ROLLER ASSEMBLY AND METHOD FOR MANUFACTURING THE SAME

Abstract: Disclosed is a roller assembly of the type comprising a roller body (1, 101, 201 or 301) provided with opposed ends (3, 103, 203 or 303), a shaft (7, 107, 207 or 307), a bearing (13, 113, 113', 213 or 313) having an inner portion (15, 115, 115', 215 or 315) and an outer portion (17, 117, 117', 217 or 317) and a casing (19, 119, 119', 219 or 319) for housing the bearing (13, 113, 113', 213 or 313) and a portion of the shaft (7, 107, 207 or 307). The casing (19, 119, 119', 219, 319) has an exterior (23, 123, 123', 223 or 323) contacting a corresponding portion of the interior (5, 105, 205 or 305) of the roller body (1, 101, 201 or 301) and an interior (25, 125, 125', 225 or 325) contacting the outer portion (17, 117, 117', 217 or 317) of the bearing (13, 113, 113', 213 or 313). The second part (29, 129, 129', 229 or 329) of the roller assembly is made of a cured material filling a gap existing between the exterior (32, 132, 132', 232 or 332) of the first part (27, 127, 127', 227 or 327) of the casing (19, 119, 119', 219 or 319) and the interior (5, 105, 205 or 305) of the roller body (1, 101, 201 or 301). The material has been introduced in said gap in a fluid state and cured in situ without any shrinkage. The roller body (1, 101, 201 or 301) according to the invention is more resistant and easier to manufacture. Also disclosed is an efficient method for manufacturing the roller assembly.

Description: ROLLER ASSEMBLY AND METHOD FOR MANUFACTURING THE SAME BACKGROUND OF THE INVENTION FIELD OF THE INVENTION The present invention relates to a roller assembly to be used, for example, as a conveyor roller. The invention also relates to a method for manufacturing such a roller assembly. DESCRIPTION OF THE PRIOR ART Usually, roller assemblies comprise a cylindrical tube which rotates on a shaft by means of bearings. U.S. patent n°4,642,862 discloses a stone roller for a paper making machine provided with a shaft and two opposite ends. At each end, plates are provided and clamped with tie-rods extending all along the inner wall of the roller body. The tie-rods are fixed to the plates and sealed with a resin. The resin is used only as sealing and protective means. The main problem arising with a conventional roller assembly is the damagement of bearings due to exterior contaminants and/or to vibrations. Aforesaid bearings may be protected from exterior contaminants (such as dust particles) by sealing means such as labyrinth seals disclosed in U.S. patent n° 4,955,462. Also, U.S. patents n°5,025,217, n°5,261,528 and n° 3,944,055 disclose roller assemblies provided with bearings means and labyrinth seals. In these patents, the size of the roller body and the size of the other elements are very closely interdependent. Indeed, each of the element has to be precisely tooled to obtain a roller assembly of a predetermined size. Moreover, materials used in the manufacturing of these elements must have a sufficient compression resistance to allow a press fit assembling. Of course, this restricts the choice of materials which can be used for manufacturing rollers assemblies. None of the roller assemblies of the prior art can be simultaneously long lasting, resistant to contaminants and/or vibration, and very easy and inexpensive to manufacture. Therefore, there is a very strong need for roller assemblies that can simultaneously have the aforesaid characteristics. SUMMARY OF THE INVENTION An object of the present invention is to provide a roller assembly that is very easy and inexpensive to manufacture, long lasting, resistant to contaminants and/or vibration. Another object of the present invention is to provide a roller assembly where it is not necessary to machine all the parts of the assembly and press fit them one against the other. Another object of the present invention is to provide a roller assembly where at least part of the manufacturing can be made by unskilled workman. Another object of the present invention is to provide a simple and inexpensive method for the manufacturing of a roller assembly according to the invention. Another object of the present invention is to embody a roller assembly where a roller body is mounted on a shaft provided with bearing means with a casing comprising two coaxial parts, that is a first part assembled on the shaft and a second part cast between said first part and an interior of the roller body, said second part being cured "in situ". Another object of the present invention is to obtain a roller assembly where the roller body and the other constitutive members of roller assembly have no need to be manufactured with a high degree of precision, the cohesion of the apparatus being obtained by a cured material contained in the gap existing between the exterior of the outer part of the bearing device and the interior of a roller body. Of course, the material is introduced in said gap in a fluid state and cured "in situ" without any shrinkage. Another object of the invention is to obtain a roller assembly where compression resistance to bring up constituting members of the assembly can be lower and the choice of usable material to embody the invention is substantially increased. Advantageously, any roller body having an inner diameter higher than the outer diameter of the first part of the casing may be used. An object of the present invention relates to an improvement in a roller assembly of the type comprising: a roller body provided with opposed ends and with an interior; a shaft having an outer surface; bearing means comprising at least one bearing device having an inner portion and an outer portion and having its inner portion coaxially mounted on the surface of the shaft; and a casing having an exterior contacting a corresponding portion of the interior of the roller body and an interior contacting the outer portion of the corresponding bearing device. The casing comprises at least two coaxial parts (preferably a first part and a second part). The first part has an interior and an exterior. The interior of the first part defines at least a portion of the interior of the casing and contacts the outer portion of the bearing means but substantially not the shaft. The exterior of said first part has at least a portion thereof defining at least a portion of the exterior of the casing and contacting the interior of the roller body. The second part has also an interior and an exterior. The interior of the second part contacts either a corresponding portion of the outer portion of the corresponding bearing device or a corresponding portion of the exterior of the first part. The improvement to the aforesaid roller assembly is that the second part of the casing is made of a cured material contained in a gap existing between the outer portion of at least one corresponding bearing device provided on the first part of the casing, and the interior of the roller body. More particularly, the second part of the casing is obtained "in situ" from a material in fluid state introduced in said gap and cured "in situ" without any shrinkage. According to a preferred embodiment, the interior of the second part contacts the exterior of the first part of the casing. According to another preferred