Coupling device having a continuous flexible coupling element

Abstract: The present invention is directed to a flexible coupling device adapted to connect a first rotatable shaft with a second rotatable shaft. The coupling device generally includes a pair of opposing hubs (12 and 14), each of which is adapted to be secured to a respective shaft. A continuous and flexible coupling element(16) extends between the hubs. According to the present invention, the coupling element (16) is nonremovably associated with a pair of inner clamp rings (54,56), each adapted to be connected to one of the hubs. The coupling element (16) can be molded about the inner (12,14) clamp rings and can be adhesively secured to the rings.

Description: Field of the Invention The present invention generally relates to a flexible coupling device, and more particularly to a flexible coupling device having a continuous elastomeric coupling element. Background of the Invention The present invention is generally directed to flexible coupling devices of the type that are adapted to connect the end of a first shaft with the end of a second shaft. Such coupling devices are used, for instance, to transmit rotary or torsional power from a driven rotating shaft to an adjacent non-driven shaft. The coupling devices also provide flexibility for interconnecting a pair of opposing shafts that are slightly out of alignment. More particularly, the present invention is directed to a flexible coupling device having a "tire style" coupling element. These types of coupling devices typically include a pair of opposing hubs, each mounted to the end of a respective rotatable shaft. The hubs are connected by a flexible, circular coupling element generally having the shape of a tire. In order to connect the opposing hubs together, each side of the coupling element is mechanically clamped between one of the hubs and an internal clamp ring. One example of a shaft coupling device as described above is disclosed in U.S. Patent No. 4,536,170 to Downey . In Downey , an elastomeric sheer shaft coupling is disclosed for connecting two rotatable shafts in an end-to-end relationship. The coupling includes hubs for mounting on the opposed ends of the shafts with a flexible element extending between the hubs. The flexible coupling element is reinforced with layers of fabric or cord interspersed in an elastomeric material. Further, the margins of the coupling element have a bead therein of elastomeric material that has a higher durometer value than that forming the body of the element. The bead and the fabric are included to reinforce the element and to prolong its effective life. Prior art constructions of coupling devices incorporating "tire style" coupling elements have provided meritorious advances in devices used to connect the ends of opposing shafts. Besides connecting the shafts together, these types of devices can accommodate slight amounts of angular misalignment and/or parallel misalignment. The flexible coupling element also cushions shock loads, putting much less stress on the industrial machinery associated with the shafts. Further, the flexible coupling element can dampen torsional vibration caused by the various engines and motors used to drive the shafts. Most tire style coupling elements, however, include a slit which completely severs the element. The slit is provided for allowing the coupling element to be placed over a pair of internal clamp rings when being secured to the opposing hubs. The slit, unfortunately, lowers the overall strength and reduces the maximum amount of speed and torque which may be placed on the coupling element. Another example of a shaft coupling device is disclosed in U.S. Patent No. 1,501,187 to Rayfield. In Rayfield a flexible coupling for uniting two shafts is diclosed. A flexible member is secured between a disk which is keyed on said shaft and a plate. Said plate having a shoulder and bosses for positioning said flexible member on it. The flexible member having holes in it for receiving said bosses. The flexible member being thicker than the height of the bosses for compressing the material of the flexible member. A further example of a shaft coupling device is disclosed in U.S. Patent No. 2,945,365 to Ulderup. In Ulderup another flexible coupling device is disclosed. Said flexible coupling device being adapted to be inserted between a flange on each shaft. Rings being completely embedded in a plastic body.Said rings are provided openings and with spaced eye-shaped bulges which have tapped holes therein. With said openings said rings are anchored within said plastic body. A disadvantage of Rayfield and Ulderup is that each of said coupling devices have several holes in the flexible member which make the coupling device less tough and durable. Additional another disadvantage is the complicated design of the plate and the ring whichare necessary for that design but causes high expenditure. Summary of the Invention The present invention is directed to further improvements in coupling devices containing a flexible coupling element. In particular, the present invention is directed to a coupling device having a continuous coupling element