Staked Flange Clutch Release Bearing Assembly

A variety of clutch release or throw-out bearing assemblies have heretofore been used or proposed for use for the actuation of a clutch in the drive train of vehicles equipped with manual transmissions. The relative severity of the operating conditions to which such clutch release bearings are subjected has prompted continuing development work to improve their durability and quiet operating performance over an increased operating life. The relatively abrupt loading and rotational forces to which such clutch release bearing assemblies are subjected during the actuation and release of the clutch assembly coupled with the marginal lubrication and vibration to which they are subjected has prompted the use of constructions which are of relatively high weight and of difficult and costly manufacture.

The present invention provides for an improved clutch release bearing assembly construction employing a composite bearing carrier which can readily be fabricated from stamped components and assembled to provide a properly aligned and dimensionally accurate assembly which is of durable operation, economical manufacture and of versatile use.

The benefits and advantages of the present invention are achieved by a clutch release bearing assembly comprising a composite bearing carrier comprised of a tubular member on which an annular collar is disposed in frictional engagement around one end portion thereof and wherein interlocking means are provided on the collar and carrier to prevent relative rotation therebetween and relative outward axial movement of the collar along the end portion of the tubular member. The collar is formed with a flange or plate extending radially therefrom and axially spaced outwardly of an inner annular edge of the collar. A bearing of the thrust-type is frictionally mounted around the other end portion of the tubular member with the inner face of the race member disposed in abutting relationship against the inner edge of the collar to maintain appropriate spaced relationship between the bearing and flange. In accordance with a preferred embodiment, the outer face of the stationary race member intersects the bore thereof in the form of a sharp annular edge which is adapted to engage the periphery of the tubular member to prevent outward axial movement of the bearing along the other end of the tubular member. Suitable engaging means such as spring clips can be incorporated on the flange or plate for coacting with the clutch actuation mechanism such as the actuating fork to assist in the axial shifting movement of the bearing along a tube or rod mounted coaxially with the clutch actuation fingers.

In accordance with a preferred embodiment of the present invention, the tubular member is formed with a plurality of indentations along the inner surface thereof which are adapted to receive and retain a lubricant to facilitate axial shifting movement of the clutch release bearing assembly during each clutch operating cycle. Additionally, the tubular member or carrier is preferably made from a rolled sheet metal blank in which the longitudinal edges thereof are disposed in abutting relationship and suitable interlocking tabs or clinch butt tabs are provided for retaining the edges in appropriate abutting relationship.

Additional benefits and advantages of the present invention will become apparent upon a reading of the description of the preferred embodiments taken in conjunction with the accompanying drawings.

FIG. 1 is an end elevational view of a clutch release bearing constructed in accordance with the preferred embodiments of the present invention;

FIG. 2 is a magnified sectional view through the clutch release bearing shown in FIG. 1 and taken substantially along the line 2--2 thereof;

FIG. 3 is a front elevational view of the composite bearing carrier with the bearing removed therefrom; and

FIG. 4 is a magnified fragmentary view of the interlocking means between the tubular member and flange shown in FIG. 1 within the encircled area indicated at 4.

Referring now in detail to the drawings and as may be best seen in FIGS. 1 and 2, a clutch release bearing assembly constructed in accordance with the preferred embodiments of the present invention comprises a tubular member or bearing carrier 10 to the rearward or right hand end as viewed in FIG. 2, an annular collar 12 is disposed in frictional engagement around the periphery thereof. The annular collar 12 includes an integrally formed radially extending plate or flange 14. The inner or left hand end of the collar 12 as viewed in FIG. 2 is formed with an annular radially extending edge 16 which is axially spaced from the face of the plate 14. A thrust-type bearing 18 including a rotatable race 20 and a stationary race 22 are formed with opposed annular raceways in which a plurality of anti-friction elements such as balls 24 are constrained. The balls 24 are maintained in appropriate circumferentially spaced relationship by means of a retainer 26. A tubular grease retainer 28 is affixed to the inner bore of the rotatable race and extends axially therefrom toward the inner face of the stationary race 22. An annular sheet metal housing 30 is affixed to the periphery of the rotatable race and extends axially therefrom around the stationary race and is formed with an inwardly directed radially flange 32 which overlies an inner face 34 of the stationary race in a manner so as to retain the race members in appropriate assembled relationship with the balls 24 constrained therebetween. The housing 30 in combination with the grease retainer 28 also serves to retain a lubricant within the bearing in an area adjacent to the annular raceways and balls.