embodiment, the interior of the second part of the casing does not contact the exterior of the first part of the casing and contacts the outer portion of at least one corresponding bearing device. According to another embodiment the roller body is in the shape of a tube. A man skilled in the art may select the material to be cured amongst absorbing materials and thus further define absorbing means that may further protect the roller assembly against vibrations that may cause damage to the bearing devices. Therefore, another particularly preferred object of the invention is to obtain a roller assembly further improved by providing absorbing means between the bearing device, preferably a portion of the exterior of the casing, and a portion of the roller body. Such an embodiment substantially increases the resistance and useful life of a roller assembly according to the invention. The invention also relates to a method for manufacturing such roller assembly. According to the invention the following steps are carried out: - pouring the curable material in fluid state in the gap existing between the outer portion of at least one bearing device and the interior of the roller body; - curing the material in situ to form the second part of the casing. This method is easy and efficient to produce roller assemblies according to the invention. BRIEF DESCRIPTION OF THE DRAWINGS Other objects and advantages of the invention will be better understood by way of the following description of four preferred embodiments with reference to the appended drawings in which: Fig. 1 is a perspective view of a first preferred embodiment of a roller assembly according to the invention; Fig. 2 is a partial cross-sectional and longitudinal view according to line II-II of the roller assembly of Figure 1; Fig. 3 is a perspective view of a second preferred embodiment of a roller assembly according to the invention; Fig. 4 is a partial cross-sectional and longitudinal view according to line IV- IV of the roller assembly of Figure 3; Fig. 5 is a partial cross-sectional and longitudinal view of a roller assembly according to a third preferred embodiment of the invention; and Fig. 6 is a partial cross-sectional and longitudinal view of another variant of a roller assembly according to a fourth preferred embodiment of the invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS In order to make easier the reading of the followings description of preferred embodiments of the invention and because all the embodiments illustrated in Figures 1 to 6 have a plurality of similar structural parts, identical but incremented reference numbers were used. Thus, for example, the shaft 7 appearing on Figure 1 is numbered 107 on Figure 3, 207 on Figure 5 and 307 on Figure 6. The following Table I illustrates different reference numbers used in Figs. 1 to 6 and more particularly a correspondence between similar constitutive parts of various preferred embodiments of the invention described hereinbelow. TABLE I Preferred embodiments Description of parts i rst 2' id 3 rd 4* 1 101 101 201 301 roller body/roller tube 3 103 103 203 303 opposed ends of the roller body/tube 5 105 105 205 305 interior of the roller body/tube 7 107 107 207 307 shaft 9 109 109 209 309 outer surface of the shaft 110 110 — — opening 11 111 111 211 311 shoulder — — 212 — another shoulder 13 113 113' 213 313 bearing device 14 114 114' 214 — roller bearing 15 115 115' 215 315 inner portion of the bearing device 17 117 117' 217 317 outer portion of the bearing device 19 119 119' 219 319 casing 20 120 — 220 — end of the casing 22 122 122' 222 322 opposite end of the casing 23 123 123' 223 323 exterior of the casing 25 125 125' 225 325 interior of the casing 27 127 127' 227 327 first part of the casing 28 128 128' 228 — first member of the first part of the casing 29 129 129' 229 329 second part of the casing 30 130 230 — second member of the first part of the casing 31 131 131' 231 331 interior of the first part of the casing 32 132 132' 232 332 exterior of the first part of the casing 33 133 133' 233 333 interior of the second part of the casing 34 134 134' 234 334 exterior of the second part of the casing 35 135 135' 235 335 fluid packing 36 136 136' 236 — third member of the first part of the casing 37 137 — 237 — labyrinth seal 39 139 — 239 .... first part of the labyrinth seal 41 141 — 241 — second part of the labyrinth seal 43 143 — - 243 — - interior of the first part labyrinth seal 45 145 — 245 — channel 47 147 — 247 — first "0"ring 49 149 149' 249 349 second "O" ring 51 151 151' 251 .... tongues — - — — — 352 circular depression 53 153 153' 253 — grooves The roller assembly shown in Figures 1 and 2 has a roller body (1) , a shaft (7) having an outer surface (9), bearing means and a casing (19). The roller body (1) may rotate about the shaft (7) by means of bearings. The roller body (1) is provided with opposed ends (3) and with an interior (5). The bearing means comprise two bearing devices (13) respectively provided near each of the ends (3) of the roller body (1) and each having an inner portion (15) and an outer portion (17). The casing (19) houses a corresponding bearing device (13) and a corresponding portion of the shaft (7). The casing (19) has also an exterior (23) contacting a corresponding portion of the interior (5) of the roller body (1) and an interior (25) contacting the outer portion (17) of the bearing device (13). The casing (19) also comprises at least two coaxial parts, that is a first part (27) and a second part (29). The first part (27) has an interior (31) and an exterior (32). The interior (31) of the first part (27) defines at least a portion of the interior (25) of the casing (19) and contacts the outer portion (17) of the bearing device (13) and substantially does not contact the shaft (7). The second part (29) has an interior (33) and an exterior (34). This interior (33) of the second part (29) contacts the exterior (32) of the first part (27). The exterior (34) of the second part (29), defining at least a portion of the exterior (23) of the casing (19), contacts the interior (5) of the roller body (1). The improvement is the second part (29) is made of a cured material filling a gap existing between the exterior (32) of the first part (27) of the casing (19) and the interior (5) of the roller body (1), said material having been introduced in said gap in a fluid state and cured "in situ" without any shrinkage for said cured material. According to a particularly preferred embodiment of the invention, the cured material may swell to thus apply a pressure against the exterior (32) of the second part (29) and the interior (5). A particularly preferred embodiment illustrated in Figures 1 and 2 also comprises means for protecting the bearing device (13) from exterior contaminants. Such protecting means may be provided between the bearing device (13) and its corresponding end (3) of the roller body (1). These protecting means for the bearing device (13) are housed inside the casing (19), once mounted on the shaft (7). They may comprise a labyrinth seal (37) having a first and a second part respectively (39) and (41). The first part (39) is provided with an interior (43) contacting the shaft (7) and eventually, as