that is nonremovably associated with a pair of inner clamp rings. As used herein, the term continuous means that the coupling element is unitary and does not contain a slit as described above. By incorporating a continuous coupling element, the coupling device of the present invention can accommodate higher torques and speeds when in use. Further, the coupling device has inherently better balance than conventional devices containing a separated coupling element. Accordingly, it is an object of the present invention to provide a flexible coupling device adapted to connect an end of a first shaft to an end of a second shaft. Another object of the present invention is to provide a coupling device having a flexible and continuous coupling element. Still another object of the present invention is to provide a coupling device having a continuous coupling element that is nonremovably associated with a pair of inner clamp rings. It is another object of the present invention to provide a coupling device having a continuous coupling element with a pair of inner clamp rings embedded within the sides of the element. Another object of the present invention is to provide a flexible coupling device having a continuous coupling element that is adhesively secured to a pair of inner clamp rings. Additional objects and advantages of the invention will be set forth in the following description, or may be obvious from the description, or may be learned through practice of the invention. The objects of the present invention are achieved by providing a coupling device adapted to connect an end of a first shaft to an end of a second shaft as defined in claim 1. The coupling device includes a pair of opposing hubs, each adapted to be secured to a respective shaft. Each hub includes an outer ring facing towards the opposing hub. A first inner clamp ring and a second inner clamp ring are provided and are adapted to be secured to the first and second hubs respectively. The coupling device further includes an elastomeric continuous coupling element extending between the opposing hubs. The coupling element is moulded about the inner clamp rings. The coupling element has a configuration including a first side and a second side. The first side of the element is clamped between the first inner clamp ring and the outer ring of the first hub. The second side of the element, on the other hand, is clamped between the second inner clamp ring and the outer ring of the second hub. In one embodiment, the inner clamp ring can be adhesively secured to the sides of the coupling element. Alternatively, the inner clamp rings can be embedded within the sides of the coupling element. The coupling element can be made from an elastomeric material, such as natural rubber, neoprene rubber, a urethane, or EPDM. In order to reinforce the coupling element, at least one tension member can be embedded within the elastomeric material. For instance, the tension member can be made from a polyester fabric. The flexible coupling element can also include a flange portion at the end of each side that is shaped to engage and interlock with the outer rings of the opposing hubs. In one embodiment, each of the opposing hubs includes a ring separating member positioned between the outer ring and the complementary inner clamp ring. Alternatively, each opposing, hub includes a flange that is secured to the rotating shaft. The flange can be connected to the outer ring of each hub. These and other objects are also achieved by providing a coupling element as defined in claim 15. Other objects, features and aspects of the present invention are discussed in greater detail below. Brief Description of the Drawings A full and enabling disclosure of the present invention, including the best mode thereof, to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which: Figure 1 is a perspective view of one embodiment of a coupling device made according to the present invention shown in a disassembled state; Figure 2 is a cross-sectional view of the coupling device shown in Figure 1; Figure 3 is a cross-sectional view of another embodiment of a coupling device made according to the present invention; and Figure 4 is a cross-sectional view of a further embodiment of a coupling device made in accordance to the present invention. Repeat use of reference characters in the present specification and drawings is intended to represent same or analogous features or elements of the invention. Detailed Description of Preferred Embodiments It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary construction. In general, the present invention is directed to coupling devices of the type that are adapted to connect an end of a first shaft to an end of a second shaft. The coupling device includes a "tire-style" flexible coupling element made from an elastomeric material. The coupling element is flexible in that it can accommodate some misalignment between the opposing shafts. According to the present invention, the flexible coupling element is a continuous and unitary structure. Referring to Figures 1 and 2, one embodiment of a coupling device, generally 10, made in accordance with the present invention is