# Patent

## Title
Chain or belt tensioner with a ratchet that deactivates

## Abstract

A tensioner comprising a piston slidably received within a piston bore of the housing having a plurality of grooves formed on an outer circumference, the piston forming a first pressure chamber with the piston bore. The tensioner uses a mechanism to remove a sliding pawl or expandable clip from engaging the grooves on the piston, such that the piston can move towards the housing and reduce chain load when fluid pressure is reduced in the first pressure chamber during engine shutdown, but not so much as to leave the chain uncontrolled during engine restart. The mechanism may for example be a fluid biased spool piston which engages the expandable clip or a pawl piston that engages a sliding pawl.

## Background
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention pertains to the field of tensioners. More particularly, the invention pertains to a chain or belt tensioner with a ratchet that deactivates.
2. Description of Related Art
In chain and belt tensioners, pistons are urged from their housings by a spring or a spring plus hydraulic pressure. Check valves are added to tensioners between the pressurized fluid source and the fluid chamber formed in the bore between the housing and the piston, to prevent backflow of the hydraulic fluid out of the fluid chamber. The rate of leakage through the clearance between the piston and the bore allows the retraction of the piston as makeup fluid subsides or ceases. As the rate of leakage increases, the resistance to retraction of the piston lessens and as the rate of leakage decreases, the resistance to retraction of the piston increases. When chain load spikes or a loss of fluid pressure is present, retraction of the plunger occurs and if the retraction of the plunger is excessive, loss of chain control, loss of engine time or other undesirable effects occur. Therefore, limiting the amount of piston retraction is desirable.
The common practice of tuning a tensioner to a system by changing the fluid leak rate occasionally results in a desired normal state piston retraction, which exceeds what is desired during startup or engine operation and shutdown. Tuning a tensioner to properly control system dynamics may also result in excessive piston extension or pump-up that may cause high chain loading or piston binding. This often results in a tensioner tune that is less than optimal in order to prevent the piston from extending beyond the allowable limit.
SUMMARY OF THE INVENTION
A tensioner comprising a piston slidably received within a piston bore having a plurality of grooves formed on an outer circumference, the piston forming a first pressure chamber with the piston bore. The tensioner uses a mechanism to remove a sliding pawl or expandable clip from engaging the grooves on the piston, such that the piston can move towards the housing and reduce chain load when fluid pressure is reduced in the first pressure chamber during engine shutdown, but not so much as to leave the chain uncontrolled during engine restart. The mechanism may for example be a fluid biased spool piston which engages the expandable clip or a pawl piston that engages a sliding pawl.



BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows an isometric view of a tensioner of a first embodiment.
FIG. 2 shows an isometric exploded view of the first embodiment.
FIG. 3 shows an isometric view sectioned to show the ratchet engaged with the piston of the tensioner of the first embodiment.
FIG. 4 shows another isometric view sectioned to show the ratchet engaged with the piston of the tensioner of the first embodiment.
FIG. 5 shows an isometric view of a tensioner of a second embodiment.
FIG. 6 shows an isometric exploded view of the second embodiment.
FIG. 7 shows an isometric view sectioned to show the ratchet engaged with the piston of the tensioner of the second embodiment.
FIG. 8 shows an isometric view sectioned to show the ratchet disengaged with the piston of the tensioner of the second embodiment.