illustrated, contacting said bearing device (13). The second part (41) defines a part of the first part (27) of the casing (19). The first part (27) of the casing may advantageously comprise, as illustrated in Figure 2, a first member (28), a second member (30) and a third member (36). The first member (28) is positioned toward the closer end (3) of the roller body (1). The second member (30) is positioned between the first member (28) and the third member (36). Furthermore, according to a particularly preferred embodiment of the invention illustrated in Figure 2 of the drawings, the second member (30) may be part of the second part (41) of the labyrinth seal (37). A first "O"-ring (47) may be positioned near an end (20) of the casing (19) which is located near the end of the roller body (1) and simultaneously contact the interior (31) of the first part (27) of the casing (19) and the outer surface (9) of the shaft (7). A second "O"-ring (49) may also be positioned near the opposite end (22) of the casing (19). This "O"-ring (49) is part of the exterior (32) of the first part (27) of the casing (19) and contacts the interior (5) of the roller body (1). Moreover a fluid packing (35) is provided between the first and the second parts (39 and 41) of the labyrinth seal (37). Such protecting means are highly efficient to avoid the damaging of bearing due to the action of foreign particles. It may also be convenient to provide a channel (45) which allows a fluid communication between the labyrinth seal (37) and the outside of the casing (19). That particular embodiment promotes a very simple method to verify if enough packing fluid have been provided between the two parts (39 and 41) of the labyrinth seal (37). In fact, the packing fluid is provided in a slight excess which can come out by the outer channel (45). The presence of this excess of fluid packing (35) at the end of the roller assembly indicates a correct packing of the labyrinth seal (37). The excess of fluid packing (35) having flow through the channel (45) is simply removed by any appropriate means such as wiping. Optionally, protecting means may further comprise the "O"-ring (47) which contacts the shaft (7) and the exterior (31) of the first part (27) of the casing (19), near the end (3) of the roller body (1). According to this embodiment, the path through which contaminants must travel to reach the bearing means is further restricted. The materials filling the gap between the roller body (1) and the first part (27) of the casing (19) is advantageously cured by a vulcanization process. It is required that the selected material does not shrink during its curing. Optionally, it is advantageous to use a material that can swell during its curing. This optional embodiment may improve the solidity of the assembly. To embody a very resistant roller assembly, absorbing means may be further provided. Those means comprise the second part (29) of the casing (19). Here, the selection of the material to be cured is made amongst material well known to a man skilled in the art. Advantageously, the materials may be selected among those having suitable coefficient of swelling and/or hardening to define a roller assembly having specific characteristics. It is to be noted that it is known in the art to control the characteristics of roller assembly by an appropriate selection of the hardening characteristic of its constitutive part. However, the present invention substantially enlarge the list of material usable because at least a part of the roller is cast and cured "in situ", said part being made with a material having a large scope of characteristics. Advantageously the roller assembly comprises at least one bearing device (13). This bearing device (13) has an outer portion (17) provided with an outer surface facing a corresponding portion of the interior (5) of the roller body (1). Moreover, absorbing means which comprise at least a portion of the second part (29) of the casing (19) are advantageously positioned between the outer surface (17) of the bearing device (13) and the corresponding portion of the interior (5) of the roller body (1). This specific positioning of said absorbing means between the bearing device (13) and the roller body (1) improve the strength of the whole roller assembly. It is also advantageous that each bearing device (13) be laterally abutted on a shoulder (11) provided on the shaft (7). To improve the adhesion of the cured material, it is advantageous to provide means for mechanically engaging the second part (29) of the casing (19) on, at least, the exterior (32) of the first part (27) of the casing (19), the interior (5) of the roller body (1) or, at once, the exterior (34) of the second part (29) of the casing (19) and the interior (5) of the roller body (1). Said means for promoting such a mechanically engagement may be of the type of a tongue and groove assembly. For example in the first preferred embodiment shown in Figures 1 and 2, tongues (51) and grooves (53) may be provided on both the interior (5) of the roller body (1) and the exterior (32) of the first part (27) of the casing (19). According to a particularly preferred embodiment of the invention illustrated in Figures 1 and 2, each bearing device (13) may advantageously consist of a roller bearing (14) having an inner race defining the inner portion ( 15) of the bearing device (13) and an outer race defining the outer portion (17) of the bearing device (13). These kind of bearing means are very commonly used in the manufacture of roller assembly, and do not require any further extensive description. Referring now to Figures 3 and 4, there is illustrated a second particularly preferred embodiment of the invention. In this second preferred embodiment it is to be noted that it differs from the one described with reference to Figures 1 and 2 only by the fact that at least one additional casing (119*) is positioned in the roller body. Therefore, in order to avoid redundancy of the disclosure, the roller body, the casing, the shaft and any parts, members or constituents thereof have received the same reference number than those already used in Figures 1 and 2 except they have been incremented by one hundred. For example, the shaft 7 in Figures 1 and 2 is now the shaft (107) in Figures 3 and 4. It is to be noted that as illustrated, advantageously no labyrinth seal was provided for the casing (119') located inside the roller body (101). More particularly, the casing (119') comprises two identical members (128 1 ) similar to the member (136) and two "O"-rings (149') (each provided on a corresponding member (128*)). For the casing (119'), all parts similar to those of the casing (119) have kept their corresponding reference numbers with in addition a prime sign (i.e. ' ). Also, at least one opening (110) is advantageously provided in the roller body (101) to allow a fluid communication with the gap existing between the first part of the casing (119') and the interior (105) of the roller body (101). This opening (110) is intended to allow the curable material in fluid state to be introduced in said gap. Also, after curing of the material, it may further contribute to define means allowing to fasten the second part (129') of the casing (119') with the roller body (101). These fastening means are similar to a tongue and groove assembly. A roller assembly having intermediary bearing means is useful when a roller having substantial length is to be used. This use of intermediary roller is well known in the art. The purpose of the above description was only to show that it was possible to embody it within the field of the present invention. Referring now to a third particularly preferred embodiment of the invention illustrated in Figure 5 of the drawings, it is to be noted that it differs from the one illustrated in Figures 1 and 2 only by the fact that the roller bearing (14) is replaced by a sleeve. This sleeve (also called bushing) is made of antifriction material, such as TEFLON (trademark). Such sleeves are commonly used in the manufacture of roller assemblies and well known by anyone skilled in the art. Optionally, the shaft (207) may further be provided with another shoulder (212) against which the labyrinth seal (237) may be laterally abutted. This particular disposition allows an easy positioning of at least a part of the protecting means such as the labyrinth seal (237). A fourth embodiment of the invention is illustrated on Figure 6 of the drawings. In this particular roller assembly the interior (333) of the second part (329) of the casing (319) contacts the outer portion (317) of the bearing device and the exterior (334) of the second part (329) contacts the interior (305) of the roller body (301). The bearing device may comprise a sleeve similar to the one provided on the third preferred embodiment. However, in order to facilitate the positioning of the interior (331) of the first part (327) of the casing (319) a portion of the outer portion (317) of the bearing device (313) may optionally present a substantially circular depression (352) as illustrated on Figure 6. As also shown on Figure 6 this first part (327) is advantageously an "O-ring" and no protecting means may be provided. Such a roller assembly according to this particular embodiment allows to obtain a low manufacturing price per unit. The invention also relates to methods of manufacture of the above mentioned roller assemblies. More particularly, this method comprises the steps of: - pouring a curable material in a fluid state in a gap existing between the outer portion (17, 117', 217 or 317) of at least one corresponding bearing device (13, 113', 213 or 313) and the interior (5, 105, 205 or 305) of the roller body (1, 101, 201 or 301); and - curing said material in situ to form the second part (29, 129, 129', 229 or 329) of the casing made of cured material. Advantageously the curable material contacts the outer portion (17, 117', 217 or 317) of at least one corresponding bearing device (13, 113', 213 or 313) and the interior (5, 105, 205 or 305) of the roller body (1, 101, 201 or 301). According to a particularly preferred embodiment of the invention, the method may comprise: - positioning at least the bearing means and its corresponding first part of the casing on a shaft (7, 107 or 207) inside the roller body (1, 101 or 201); - pouring a curable material in a fluid state in a gap existing between the exterior (32, 132' or 232) of the first part (23, 123' or 323) of the casing (19, 119' or 219) and the interior of the roller body (1, 101 or 201); and - curing said material in situ to form the second part (29, 129, 129' or 229) of the casing (19, 119',or 219) made of cured material. The aforesaid method is simple to carry out and, cheaper than the usual methods for manufacturing roller assembly. The pouring and the curing steps may be carried out by any technique conventionally used in the art. According to a more particularly preferred method according to the invention, the following steps may be carried out: - positioning at least one pre-assembly resulting from the positioning of bearing means (especially bearing devices 13, 113' or 213) and its corresponding first part (27, 127 or 227) of the casing on a shaft (7, 107, or 207) inside the roller body (1, 101 or 201) and temporarily maintaining its spatial relation, by any appropriate means, with respect to the interior of the roller body (1, 101 or 201); - pouring a curable material in a fluid state in a gap existing between the exterior (32, 132', 232) of the first part of the casing and the interior (5, 105 or 205) of the roller body (1, 101 or 201); and - curing said material in situ to form the second part (29, 129, 129' or 229) of the casing made of cured material. This method has the advantage to make very easy a pre-assembling comprising the shaft (7, 107 or 207), the bearing devices (13, 113' or 213) and the first part (27, 127 or 227) of the casing with respect to the roller body (1, 101 or 201). This method can be further improved by the providing of an "O"-ring (49,149' or 249) on the casing to temporarily maintain and coaxialally position the shaft, the bearing means and the first part of the casing inside the roller body. Thus, the positioning step is much easier to carry out. Advantageously the roller body is positioned perpendicularly to the ground during all the steps involving the curing of the material to define the second part (29, 129, 129' or 229). This is a good and simple way to promote an homogenous pouring and subsequent curing of the materials following the gap. Advantageously, the pouring step may be carried out by the ends of the roller body. Moreover other methods to fill the gaps existing between the interior of the roller body and the first part of the casing may be used such as for example openings (such as opening 110) defining filling channels provided through the roller body. This method is very efficient to fill a corresponding gap. Furthermore it allows a simultaneous filling of several gaps of a same roller assembly and by the way increase the speed of the fabrication of the roller assembly. The roller assembly according to the invention can be manufactured with any materials suitable but some kind of materials are preferred. For the roller body, metals like iron, steel, cast iron or aluminium, rubber, polyurethane, epoxy resin, concrete, polymers or composite may be used. The bearing means and the shaft may be made of iron, steel, plastic or in composite. The curable material having no shrinkage is advantageously selected from the group comprising rubber, polyurethane, epoxy resin, plastic, cast iron, aluminium and composite, well known to have the required properties. As can be understood from the above description, the invention provides a novel roller assembly which offers the following advantages: they can be manufactured with rollers having an internal diameter which is substantially greater than the external diameter of the shaft with bearing means fitted thereon and the first part of the casing. Therefore, said constituent parts of the roller assembly may be manufactured independently of each other. The manufacture of roller assemblies according to the invention is simple because it is not required to press-fit a roller body on a bearing device which is itself press fitted on a shaft. Then another advantage of this invention is to allow the use of a larger variety of material for defining the elements of the roller assembly.