illustrated. Coupling device 10 includes a pair of opposing hubs 12 and 14, which can be interconnected by a flexible and continuous coupling element 16. As shown in Figure 2, coupling device 10 is adapted to connect a first rotatable shaft 18 with a second rotatable shaft 20. Through coupling device 10, rotary or torsional power can be transmitted from first shaft 12 (the driving shaft) to second shaft 14 (the driven shaft). The connected shafts may be of equal size as shown in Figure 2 or, alternatively, the shafts may be of different diameters. Ideally, the two shafts will be in precise axial alignment. However, this is often not the case, and the shafts may exhibit slight amounts of angular misalignment, parallel misalignment and/or endfloat. Being made from an elastomeric material, flexible coupling element 16 of coupling device 10 is capable of accommodating any of these types of misalignment. Further, flexible coupling element 16 also cushions shock loads caused by the machinery connected to shafts 18 and 20 and dampens torsional vibrations. Hubs 12 and 14 include respective outer rings 22 and 24 which are adapted to be mounted against and connected to coupling element 16, as will be described in more detail hereinafter. Hubs 12 and 14 are each adapted to be placed upon and secured to a respective rotatable shaft. For instance, in the embodiment shown in Figure 1, hub 12 includes a key receiving notch 26, while hub 14 includes a key receiving notch 28. When hub 12 is placed on a shaft, key receiving notch 26 is placed in alignment with a keyway formed into the shaft. A rectangular key is then inserted into key receiving notch 26 and into the corresponding keyway formed into the shaft. Hub 12 thus becomes secured to the shaft during rotation. Hub 12 is then further secured to the shaft by set screws 30 and 32. Specifically, set screws 30 and 32 prevent hub 12 from sliding along the shaft. As shown in Figure 1, it has been found that having two set screws at an angle of approximately 65 degrees provides the most optimum holding force. Hub 14 can be secured to an opposing shaft using similar means. As shown, hub 14 also includes a pair of set screws 34 and 36. When hub 12 or hub 14 is mounted to a shaft of smaller diameter, the hub can include a tapered bore through which the shaft is inserted. A split contractible bushing having an outer circumferential surface that is oppositely tapered relative to the tapered bore of the hub can be placed between the hub and the shaft. Using screws, the bushing can then be tightened drawing the tapered surfaces together and securing the hub on the shaft. As stated above, once secured to opposing shafts, hubs 12 and 14 are interconnected by flexible coupling element 16. According to the present invention, coupling element 16 is continuous and is made from a suitable elastomeric material. Such materials can include, for instance, a natural rubber, a neoprene rubber, EPDM, a polyurethane, a urethane blend, or any other suitable material. EPDM refers to ethylene and propylene terpolymers with nonconjugated dienes. In one embodiment, the elastomer used to make coupling element 16 has a Shore A hardness of between about 60 to about 70. As shown in Figure 2, coupling element 16 can also be reinforced with a tension member 38. Tension member 38 can be made from a ply or plies of cord or fabric, such as polyester fabric. Preferably, two-plys of a polyester fabric having a weight of 313 gram (11.04 ounces) and having 1 end per millimeter (25.37 ends per inch) is used that are laid at 90 degrees to each other within the elastomeric coupling element. Also, preferably beads 40 and 42 made from an elastomeric material harder than the material used to make coupling element 16 are placed at the outer edges of tension member 38. Beads 40 and 42 reinforce the sides of coupling element 16 when clamped to hubs 12 and 14. Flexible coupling element 16 has a "tire-like" shape. As shown in Figure 2, coupling element 10 has a U-shaped cross-sectional configuration defining an inner channel 44 spaced between a first side 46 and a second side 48. Further, at the ends of sides 46 and 48 are respective flange portions 50 and 52. Adjacent to side 46 and side 48 of coupling element 16 are positioned a pair of inner clamp rings 54 and 56. Inner clamp rings 54 and 56 have threaded bores in axial alignment with bores running through hubs 12 and 14. As shown in Figure 2, a lug 58 is used to connect inner clamp ring 54 to hub 12, while lug 60 connects inner clamp ring 56 to hub 14. When inner clamp rings 54 and 56 are tightened against hubs 12 and 14 respectively, the sides of coupling element 16 become clamped or otherwise secured between inner clamp rings 54 and 56 and outer rings 22 and 24. As shown, outer rings 22 and 24 are shaped to interlock with flange portions 50 and 52 respectively. In this manner, coupling element 16 becomes securely fastened between hubs 12 and 14. According to the present invention, besides flexible coupling element 16 being continuous, inner clamp rings 54 and 56 can also be nonremovably held by coupling element 16. As used herein, the phrase, nonremovably held, means that the inner