third stop portion  14  formed from the head portion  51  of the connection component  5 , thereby allowing the stop component  41  to be coupled to the axial portion  12  firmly. 
         [0066]    Referring to  FIG. 3  and  FIG. 5 , a receiving chamber  15  concentric with the axial portion  12  is disposed on one or two sides of the roller  1  and is round, polygonal or of any appropriate geometric shape such that the first stop portion  21 , the second stop portion  4  or the third stop portion  14  is received in the receiving chamber  15  of the roller  1  to thereby prevent the first stop portion  21 , the second stop portion  4  or the third stop portion  14  from protruding from the roller  1  laterally. Referring to  FIG. 7  and  FIG. 8 , a limiting portion  16  is disposed on another side of the roller  1  and provided in the form of a neck portion disposed on the inner wall of the receiving chamber  15  to not only confine the second stop portion  4  to between the limiting portion  16  and the roller  1  but also prevent the roller  1  from loosening. 
         [0067]    Referring to  FIG. 6 , preferably, in an embodiment of the present invention, the roller  1  is provided with an inner ring  17   a  which fits around the axial portion  12 . The inner diameter of the inner ring  17   a  defines the axial hole  13 . The contact between the inner ring  17   a  and the axial portion  12  enhances the mechanical strength of the roller  1  and reduces the wear and tear of the axial hole  13 . For example, when the roller  1  is made of a plastic or a rubber, the inner ring  17   a  is made of a metal of high rigidity. Referring to  FIG. 7 , the roller  1  is preferably provided with a rolling component  17   b  for fitting around the axial portion  12  and exemplified by a ball bearing, a needle bearing or an equivalent component, wherein the inner diameter of the rolling component  17   b  defines the axial hole  13 . The rolling component  17   b  not only functions as well as the inner ring  17   a  but is also effective in reducing the coefficient of friction between the roller  1  and the axial portion  12  to thereby enable the roller  1  to rotate smoothly. Referring to  FIG. 9 , the roller  1  is preferably provided with a sliding component  17   c  for fitting around the axial portion  12  and exemplified by a bush capable of self-lubrication and thus capable of bearing a heavy load and being more durable. Referring to  FIG. 10 , the second stop portion  4  preferably penetrates the axial portion  12  and is preferably coupled to the axial portion  12  by an expansion mechanism (or a riveting mechanism, a welding mechanism, an engaging mechanism, a fastening mechanism, an adhesion mechanism or a magnetic attraction mechanism), or the second stop portion  4  preferably penetrates the axial portion  12  and the bush  2  and is preferably coupled to the bush  2  by an expansion mechanism (or a riveting mechanism, a welding mechanism, an engaging mechanism, a fastening mechanism, an adhesion mechanism or a magnetic attraction mechanism). Referring to  FIG. 11 , the axial portion  12  preferably penetrates the second stop portion  4 . 
         [0068]    As indicated above, according to the present invention, the engaging portion  22  of the bush  2  enables the roller  1  to be mounted on the load  3 , and the engaging portion  22  is coupled to the load  3  by a riveting mechanism (shown in  FIG. 3 ), an expansion mechanism (shown in  FIG. 5 ), a welding mechanism (shown in  FIG. 6 ), an engaging mechanism, a fastening mechanism or a magnetic attraction mechanism, or by any other means of fixation. Referring to  FIG. 8 , the engaging portion  22  of the bush  2  is not directly coupled to the load  3  but is positioned proximate to the load  3  from one side thereof and then coupled to the bush  2  and the load  3  through a connection component  5 . Referring to  FIG. 9 , the present invention is not limited to an embodiment where the first stop portion  21  of the bush  2  is formed integrally with the bush  2 ; instead, in a variant embodiment, it is also practicable that the first stop portion  21  is provided with a stop component  212  which functions as a hollow-core component, ring, C-ring, clip, bush or bearing for use in penetrable coupling or snug engagement. Likewise, one side of the stop component  212  has the first stop surface  211  corresponding in position to one side of the roller  1  so as to come into smooth contact with the roller  1 . 
         [0069]    In addition, the present invention puts no limit on the technical feature that the roller  1  is directly coupled to the load  3  through the bush  2 . Referring to  FIG. 16 , in a variant embodiment, a frame  6  is provided. The engaging portion  22  of the bush  2  is coupled to the frame  6  in advance, and then the engaging portion  22  of the bush  2  is coupled to the load  3  through the frame  6 ; hence, one or more roller structures of the present invention function as module with standard specifications so as to couple the rollers and the load  3  quickly. In a preferred embodiment, the frame  6  is slender, plate-shaped or of any other geometric shapes as needed, and is coupled to the load  3  by the load  3  by a riveting mechanism, an expansion mechanism, a welding mechanism, an engaging mechanism, a fastening mechanism, a magnetic attraction mechanism, or any equivalent mechanism. 