Claims: CLAIMS: 1. In a roller assembly of the type comprising: a roller body (1, 101, 201 or 301) provided with opposed ends (3, 103, 203 or 303) and with an interior (5, 105, 205 or 305); a shaft (7, 107, 207 or 307) having an outer surface (9, 109, 209 or 309); bearing means comprising at least one bearing device (13, 113, 113', 213 or 313) having an inner portion (15, 115, 115', 215 or 315) and an outer portion (17, 117, 117', 217 or 317) said bearing device (13, 113, 113', 213 or 313) having its inner portion (15, 115, 115', 215 or 315) coaxially mounted on the surface of the shaft (7, 107, 207 or 307); and a casing (19, 119, 119', 219 or 319) having an exterior (23, 123, 123', 223 or 323) contacting a corresponding portion of the interior (5, 105, 205 or 305) of the roller body (1, 101, 201 or 301) and an interior (25, 125, 125', 225 or 325) contacting the outer portion (17, 117, 117', 217 or 317) of the corresponding bearing device (13, 113, 113', 213 or 313); said casing (19, 119, 119', 219 or 319) comprising at least two coaxial parts, that is a first part (27, 127, 127', 227 or 327) and a second part (29, 129, 129', 229 or 329), the first part (27, 127, 127', 227 or 327) having an interior (31, 131, 131', 231 or 331) and an exterior (32, 132, 132', 232 or 332), the interior (31, 131, 131', 231 or 331) of said first part (27, 127, 127', 227 or 327) defining at least a portion of the interior (25, 125, 125', 225 or 325) of the casing (19, 119, 119', 219 or 319) and contacting the outer portion (17, 117, 117', 217 or 317) of the corresponding bearing device (13, 113, 113', 213 or 313) while substantially not contacting the shaft (7, 107, 207 or 307), the exterior (32, 132, 132', 232 or 332) of said first part (27, 127, 127', 227 or 327) having at least a portion thereof defining at least a portion of the exterior (23, 123, 123', 223 or 323) of the casing (19, 119, 119', 219 or 319) and contacting the interior (5, 105, 205 or 305) of the roller body (1, 101, 201 or 301), and the second part (29, 129, 129', 229 or 329) having an interior (33, 133, 133', 233 or 333) and an exterior (34, 134, 134', 234 or 334), the interior (33, 133, 133', 233 or 333) of the second part (29, 129, 129', 229 or 329) contacting a corresponding portion of the outer portion (17, 117, 117', 217 or 317) of the corresponding bearing device (13, 113, 113', 213 or 313) and/or a corresponding portion of the exterior (32, 132, 132', 232 or 332) of the first part (27, 127, 127', 227 or 327) and the exterior (34, 134, 134', 234 or 334) of the second part (29, 129, 129', 229 or 329) defining a corresponding portion of the exterior (23, 123, 123', 223 or 323) of the casing (19, 119, 119', 219 or 319) and contacting the interior (5, 105, 205 or 305) of the roller body (1, 101, 201 or 301); the improvement wherein said second part (29, 129, 129', 229 or 329) is made of a cured material contained in a gap existing between the outer portion (17, 117, 117', 217 or 317) of at least one corresponding bearing device (13, 113, 113', 213 or 313) and the interior (5, 105, 205 or 305) of the roller body (1, 101, 201 or 301), said material having been introduced in said gap in a fluid state and cured "in situ" without any shrinkage. 2. A roller assembly according to claim 1, wherein the exterior (332) of said first part (327) contacts only the interior (305) of the roller body (301) and does not contact the interior (333) of said second part (329) of the casing (319). 3. In a roller assembly of the type comprising: a roller body (1, 101 or 201) provided with opposed ends (3, 103 or 203) and with an interior (5, 105 or 205); a shaft (7, 107 or 207) having an outer surface (9, 109 or 209); bearing means comprising at least one bearing device (13, 113, 113' or 213) having an inner portion (15, 115, 115' or 215) and an outer portion (17, 117, 117' or 217); and a casing (19, 119, 119' or 219) for housing a corresponding bearing device (13, 113, 113' or 213) and a portion of the shaft (7, 107 or 207) said casing (19, 119, 119' or 219) having an exterior (23, 123, 123' or 223) contacting a corresponding portion of the interior (5, 105 or 205) of the roller body (1, 101 or 201) and an interior (25, 125, 125' or 225) contacting the outer portion (17, 117, 117' or 217) of the corresponding bearing device (13, 113, 113' or 213); said casing (19, 119, 1 19' or 219) comprising at least two coaxial parts, that is a first part (27, 127, 127' or 227) and a second part (29, 129, 129' or 229), the first part (27, 127, 127' or 227) having an interior (31, 131, 131' or 231) and an exterior (32, 132, 132' or 232), the interior (31, 131, 131' or 231) of said first part (27, 127, 127' or 227) defining at least a portion of the interior (25, 125, 125' or 225) of the casing (19, 119, 119' or 219) contacting the outer portion (17, 117, 117' or 217) of the corresponding bearing device (13, 113, 113' or 213) while substantially not contacting the shaft (7, 107 or 207) and the second part (29, 129, 129' or 229) having an interior (33, 133, 133' or 233) and an exterior (34, 134, 134' or 234), the interior (33, 133, 133' or 233) of said second part (29, 129, 129' or 229) contacting the exterior (32, 132, 132' or 232) of the first part (27, 127, 127' or 227), and the exterior (34, 134, 134' or 234) of the second part (29, 129, 129' or 229) defining at least a portion of the exterior (23, 123, 123' or 223) of the casing (19, 119, 119' or 219) and contacting the interior (5, 105 or 205) of the roller body (1, 101 or 201); the improvement wherein said second part (29, 129, 129' or 229) is made of a cured material contained in a gap existing between the exterior (32, 132, 132' or 232) of the first part (27, 127, 127' or 227) of the casing (19, 119, 119' or 219) and the interior (5, 105 or 205) of the roller body (1, 101 or 201) said material having been introduced in said gap in a fluid state and cured "in situ" without any shrinkage. 4. A roller assembly according to claim 3, wherein the cured material swells during its curing. 5. A roller assembly according to claim 3, wherein absorbing means are further provided between a portion of the exterior (23, 123, 123' or 223) of the casing (19, 119, 119' or 219) and a portion of the roller body (1, 101 or 201). 6. A roller assembly according to claim 5, wherein said absorbing means comprise the second part (29, 129, 129' or 229) of the casing (19, 119, 119' or 219). 7. A roller assembly according to claim 5, wherein each bearing device (13, 113, 113' or 213) has an outer portion (17, 117, 117' or 217) provided with an outer surface facing a corresponding portion of the interior (5, 105 or 205) of the roller body (1, 101 or 201) and wherein absorbing means comprising a portion of the second part (29, 129, 129' or 229) of the casing (19, 119, 119' or 219) are provided between said outer surface of the bearing device (13, 113, 113' or 213) and said portion of the interior (5, 105 or 205) of the roller body (1, 101 or 201). 