clamp rings cannot be removed from inner channel 44 of coupling element 16 unless either the coupling element or the inner clamp rings are damaged. As shown in Figures 1 and 2, inner clamp rings 54 and 56 are contained within coupling element 16 forming a unitary structure. As shown in Figure 2, flexible coupling element 16 can border inner clamp rings 54 and 56 along the top and along one side. Many advantages are achieved by having the inner clamp rings be nonremovably held by the coupling element as will be described and made apparent from the following description. In a preferred embodiment, flexible coupling element 16 is molded or formed about inner clamp rings 54 or 56. For instance, a collapsible, multipiece center core defining the shape of innerchannel 44 of coupling element 16 can be placed adjacent to a pair of inner clamp rings and wrapped with rectangular sheets of elastomeric material. When wrapping the center core, plies of reinforcing fabric, such as polyester, can be alternated with the elastomeric material. Once a sufficient amount of elastomeric material has been applied to the core, the core can be placed into a heated mold where the elastomeric material is formed into the coupling element and is vulcanized. For instance, when using natural rubber, the mold can be heated to a temperature of approximately 149° Celsius (300 degrees fahrenheit) and the core wrapped with the elastomeric material can be placed in the mold under pressure for about 30 minutes. Once removed from the mold, the center core can be disassembled and removed leaving behind the inner clamp rings encased within flexible coupling element 16. If desired, inner clamp rings 54 and 56 can be completely embedded within insides 46 and 48 of coupling element 16. Also, inner clamp rings 54 and 56 can have holes to promote mechanical interlocking and encapsulation during molding and formation of elastomeric coupling element 16. In an alternative embodiment, an adhesive can be used to bond inner clamp rings 54 and 56 to sides 46 and 48 respectively. For instance, if inner clamp rings 54 and 56 are made of a metal, one adhesive that is suitable for bonding an elastomeric material to the inner clamp rings is CHEM-LOCK marketed by Houston Chemicals. Of course, any suitable adhesive for bonding elastomeric materials to either metals or plastics may be used. Many advantages are achieved by providing a continuous coupling element nonremovably associated with the inner clamp rings. As discussed above, in the past most coupling devices of the type described herein were made with a split coupling element. In comparison to these conventional coupling devices, the coupling device of the present invention is capable of accommodating higher torques and speeds. Also, because the coupling element is continuous, the coupling device of the present invention has inherently better balance. Referring to Figure 3, another embodiment of a coupling device generally 110 made in accordance with the present invention is shown. Coupling device 110 includes a first hub generally 112 mounted to a shaft 118 and a second hub generally 114 mounted to an opposing shaft 120. A flexible, continuous coupling element 116 interconnects first hub 112 to second hub 114. Coupling element 116 is nonremovably associated with a pair of inner clamp rings 154 and 156. In this embodiment, hubs 112 and 114 have a two-piece configuration. Specifically, hub 112 includes an outer ring 122 adjacent to a ring separating member 170. Similarly, hub 114 includes an outer ring 124 and a ring separating member 172. As shown, lugs 158 and 160 connect the inner clamp rings to the outer rings, securing the sides of coupling element 116 therebetween. Referring to Figure 4, another embodiment of a coupling device generally 210 also made in accordance with the present invention is shown. Coupling device 210 includes a first hub generally 212 mounted on a first shaft 218 and a second hub generally 214 mounted on an opposing shaft 220. In this embodiment, hub 212 includes an outer ring 222 separate from a flange 270, while hub 214 similarly includes an outer ring 224 separate from a flange 272. Flanges 270 and 272 are adapted to be secured to shafts 218 and 220 respectively. First hub 212 is interconnected with second hub 214 by a continuous coupling element 216. Coupling element 216, made from an elastomeric material, is nonremovably associated with a pair of inner clamp rings 254 and 256. Inner clamp rings 254 and 256 are connected to outer rings 222 and 224 respectively by lugs 258 and 260. Coupling element 216, inner rings 254 and 256, and outer rings 222 and 224, in this embodiment form a center assembly that is connected to flange 270 by lug 274 and to flange 272 by lug 276. In this arrangement, the center assembly can be removed and installed without disturbing the relative position of shafts 218 and 220. Coupling device 210 is particularly well suited for interconnecting a shaft of a motor with a shaft of a pump, where it is typically undesirable to move the connected units when servicing the machinery. By not having to disturb the relative position of the shafts, maintenance time is reduced.