DETAILED DESCRIPTION OF THE INVENTION
The tensioner systems of the present invention include a tensioner 2 (describe in further detail below) for a closed loop chain drive system used in an internal combustion engine. It may be utilized on a closed loop power transmission system between a driveshaft and at least one camshaft or on a balance shaft system between the driveshaft and a balance shaft. The tensioner system may also include an oil pump and be used with fuel pump drives. Additionally, the tensioner system of the present invention may also be used with belt drives.
The embodiments of the present invention are designed to disengage a ratcheting device, for example an expandable circlip or a pawl plate, when the limits of piston retraction of the tensioner are too restrictive during normal engine running conditions.
FIGS. 1-4 show a tensioner 2 of a first embodiment. The tensioner 2 has a housing 22 with a piston bore 22a connected to a spool piston bore 22b. A housing shoulder 22c is present between the piston bore 22a and the spool piston bore 22b. The piston bore 22a slidably receives a piston 14. The outer circumference of the piston 14 has a series of grooves 16 each with a shoulder 16a and a ramp 16b around or across at least a portion of the outer circumference of the piston 14. Preferably at least one of the grooves 16 acts as a stop groove 17 to help prevent ejection of the piston 14 from the housing 22. The piston bore 22a is in fluid communication with a first supply 25 through an inlet check valve 24. The inlet check valve 24 allows fluid to flow from the first supply 25 into a first pressure chamber formed 19 between the piston 14 and the piston bore 22a of the housing 22.
An expandable circlip 6 having an expandable ring shaped body 6a connected to a first leg 6b and a second leg 6c engages the grooves 16 of the piston 14. The expandable circlip 6 has a free state in which the ring shaped body 6a is engaged with the plurality of grooves 16 of the piston 14 and allows limited movement of the piston 14 outwards from the housing 22, and an expanded state in which the ring shaped body 6a is expanded and disengaged from the plurality of grooves 16 of the piston 14. When the expandable ring shaped body 6a of the expandable circlip 6 engages the shoulder 16a of the grooves 16, extension of the piston 14 outwards from the housing 22 is limited. When the expandable ring shaped body 6a of the expandable circlip 6 engages the ramp 16b of the grooves 16, the expandable circlip 6 allows movement of the piston 14 outwards from the housing 22 and prevents movement of the piston 14 towards the housing 22.
Within the piston 14 is a piston spring 20 for biasing the piston 14 outwards from the housing 22 and towards a belt or chain (not shown). A volume reducer 18 may be present between the piston 14 and the piston spring 20.
The spool piston bore 22b has a first end in fluid communication with a second supply 26. The spool piston bore 22b receives a spool piston 8. The spool piston 8 translates fluid pressure from the second supply 26 into a directional force. A second pressure chamber 28 is formed between the spool piston bore 22b and the spool piston 8.
The spool piston 8 has a cutout 8a of a length L defined by a first spool piston shoulder 8b and a second spool piston shoulder 8c. The spool piston 8 is biased towards the first end of the spool piston bore 22b by a spool piston spring 12 at the second end of the spool piston bore 22b. The travel of the spool piston 8 is limited within the spool piston bore 22b by a circlip 10 which acts as a stop.
Therefore, in FIG. 3, the spool piston 8 is in a fully extended spool piston position at the end of travel, with the spool piston 8 in contact with the circlip 10. The total travel distance that spool piston 8 can travel is indicated by T.
The legs 6b, 6c of the expandable circlip 6 are received within the cutout 8a of the spool piston 8 and the second leg 6c engages the housing shoulder 22c. The housing shoulder 22c may be secured to the second leg 6c. The engagement of the expandable circlip 6 with the housing shoulder 22c prevents the expandable circlip 6 from rotating when force is applied to the first leg 6b to expand the ring shaped body 6a of the expandable circlip 6 and disengage the expandable circlip 6 from the grooves 16 of the piston 14.
The length L of the cutout 8a is preferably sufficiently long enough to accommodate the legs 6b, 6c of the expandable circlip 6 without applying any force to legs 6b, 6c which might cause the expandable body 6a of the circlip 6 to expand and disengage from the grooves 16 on the piston 14. The length L of the cutout 8a is also of a sufficient length to accommodate the expandable clip 6 during assembly, since the expandable clip 6 is in its free state and the legs 6b, 6c are actually farther apart since the expandable clip 6 is not yet expanded over the piston 14.
A second pressure chamber 28 is defined as the portion of spool piston bore 22b at the end of spool piston 8 which is opposite bias spring 12. When fluid is supplied to the second pressure chamber 28, the pressure of the fluid biases the spool piston 8 against the force of the spool piston spring 12, moving the spool piston 8 away from the second supply 26, such that the first spool piston shoulder 8b of the cutout 8a of the spool piston 8 exerts a force on a first leg 6b of the expandable circlip 6 and in doing so also exerts a force on a second leg 6c of the expandable circlip through the housing shoulder 22c. Force on both of the legs 6b, 6c of the expandable clip 6 from opposite directions causes the ring shaped body 6a to expand and be in the expanded state. The expansion of the ring shaped body 6a of the expandable circlip 6 disengages the ring shaped body 6a from the grooves 16 on the piston 14.
With the expandable circlip body 6a in the expanded state and disengaged from the grooves 16 on the piston 14, the piston 14 is no longer prevented from retracting or moving in towards the housing 22 as long as sufficient pressure is present in the second pressure chamber 28.
This allows the piston 14 to retract and reduce chain load when fluid pressure is reduced during engine shutdown, but not so much as to leave the chain uncontrolled during engine restart. This also allows the piston 14 to extend out as far as required by the timing drive to control the drive at high engine speed but return back to a lower extension at low engine speed but still prevent tooth jump during engine shutdown. The retraction of the piston 14 is limited by the amount of backlash of the expandable circlip 6. However, it should be noted that nothing limits retraction of the piston 14 when the pressure in the second pressure chamber 28 is sufficient to prevent the spool piston 8 from being biased by the spring towards the first end of the spool piston bore 22b. 