8. A roller assembly according to claim 3, wherein between each end (3, 103, 203 or 303) of the roller body (1, 101 or 201) and a neighbouring bearing device (13, 113 or 213) protecting means are respectively provided. 9. A roller assembly according to claim 8, wherein each protecting means comprise at least one labyrinth seal (37, 137 or 237) having a first part (39, 139 or 239) and a second part (41, 141 or 241), the first part (39, 139 or 239) being provided with an interior (43, 143 or 243) contacting the shaft (7, 107 or 207) and the second part (41, 141 or 241) defining a part of said first part (27, 127 or 227) of said casing (19, 119 or 219); wherein a fluid packing (35, 135 or 235) is provided between said first part (39, 139 or 239) and second part (41, 141 or 241) of the labyrinth seal (37, 137 or 237); wherein said first part (27, 127 or 227) of the casing (19, 119 or 219) comprises a first (28, 128 or 228), a second (30, 130 or 230) and a third member (36, 136 or 236), the second member (30, 130 or 230) being positioned between said first (28, 128 or 228) and third (36, 136 or 236) members and being defined by the second part (41, 141 or 241) of the labyrinth seal (37, 137 or 237); and wherein the first member (28, 128 or 228) of the casing (19, 119 or 219) is provided with at least one channel (45, 145, or 245) allowing a fluid communication between the labyrinth seal (37, 137 or 237) and the outside of the casing (19, 119 or 219). 10. A roller assembly according to claim 3, wherein on at least the exterior (32, 132, 132' or 232) of the first part (27, 127, 127 or 227) of the casing (19, 119, 119' or 219), the interior (5, 105 or 205) of said roller body (1, 101 or 201) or at once the exterior (32, 132, 132' or 232) of the first part (27, 127, 127' or 227) of the casing (19, 119, 119' or 219) and the interior (5, 105 or 205) of the roller body (1, 101 or 201) means are provided for mechanically engaging it or them with the second part (29, 129, 129' or 229) of the casing (19, 119, 119' or 219). 11. A roller assembly according to claim 10, wherein said means for mechanically engaging at least the exterior (32, 132, 132' or 232) of the first part (27, 127, 127' or 227) of the casing (19, 119, 119' or 219), the interior (5, 105 or 205) of said roller body (1, 101 or 201) or at once the exterior (32, 132, 132' or 232) of the first part (27, 127, 127' or 227) of the casing (19, 119, 119' or 219) and the interior (5, 105 or 205) of the roller body (1, 101 or 201), with the second part (29, 129, 129' or 229) of the casing (19, 119, 119' or 219), are of the type tongue and groove assembly. 12. A roller assembly according to claim 9, wherein said first part ( 27, 127, 127' or 227) is further provided with positioning means for co-axial mounting of the shaft (7, 107 or 207) in the roller body (1, 101 or 201). 13. A roller assembly according to claim 12, wherein said positioning means are part of the first part (27, 127, 127' or 227) of the casing (19, 119, 119' or 219) and further define means for retaining the fluid material to be cured in the gap existing between the first part (27, 127, 127' or 227) of the casing (19, 119, 119' or 219) and the interior (5, 105 or 205) of the roller body (1, 101 or 201). 14. A roller assembly according to claim 3, wherein two bearing devices (213) are respectively provided near each of said ends (203) of the roller body (201), each bearing device (213) comprising a sleeve of antifriction material having an inner portion and an outer portion corresponding to those of the bearing device (213). 15. A roller assembly according to claim 3, wherein two bearing devices (213 ) are respectively provided near each of said ends (203) of the roller body (201) and wherein at least one other bearing device is further provided between those already provided near each of said ends (203), each bearing device (213) comprising a sleeve of antifriction material having an inner portion and an outer portion corresponding to those of the bearing device (213). 16. A roller assembly according to claim 3, wherein two bearing devices (13 or 113) are respectively provided near each of said ends (3 or 103) of the roller body (1 or 101), each bearing device (13 or 113) comprising at least one roller bearing (14 or 114) provided with an inner race defining the inner portion (15 or 115) of the bearing device (13 or 113) and an outer race defining the outer portion (17 or 117) of said bearing devices (13 or 113). 17. A roller assembly according to claim 3, wherein two bearing devices (13 or 113) are respectively provided near each of said ends (3 or 103) of the roller body (1 or 101) wherein at least another bearing device ( 113') is further provided between those already provided near each of said ends (3 or 103), and wherein each of said bearing device (13, 113 or 113') comprise at least one roller bearing (14, 114 or 114') provided with an inner race defining the inner portion (15, 115 or 115') of the bearing device (13, 113 or 113') and an outer race defining the outer portion (17, 117 or 117' ) of said bearing device (13, 113 or 113'). 18. In a roller assembly of the type comprising: a roller tube (1 or 101) provided with opposed ends (3 or 103) and with an interior (5 or 105); a shaft (7 or 107) having an outer surface (9 or 109) and provided with two shoulders (11 or 111); bearing means comprising at least two bearing devices (13 or 113) that are respectively provided near each of said ends (3 or 103) of the roller tube (1 or 101), each of said bearing device (13 or 113) comprising at least one roller bearing (14 or 114) provided with an inner race defining an inner portion (15 or 115) of the bearing device (13 or 113) and an outer race defining an outer portion (17 or 117) of said bearing device (13 or 113); each bearing device (13 or 113) being laterally abutted against a corresponding shoulder (11 or 111) of the shaft (7 or 107); a casing (19 or 119) for housing a corresponding bearing device (13 or 113) and a portion of the shaft (7 or 107), said casing (19 or 119) having an exterior (23 or 123) contacting a corresponding portion of the interior (5 or 105) of the roller tube (1, 101) and an interior (25 or 125) contacting the outer portion (17 or 117) of the bearing device (13 or 113); said casing (19 or 119) comprising at least two coaxial parts, that is a first part (27 or 127) and a second part (29 or 129), the first part (27 or 127) having an interior (31 or 131) and an exterior (32 or 132), the interior (31 or 131) of said first part (27 or 127) defining at least a portion of the interior (25 or 125) of the casing (19 