Claims: A coupling device adapted to connect an end of a first shaft (18,118,218) to an end of a second shaft (20,120,220), said coupling device (10,110,210) comprising: a first hub (12,112,212) and a second opposing hub (14,114,214), each of said hubs (12,112,212;14,114,214) adapted to be secured to a respective shaft (18,118,218;20,120,220), each hub (12,112,212;14,114,214) including an outer ring (22,122,222;24,124,224) facing towards the opposing hub (12,112,212; 14,114,214); a first inner clamp ring (54,154,254) adapted to be secured to said first hub (12,112,212) and a second inner clamp ring (56,156,256) adapted to be secured to said second hub (14,114,214); wherein said first side (46) of said coupling element (16,116,216) is clamped between said first inner clamp ring (54,154,254) and said outer ring (22,122,222) of said first hub (12,112,212), while said second side (48) is clamped between said second inner clamp ring (56,156,256) and said outer ring (24,124,224) of said second hub (14,114,214). an elastomeric continuous coupling element (16,116,216) extending between said opposing hubs (12,112,212;14,114,214), said coupling element (16,116,216) defining an inner channel (44) spaced between the axial inner surfaces of the first side (46) and the second side (48) of said coupling element (16,116,216) whereby said coupling element (16,116,216) is moulded about said inner clamp rings (54,154,254;56,156,256) such that said inner clamp rings (54,154,254;56,156,256) are non-removably held within said inner channel (44) adjacent to said axial inner surface. A coupling device as defined in claim 1, wherein said inner clamp rings (54,154,254;56,156,256) being adhesively secured to said coupling element (16,116,216) A coupling device as defined in claim 1, wherein said inner clamp rings (54,154,254;56,156,256) being non-removably held and embedded within said inner channel (44) on said side of said coupling element (16,116,216) adjacent to said axial inner surface; A coupling device as defined in claim 1, wherein said coupling element (16,116,216) having a U-shaped cross-sectional configuration including said first side (46) and said second side (48) of said coupling element (16,116,216). A coupling device as defined in claim 1, wherein at least one tension member (38) is embedded within said coupling element (16,116,216) for reinforcing same. A coupling device as defined in claim 3, wherein said at least one tension member (38) comprises a polyester fabric. A coupling device as defined in claim 1, wherein each side of said coupling element (16,116,216) includes a flange portion (50,52), said flange portions (50,52) being engaged with said outer rings (22,122,222;24,124,224). A coupling device as defined in claim 1, wherein said coupling element (16,116,216) is made from a material selected from the group consisting of a natural rubber, a neoprene rubber, a urethane, and an EPDM. A coupling device as defined in claim 1, wherein each of said hub (112,114) includes a ring separating member (170,172) positioned between said outer ring (122,124) and said respective inner clamp ring (154,156). A coupling device as defined in claim 1, wherein each of said hub (212,214) includes a flange (210,212) adapted to be secured to a respective shaft (218,220) and connected to said outer ring (222,224). A coupling device as defined in claim 1, wherein said coupling element (16,116,216) is in contact with at least two sides of each of said inner clamp rings (56,156,256). A coupling device as defined in claim 1, wherein said coupling element (16,116,216) is molded about said inner clamp rings (56,156,256). A coupling device as defined in claim 1, wherein said coupling element (16,116,216) is an elastomeric continuous coupling element (16,116,216). A coupling device as defined in claim 