         [0070]    As regards the sequence of the assembly of the roller structures of the present invention, it is feasible that the roller  1  and the axial portion  12  are coupled to the bush  2  and the second stop portion  4  in advance to form a module, and then the engaging portion  22  of the bush  2  is coupled to the load  3  or the frame  6  by one of the aforesaid mechanisms. In a variant embodiment, it is practicable for the roller  1  and the axial portion  12  to be coupled to the second stop portion  4  in advance to form module, and then for the bush  2  to be coupled to the load  3  to form a module, and eventually for the axial portion  12  to be coupled to the bush  2 , the two modules are coupled together. However, the aforesaid sequence is subject to changes as needed. In addition, the present invention is characterized in that the engaging portion  22  of the bush  2  is coupled to the load  3  or frame  6  by a riveting mechanism, an expansion mechanism, a welding mechanism, an engaging mechanism, a fastening mechanism or a magnetic attraction mechanism. The engaging portion  22  of the bush  2  has a feeding space  221 . After the feeding space  221  has been aligned with an installation hole  31  of the load  3 , the material which the load  3  is to be made of is injected into the feeding space  221  of the engaging portion  22  as soon as a die  10  presses against the roller  1  or the second stop portion  4  (shown in  FIG. 13 ) or another die  20  presses against the load  3  (shown in  FIG. 13 ) or the engaging portion  22  (shown in  FIG. 15 ), thereby allowing the engaging portion  22  to be coupled to the load  3  to therefore effectuate quick assembly and enhance the efficiency of assembly. In addition, referring to  FIG. 14  and  FIG. 15 , when the engaging portion  22  of the bush  2  is transformed via a die  20  to have a feeding space  221 , the feeding space  221  receives a material of the load  3  to couple the engaging portion  22  to the load  3 . 
         [0071]    The present invention further provides a manufacturing method for use with the aforesaid roller structure. The manufacturing method is characterized in that: a pressed portion  121  (shown in  FIG. 12  and  FIG. 14 ) is disposed at one end of the axial portion  12  by being formed integrally therewith, and the pressed portion  121  is cylindrical or of any equivalent shape. Referring to  FIG. 13  and  FIG. 15 , and the second stop portion  4  positioned proximate to the roller  1  is formed by performing a pressing process on the pressed portion  121  via a die  10 . The advantages of the manufacturing method are as follows: the second stop portion  4  is formed quickly; and an assembly process of the roller  1  is quickly carried out especially when the roller structure of the present invention functions as a standardized module. 
         [0072]    As regards the manufacturing method for use with the aforesaid roller structure according to the present invention, the engaging portion  22  of the bush  2  is coupled to the load  3  or the frame  6  by a riveting mechanism, an expansion mechanism, a welding mechanism, an engaging mechanism, a fastening mechanism or a magnetic attraction mechanism. The engaging portion  22  of the bush  2  has a feeding space  221 ; hence, after the feeding space  221  has been aligned with the installation hole  31  of the load  3 , the material which the load  3  is to be made of is injected into the feeding space  221  of the engaging portion  22  as soon as a die  10  presses against the roller  1  or the second stop portion  4  (shown in  FIG. 13 ) or another die  20  presses against the load  3  (shown in  FIG. 13 ) or the engaging portion  22  (shown in  FIG. 15 ), thereby allowing the engaging portion  22  to be coupled to the load  3  to therefore effectuate quick assembly and enhance the efficiency of assembly. 
         [0073]    Referring to  FIG. 3  and  FIG. 17 , a diameter a of the engaging portion  22  of the bush  2  is larger (shown in  FIG. 17 ) or smaller (shown in  FIG. 3 ) than a diameter b of the roller  1 . In addition, the feeding space  221  of the engaging portion  22  of the bush  2  faces the roller  1  (shown in  FIG. 17 ) or faces away from the roller  1  (shown in  FIG. 3 ). 
         [0074]    Referring to  FIG. 16  and  FIG. 18  to  FIG. 21 , the engaging portion  22  of the bush  2  is coupled to the load  3  (or the frame  6 ) via using a die  10  to press the second stop portion  4  (shown in  FIG. 18 ), the roller  1  (shown in  FIG. 19 ), the engaging portion  22  of the bush  2  (shown in  FIG. 21 ) or the first stop portion  21  of the bush  2  (shown in  FIG. 20 ). 
         [0075]    The present invention is disclosed above by preferred embodiments. However, persons skilled in the art should understand that the preferred embodiments are illustrative of the present invention only, but should not be interpreted as restrictive of the scope of the present invention. Hence, all equivalent modifications and replacements made to the aforesaid embodiments should fall within the scope of the present invention. Accordingly, the legal protection for the present invention should be defined by the appended claims.