or 119) contacting the outer portion (17 or 117) of the corresponding bearing device (13 or 113) while substantially not contacting the shaft (7 or 107), and the second part (29 or 129) having an interior (33 or 133) and an exterior (34 or 134), the interior (33 or 133) of said second part (29 or 129) contacting the exterior (32 or 132) of the first part (27 or 127), and the exterior (34 or 134) of the second part (29 or 129) defining at least a portion of the exterior (23 or 123) of the casing (19 or 119) and contacting the interior (5 or 105) of the roller tube (1 or 101); said first part (27 or 127) of the casing (19 or 119) comprising a first member (28 or 128), a second member (30 or 130) and a third member (36 or 136), the second member (30 or 130) being positioned between said first (28 or 128) and third (36 or 136) members, the first member (28 or 128) being positioned toward the closer end of the roller tube (1 or 101); - protecting means for the roller bearing (14 or 114) inside each casing (19 or 119) once mounted on the shaft (7 or 107), said protecting means comprising: - a labyrinth seal (37 or 137) having a first (39 or 139) and a second part (41 or 141), the first part (39 or 139) being provided with an interior (43 or 143) contacting the shaft (7 or 107) and the second part (41 or 141) having a portion defining a part of said first part (27 or 127) of said casing (19 or 119) and having a grease or a high viscosity heat resistant lubricant between said first (39 or 139) and second (41 or 141) parts of the labyrinth seal (37 or 137); said first member (28 or 128) being further provided with a channel (45 or 145) allowing a fluid communication between the labyrinth seal (37 or 137) and the outside of the casing (19 or 119); and - means for further protecting the bearing device (13 or 113) comprising an "O"-ring (47 or 147) positioned near the end of the roller tube ( 1 or 101 ) and contacting the exterior (32 or 132) of the first member (28 or 128) casing (19 or 119) and the shaft (7 or 107); - means for positioning and retaining the shaft (7 or 107) co-axial with the roller tube (1 or 101) and comprising an "O"-ring (49 or 149) defining a part of the exterior of the third member (36 or 136) and contacting the interior (5 or 105) of the roller tube (1 or 101); the improvement wherein said second part (29 or 129) is made of a cured material filling a gap existing between the exterior (32 or 132) of the first part (27 or 127) of the casing (19 or 119) and the interior (5 or 105) of the roller tube (1 or 101), said material having been introduced in said gap in a fluid state and cured "in situ" without any shrinkage, said cured material having such properties to define absorbing means between the first part (27 or 127) of the casing (19 or 119) and the interior (5 or 105) of the roller tube (1 or 101). 19. A roller assembly according to claim 18, wherein on at least the exterior (32 or 132) of the first part (27 or 127) of the casing ( 19 or 119), the interior (5 or 105) of said roller tube (1 or 101) or at once the exterior (32 or 132) of the first part (27 or 127) of the casing (19 or 119) and the interior (5 or 105) of the roller tube (1 or 101), means comprising tongues (51 or 151) and grooves (53 or 153) are provided for mechanically engaging it or them with the second part (29 or 129) of the casing (19 or 119). 20. A roller assembly according to claim 18, wherein the bearing means comprise two bearing devices ( 13 or 113) which are respectively provided near each of said ends (3 or 103) of the roller body (1 or 101), wherein at least another bearing device (113') is further provided between those already provided near each of said ends ( 3 or 103), and wherein each of said bearing device (113') comprises at least one roller bearing (114') provided with an inner race defining the inner portion (115') of the bearing device (113') and an outer race defining the outer portion (117') of said bearing device (113'). 21. In a roller assembly of the type comprising: a roller tube (201) provided with opposed ends (203) and with an interior (205); a shaft (207) having an outer surface (209) and provided with two shoulders (211 ) and two shoulders (212); bearing means comprising at least two bearing devices (213) having an inner portion (215) and an outer portion (217), two of said bearing devices (213) being respectively provided near each of said ends (203) of the roller tube (201), each of said bearing devices (213) comprising a sleeve made of antifriction material, each bearing device (213) being laterally abutted against a corresponding shoulder (211) of the shaft (207); a casing (219) for housing a corresponding bearing device (213) and a portion of the shaft (207), said casing (219) having an exterior (223) contacting a corresponding portion of the interior (205) of the roller tube (201) and an interior (225) contacting the outer portion (217) of the bearing device (213); said casing (219) comprising at least two coaxial parts, that is a first part (227) and a second part (229), the first part (227) having an interior (231) and an exterior (232), the interior (231) of said first part (227) defining at least a portion of the interior (225) of the casing (219) contacting the outer portion (217) of the corresponding bearing device (213) while substantially not contacting the shaft (207), and the second part (229) having an interior (233) and an exterior (234), the interior (233) of said second part (229) contacting the exterior (232) of the first part (227), and the exterior (234) of the second part (229) defining at least a portion of the exterior (223) of the casing (219) and contacting the interior (205) of the roller tube (201); said first part (227) of the casing (219) comprising a first (228), a second (230) and a third member (236), the second member being positioned between said first (228) and third (236) members, the first member (228) being positioned toward the closer end of the roller tube (201); - protecting means for the bearing device (213) inside each casing (219) once mounted on the shaft (207) said protecting means comprising: - a labyrinth seal (237) having a first (239) and a second part (241), the first part (239) being provided with an interior (243) contacting the shaft (207) and abutting against another shoulder (212) of said shaft (207), while the second part (241) having a portion defining a part of said first part (227) of said casing (219), and having a grease or a high viscosity heat resistant lubricant is provided between said first (239) and second (241) parts of the labyrinth seal (237), said first member (228) of the casing (219) being further provided with a channel (245) allowing a fluid communication between the labyrinth seal (237) and the outside of the casing (219); and - means for further protecting the corresponding bearing device (213) comprising an "O"-ring (247) positioned near the end of the roller tube (201) and contacting the exterior (232) of the first member (228) and the shaft (207); - means for positioning and retaining the shaft (207) co-axial with the roller tube (201) and comprising an "O"-ring (249) positioned near the opposite end (222) of the casing (219), defining the exterior (232) of the first part (227) of the casing (219) and contacting the interior (203) of the roller tube; the improvement wherein said second part (229) is made of a cured material filling a gap existing between the exterior (232) of the first part (227) of the casing (219) and the interior (205) of the roller tube, said material having been introduced in said gap in a fluid state and cured "in situ" without shrinkage, said cured material having such properties to define absorbing means between the first part (227) of the casing (219) and the interior (205) of the roller tube (201). 