The tubular bearing carrier 10 is preferably formed from a rolled sheet metal stock such that the longitudinal edges 36, 38 as best seen in FIG. 2 are disposed in abutting relationship. Suitable interlocking means such as a tab 40 formed along the longitudinal edge 36 and a correspondingly contoured recess 42 formed along the longitudinal edge 38 are provided to form a so-called clinch butt connection to maintain the edges in appropriate abutting relationship. The inner surface of the tubular carrier 10, as best seen in FIG. 2 is preferably provided with a plurality of dimpled recesses indicated at 44 as well as an annular groove 46 which are adapted to receive and retain an appropriate lubricant such as grease to facilitate axial reciprocating movement of the tubular carrier along a tube or shaft on which the clutch release bearing is mounted when assembled in a vehicle drive train. The tubular carrier may also be provided with an appropriate lining around the inner surface thereof to further improve its anti-frictional characteristics.

In accordance with a preferred embodiment, the annular collar 12 is integrally formed with the flange 14 as best seen in FIGS. 1-3 and can readily be fabricated employing conventional blanking, stamping and forming practices. The collar 12 is in the form of a plurality of individual arcuate segments 48 which are separated by circumferentially spaced openings 50 which serve the dual function of facilitating the formation of the arcuate segments and also provide recesses for interlockingly receiving outward radially deformed sections 52 of the tubular carrier. The radially deformed sections 52 along the rearward edge of the tubular carrier are formed by a staking operation after the collar and flange are assembled around the end portion of the tubular carrier employing a friction fit therebetween. The outward radial deformation of diametrically opposite portions of the edge of the tubular carrier causes coacting engagement of such deformed sections within the openings 50 of the flange serving to interlock the two components thereby preventing relative rotation and outward axial movement of the collar and flange along the rearward end of the tubular carrier.

As best seen in FIGS. 1 and 2, the flange 14 is also provided with a pair of transversely spaced spring clips 54 secured such as by means of rivets 56 which are adapted to engage the operating ends of an actuating fork in a well known manner for effecting reciprocating movement of the clutch release bearing assembly.

The stationary race 22 is formed with a internal bore 58 which is adapted to be press fit and disposed in frictional engagement around the periphery of the tubular carrier along the other end portion thereof opposite to said collar. The inner face 34 of the stationary race is disposed in abutting relationship against the annular radial edge 16 of the collar 12 thereby appropriately positioning the bearing in proper axial spaced relationship from the flange 14. This axial spacing is controlled by the axial length or offset of the annular collar 12 or arcuate segments 48 relative to the plane of the flange 14.

The retention of the bearing 18 with the inner face 34 of its stationary race in abutting relationship against the annular edge of the collar and against outward axial movement of the bearing along the tubular carrier is achieved by suitable interlocking or frictional engagement between the bore of the stationary race and the periphery of the carrier. Suitable staking of the stationary race after assembly on the carrier by indentations formed around the periphery of the tubular carrier adjacent to the outer face 62 of the stationary race is suitable. Preferably, the stationary race is installed as a press-fit providing frictional engagement with the periphery of the carrier and further interlocking engagement can be achieved, in accordance with a preferred embodiment, by forming a sharp annular edge indicated at 60 in FIG. 2 by the intersection of the bore 58 with an outer face 62 of the stationary race member. The sharp annular edge 60 engages the periphery of the tubular carrier and resists outward axial movement of the bearing along the left end portion of the carrier as viewed in FIG. 2. The internal bore 58 intersects the inner face 34 of the stationary race member in the form of a somewhat rounded or chamfered annular edge 64 which facilitates the operation of press fitting the bearing over the end portion of the tubular carrier during the assembly operation. The composite bearing carrier and thrust bearing components can be assembled in one step employing a suitable fixture in which the preassembled bearing, tubular bearing carrier and composite collar and flange are arranged in stacked relationship. The tubular bearing carrier is pressed through the collar and internal bore of the bearing whereafter the end edges of the tubular carrier are staked to form the interlocking radially deformed sections which in combination with the sharp annular edge on the stationary race serves to retain the three components in appropriate axially and angularly aligned relationship. When a tubular bearing carrier of the clinch butt type is employed, the longitudinal seam defined by the opposed longitudinal edges 36, 38 are positioned at a circumferential position angularly offset from the position at which the carrier is staked to form the deformed sections 52.

It will be appreciated that the thrust bearing 18 may also be of the angular contact type as well as of the axial thrust type as specifically shown in the drawing.

While it will be apparent that the invention herein disclosed is well calculated to achieve the benefits and advantages as hereinabove set forth, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the spirit thereof.