1, wherein said outer ring (22,122,222) of said first hub (12,112,212) defining a first hub bore and said outer ring (24,124,224) of said second hub (14,114,214) defining a second hub bore; said first inner clamp ring (54,154,254) defining a first inner clamp bore alignment with said first hub bore; a first securing device extending through said first inner clamp ring bore and through said first hub bore for tightening said first inner clamp ring (54,154,254) towards said outer ring (22,122,222) of said first hub (12,112,212) thereby securing said first side (46) of said coupling element (16,116,216) therebetween, said first side (46) of said coupling element (16,116,216) being positioned radially outward from said first securing device; said second inner clamp ring (56,156,256) defining a second inner clamp bore alignment with said second hub bore; and a second securing device extending through said second inner clamp ring bore and through said second hub bore for tightening said second inner clamp ring (56,156,256) towards said outer ring (24,124,224) of said second hub (14,114,214) thereby securing said second side (48) of said coupling element (16,116,216) therbetween, said second side (48) of said coupling element (16,116,216) being positioned radially outward from said second securing device. A continuous and flexible coupling element (16,116,216) for use in a flexible coupling device (10,110,210) adapted to connect an end of a first shaft (18,118,218) to an end of a second shaft (20,120,220), said coupling element (16,116,216) being adapted to extend between and interconnect a first hub (12,112,212) with a second hub (14,114,214) of said coupling device (10,110,210), said coupling element (16,116,216) comprising: a continuous and circular elastomeric shell including an inner channel (44) spaced between the axial inner surfaces of a first side (46) and a second side (48) of said coupling element (16,116,216), a first inner damp ring (54,154,254) non-removably held and positioned within said inner channel (44) adjacent to said axial inner surface of said elastomeric shell and positioned adjacent to said first side (46) of said shell, whereby said elastomeric shell is moulded about said first inner clamp ring said first inner clamp ring (54,154,254) being adapted to be connected to a first hub (12,112,212) secured to said rotatable shaft (18,118,218); and a second inner clamp ring (56,156,256) nonremovably held and positioned within said inner channel (44) adjacent to said axial inner surface of said elastomeric shell and positioned adjacent said second side (48) of said shell whereby the elastomeric shell is moulded about said second inner clamp ring, said second inner clamp ring (56,156,256) being adapted to be connected to a second opposing hub (14,114,214) secured to said rotatable shaft (20,120,220). A continuous and flexible coupling element (16,116,216) as defined in claim 15, wherein said inner damp rings (54,154,254;56,156,256) are adhesively secured to the sides (46,48) of said elastomeric shell. A continuous and flexible coupling element (16,116,216) as defined in claim 15, wherein said inner clamp rings (54,154,254;56,156,256) are embedded within the sides (46,48) of said elastomeric shell. A continuous and flexible coupling element (16,116,216) as defined in claim 15, wherein said elastomeric shell is reinforced by a polyester fabric. A continuous and flexible coupling element (16,116,216) as defined in claim 15, wherein said elastomeric shell is made from a material selected from the group consisting of a natural rubber, a neoprene rubber, a urethane, and an EPDM.

Inventors: REYNOLDS DAVID F, REYNOLDS, DAVID F.
Applicants: RELIANCE ELECTRIC IND CO, RELIANCE ELECTRIC INDUSTRIAL COMPANY
Application year: 1997
Main classification: F16D3
IPC codes: F16D3