22. A roller assembly according to claim 21, wherein on at least the exterior (232) of the first part (227) of the casing (219), the interior (205) of said roller tube (201), or at once the exterior (232) of the first part (227) of the casing (219) and the interior (205) of the roller tube (201), means comprising tongue (251) and groove (253) are provided for mechanically engaging it or them with the second part (229) of the casing (219). 23. A roller assembly according to claim 21, wherein two bearing devices (213) are respectively provided near each of said ends (203) of the roller body (201), and wherein at least one other bearing device is further provided between those already provided near each of said ends (203), each bearing device comprising a sleeve of antifriction material having an inner portion and an outer portion corresponding to those of the bearing device. 24. Method for manufacturing the roller assembly defined in claim 1, wherein the following steps are carried out: - pouring the curable material in a fluid state in the gap existing between the outer portion (17, 117, 117', 217 or 317) of at least a bearing device (13, 113, 113', 213 or 313) and the interior (5, 105, 205 or 305) of the roller body (1, 101, 201 or 301); and - curing said material in situ to form the second part (29, 129, 129', 229 or 329) of the casing ( 19, 119, 119', 219 or 319) made of cured material. 25. Method for manufacturing the roller assembly defined in claim 3, wherein the following steps are carried out: - pouring the curable material in a fluid state in the gap existing between the exterior (32, 132, 132' or 232) of the first part (27, 127, 127' or 227) of the casing (19, 119, 119' or 219) and the interior (5, 105 or 205) of the roller body (1, 101 or 201); and - curing said material in situ to form the second part (29, 129, 129' or 229) of the casing (19, 119, 119' or 219) made of cured material. 26. Method for manufacturing the roller assembly defined in claim 3, wherein the following steps are carried out: - vertically positioning at least one pre-assembly resulting from positioning of at least one bearing device (13, 113, 113' or 213) and its corresponding first part (27, 127, 127' or 227) of the casing (19, 119, 119' or 219) on a shaft (7, 107 or 207) inside the roller body (1, 101 or 201) and temporarily maintaining its spatial relation with respect to the interior (5, 105 or 205) of the roller body (1, 101 or 201); - pouring a curable material in a fluid state in a gap existing between the exterior (32, 132, 132' or 232) of the first part (27, 127, 127' or 227) of the casing (19, 119, 119' or 219) and the interior (5, 105 or 205) of the roller body (1, 101 or 201); and - curing said material in situ to form the second part (29, 129, 129' or 229) of the casing (19, 119, 119' or 219) made of cured material. 27. Method for manufacturing the roller assembly according to claim 26, wherein the pouring step is carried out by the upper end of the roller body (1, 101 or 201). 28. Method according to claim 26, wherein the pouring step is further carried out by means of filling channels (110) provided in the roller body (1 or 101). 29. Method for manufacturing the roller assembly defined in claim 14, wherein the following steps are carried out successively for both the bearing devices (213) respectively provided near each end (203) of the roller body (201): - vertically positioning trough an upper end of the roller body (201) a first pre-assembly resulting from the positioning of one of the bearing devices (213) and its corresponding first part (227) of the casing (219) on a shaft (207) inside the roller body (201), and temporarily maintaining its spatial relation with respect to the interior (205) of the roller body (201); - pouring a curable material in a fluid state in a gap existing between the exterior (232) of the first part (227) of the casing (219) and the interior (205) of the roller body (201); - curing said material in situ to form the second part (229) of the casing (219) made of cured material; - turning the roller upside down; and - repeating the above steps at the opposite end of the roller body (201). 30. Method for manufacturing the roller assembly according to claim 29, wherein the pouring step is carried out by the upper end of the roller body (201). 31. Method for manufacturing the roller assembly defined in claim 16, wherein the following steps are carried out successively for both the bearing devices (13 or 113) respectively provided near each end (3 or 103) of the roller body (1 or 101): - vertically positioning through an upper end of the roller body (1 or 101,) a first pre-assembly resulting from the positioning of one of the bearing devices (13 or 113) and its corresponding first part (27 or 127) of the casing (19 or 119) on a shaft (7 or 107) inside the roller body (1 or 101), and temporarily maintaining its spatial relation with respect to the interior (5 or 105) of the roller body (1 or 101); - pouring a curable material in a fluid state in a gap existing between the exterior (32 or 132) of the first part (27 or 127') of the casing (19 or 119) and the interior (5 or 105) of the roller body (1 or 101); - curing said material in situ to form the second part (29 or 129) of the casing (19 or 119) made of cured material; - turning the roller assembly upside down; and - repeating the above steps at the opposite end of the roller body (1 or 101). 32. Method for manufacturing the roller assembly according to claim 31 , wherein the pouring step is carried out by the upper end of the roller body (1 or 101).

Inventors: GAGNON JEAN-PIERRE, GAGNON, JEAN-PIERRE
Applicants: GAGNON JEAN PIERRE, GAGNON, JEAN-PIERRE
Application year: 1995
Main classification: B65G39
IPC codes: B29D31, B65G39, F16C13, F16C35