As pressure in the second pressure chamber 28 decreases, the spool piston spring 12 biases the spool piston 8 towards the second fluid supply 26, removing the force exerted on the legs 6b, 6c of the expandable circlip 6 and allowing the expandable ring shaped body 6a of the circlip 6 to engage the grooves 16 of the piston 14 and restrict the movement of the piston 14 towards the housing 22.
A lock pin 4 may lock the spool piston 8 in place for shipping or assembly, preventing any movement during these processes.
In one embodiment the first supply 25 is connected to the second supply 26. In an alternate embodiment, the first supply 25 and second supply 26 are not directly connected.
While the spool piston 8 is shown as being received within a radially extending bore of the housing 22b, other configurations and arrangements of the spool piston 8 relative to the piston 14 and the expandable circlip 6 may be used to apply force to the legs 6b, 6c of the expandable circlip 6, such that the ring shaped body 6a of the expandable circlip 6 does not engage the grooves 16 of the piston 14.
In another alternate embodiment, the spool piston spring 12 would bias the spool piston 8 so that the first spool piston shoulder 8b of the cutout 8a of the spool piston 8 exerts a force on a first leg 6b of the expandable circlip 6 and in doing so also exerts a force on a second leg 6c of the expandable circlip through the housing shoulder 22c. The force on the legs 6b, 6c of the circlip 6 would be removed when fluid pressure was provided to a second pressure chamber from the first pressure chamber 19 of the tensioner.
FIGS. 5-8 show a second embodiment of the present invention. It should be noted that the pawl piston spring 64 is omitted from FIG. 8 for clarity purposes. The tensioner 50 has a housing 56 with a piston bore 56a connected to a pawl bore 56b, as well as a piston pawl bore 56c. The piston bore 56a slidably receives a piston 54. The outer circumference of the piston 54 has a series of grooves 55 each with a shoulder 55a and a ramp 55b around or across at least a portion of the outer circumference of the piston 54. Preferably at least one of the grooves 55 acts as a stop groove 53 to help prevent ejection of the piston 54 from the housing 56.
The piston bore 56a is in fluid communication with a first supply 74 through an inlet check valve 72. The inlet check valve 72 allows fluid to flow from the first supply 74 into a first pressure chamber 76 formed between the piston 54 and the piston bore 56a of the housing 56.
Within the piston 54 is a piston spring 70 for biasing the piston 54 outwards from the housing 56 and towards a belt or chain. A volume reducer 68 may be present between the piston 54 and the piston spring 70.
The pawl bore 56b receives a flat pawl plate 58. The flat pawl plate 58 has a first end with at least one tooth 58a for engagement with the grooves 55 on the outer circumference of the piston 54. A second end of the flat pawl plate 58, opposite the first end is biased by a pawl spring 62 towards the piston 54 and contact with the grooves 55 on the outer circumference of the piston 54. The pawl spring 62 is preferably a leaf spring. The flat pawl plate 58 also has a hole 60 formed along its length. The hole 60 is preferably formed along the length of the flat pawl plate 58 such that when engaged by a pawl piston 66 as described below, the piston 54 can move within the piston bore 56a without the grooves 56 of the piston 54 engaging the flat pawl plate 58.
The piston pawl bore 56c is slidably receives a pawl piston 66. The pawl piston 66 translates fluid pressure from the second supply 78 into a directional force. The pawl piston 66 is biased towards the housing 56 by a pawl piston spring 64. The pawl piston 66 is biased outwards from the housing 56 by fluid pressure from a second fluid supply 78.
A second pressure chamber 79 is defined as the portion of piston pawl bore 55c at the end of pawl piston 66 which is opposite pawl piston spring 64. When pressure from fluid in the second pressure chamber 79 is greater than the force of the pawl piston spring 64, the end of the pawl piston 66 engages the hole 60 of flat pawl plate 58 and prevents the at least one tooth 58 of the flat pawl plate 58 from engaging the grooves 56 on the outer circumference of the piston 54.
With the at least one tooth 58a of the flat pawl 58 disengaged from the grooves 56 on the piston 54, the piston 54 is no longer prevented from retracting as long as sufficient pressure is present in the second pressure chamber 79. This allows the piston 54 to retract and reduce chain load when fluid pressure is reduced during engine shutdown, but not so much as to leave the chain uncontrolled during engine restart. The retraction of the piston 54 is limited by the amount of the flat pawl plate 58. However, it should be noted that nothing limits retraction of the piston 54 when the pressure in the second pressure chamber 79 is sufficient to prevent the pawl piston 64 from being biased by the spring away from the hole 60 in the flat pawl plate 58.
As pressure in the second pressure chamber 79 decreases, the pawl piston spring 64 biases the pawl piston 66 towards the housing 56, the pawl piston 66 disengages the hole 60 in the flat pawl plate 58, allowing the pawl spring 62 to bias the at least one tooth 58a of the flat pawl plate 58 to engage the grooves 56 of the piston 54 and restricting the movement of the piston 54 towards the housing 56.
When the tensioner 50 is assembled, a cover 52 covers the pawl bore 56b and the piston pawl bore 56c to prevent the flat pawl bore 58 from being dislodged from the housing and to resist the force of the pawl piston 66.
In one embodiment, the end of the pawl piston 66 that engages the hole 60 in the flat pawl plate 58 and the hole 60 itself may be conically shaped, although other shapes may also be used to establish a wedge type contact between the pawl piston 66 and the hole 60 of the flat pawl plate 58.
In another embodiment the first supply 74 is connected to the second supply 78. In an alternate embodiment, the first supply 74 and second supply 78 are not directly connected.
Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention.

