Composite roller header assembly and composite roller formed therewith

1 . A header assembly comprising:

a core having a radially outwardly facing surface;

a head formed around said outwardly facing surface and extending radially from said outwardly facing surface, said head including a first axially extending face and a second axially extending face facing away from said first axially extending face; and

an axially opening channel formed in said head for receiving at least one balancing weight.

2 . The assembly as in claim 1 , in which said head includes an axially extending circumferential lip, and said channel is formed at a junction of said lip and said first axially extending face.

3 . The assembly as in claim 1 , in which said head is formed from a curable material.

4 . The assembly as in claim 1 , in which said head is bonded to said core.

5 . The assembly as in claim 1 , in which said core is selected from a group consisting of an annular ring and a journal.

6 . The assembly as in claim 1 , in which locking structure formed on said outwardly facing surface of said core locks said head relative to said core.

7 . The assembly as in claim 1 , including a balancing weight received in said channel and fixed relative to said head.

8 . The assembly as in claim 1 , including a cover fixed relative to said head covering said channel.

9 . A composite roller comprising:

a tubular shaft formed from a composite material and having opposing open ends defining an inner surface; and

at least one composite header assembly received in one end of said opposing ends, said header assembly including a core having a radially outwardly facing surface, a head formed around said outwardly facing surface and fixed relative to said tubular shaft, said head including a first axially extending face facing into said tubular shaft and a second axially extending face facing away from said first axially extending face; said head including an axially opening channel for receiving at least one balancing weight.

10 . The roller as in claim 9 , in which said head includes an axially extending circumferential lip, and said channel is formed at a junction of said lip and said first axially extending face.

11 . The roller as in claim 9 , in which said head is formed from a curable material.

12 . The roller as in claim 9 , in which said head is bonded to said core.

13 . The roller as in claim 9 , in which said core is selected from a group consisting of an annular ring and a journal.

14 . The roller as in claim 9 , in which locking structure formed on said outwardly facing surface of said core locks said head relative to said core.

15 . The roller as in claim 9 , including a balancing weight received in said channel and fixed relative to said head.

16 . The roller as in claim 9 , including a cover fixed relative to said head covering said channel.

17 . A method of making a composite roller, said method comprising:

pouring a moldable material into a mold to form a head around a core, said mold including an opening closed by said core; and

hardening said moldable material to form the head and fix the head to the core;

inserting said head into one end of a tubular body; and

fixing said head relative to said tubular body to make the roller.

18 . The method as in claim 17 , including forming a channel in said head

19 . The method as in claim 18 , including fixing a cover over said channel.

20 . The method as in claim 17 , including balancing the roller by fixing at least one balancing weight in said channel.

21 . The method as in claim 17 , in which said core is selected from a group consisting of an annular ring and a journal.

22 . The method as in claim 17 , in which said moldable material includes a curable resin, and hardening said moldable material includes curing said resin.

23 . The method as in claim 22 , in which said core is formed from a metal, and curing said resin causes said head to lock onto said core.