## Claims

1. A tensioner for use with a chain or a belt comprising:
a housing comprising a piston bore, a spool piston bore in fluid communication with the piston bore, and a housing shoulder between the piston bore and the spool piston bore;
a piston having a plurality of grooves formed along at least a portion of an outer circumference of the piston, the piston being slidably received within the piston bore and forming a first pressure chamber within the piston bore;
a piston spring biasing the piston in an outward direction from the housing; and
a spool piston slidably received by the spool piston bore, biased in a first direction within the spool piston bore by a spool piston spring, the spool piston having a cutout of a length defined by a first spool piston shoulder and a second spool piston shoulder;
an expandable circlip comprising a ring shaped body attached to a first leg and a second leg; the expandable circlip having an free state in which the ring shaped body is engaged with the plurality of grooves of the piston, and an expanded state in which when the first leg and the second leg are moved toward each other, the ring shaped body is expanded and disengaged from the plurality of grooves of the piston, the first leg and second leg of the expandable circlip being received within the cutout of the spool piston and the second leg contacting the housing shoulder;
wherein when fluid is supplied from a second supply to a second pressure chamber in the spool piston bore at an end of the spool piston opposite the spool piston spring, pressure of the fluid in second pressure chamber biases the spool piston against the spool piston spring, and the first spool piston shoulder pushes the first leg of the expandable circlip towards the second leg, expanded the ring shaped body of the expandable circlip, disengaging the ring shaped body of the expandable circlip from the grooves on the outer circumference of the piston; such that the piston can move towards the housing and reduce chain load when fluid pressure is reduced in the first pressure chamber during engine shutdown.

2. The tensioner of claim 1, wherein the second leg of the expandable circlip is secured to the housing shoulder.

3. The tensioner of claim 1, wherein the spool piston bore further comprises a circlip in the second pressure chamber, which acts a stop to limit the movement of the spool piston within the spool piston bore.

4. A tensioner for use with a chain or a belt comprising:
a housing comprising a piston bore, connected to a pawl bore and a piston pawl bore;
a piston having a plurality of grooves formed along at least a portion of an outer circumference of the piston, the piston being slidably received within the piston bore and forming a first pressure chamber with the piston bore;
a piston spring biasing the piston in an outward direction from the housing; and
a flat pawl plate slidably received within the pawl bore comprising: a first pawl plate end with at least one tooth for engagement with the grooves of the piston, a second pawl plate end biased towards the piston by a spring, and a hole between the first end and the second of the flat pawl plate;
a pawl piston comprising a first pawl piston end and second pawl piston end, the pawl piston being slidably received within the piston pawl bore and biased in an inwards direction towards the housing by a pawl piston spring, the first end of the pawl piston forming a second pressure chamber in the pawl piston bore, such that fluid pressure in the second pressure chamber biases the second pawl piston end in an outwards direction from the housing against the pawl piston spring;
wherein when pressure in the second pressure chamber biases the pawl piston in an outwards direction from the housing with the first pawl piston end seating in the hole of the flat pawl plate, the first pawl plate end with at least one tooth is disengaged from the grooves on the outer circumference of the piston;
such that the piston can move towards the housing and reduce chain load when fluid pressure is reduced in the first pressure chamber during engine shutdown.

5. The tensioner of claim 4, wherein the first pressure chamber is supplied with fluid from a first supply and the second pressure chamber is supplied with fluid from a second supply.

6. The tensioner of claim 5, wherein the first supply is connected to the second supply.

7. The tensioner of claim 5, wherein the first supply and second supply are separate.

8. The tensioner of claim 4, wherein the hole in the flat pawl plate is conical shaped and receives a conical shaped first end of the pawl piston.