High-offset belt tensioner with counterbalance torsion spring force

1. A high-offset belt tensioner comprising:

a support base having a pivot tube that defines a pivot axis;

an arm coupled to the support base for rotation about the pivot axis, the arm having a pivot tube-receiving first end having a lower surface facing the support base and an upper surface that in part defines a cup and having a second end offset axially from the first end, wherein the second end defines a pulley rotation axis;

a flat wire torsion spring having an inner spring hook attached to the pivot tube and an outer spring hook attached to the first end of the arm at a position that counterbalances a hub load force, wherein the flat wire torsion spring biases the arm in a belt engaging direction and applies a spring force acting on the arm; and

a damper bushing in operative engagement with the first end of the arm by a spring plate or an axially biasing member;

wherein a direction of the spring force acting on the arm stays in the same location with respect to the arm and moves with the arm throughout its entire sweep in the belt engaging direction;

wherein the spring plate and the axially biasing member each have a deflection height that is varied across a surface area thereof, and a greatest deflection height is positioned to be opposite the hub load;

wherein a plane of the hub load force is axially offset from a plane of the spring force.

2. The high-offset belt tensioner of claim 1 , comprises a pivot bushing seated within the first end of the arm.

3. The high-offset belt tensioner of claim 2 , wherein the spring plate is present and has the damper bushing co-molded thereto.

4. The high-off-set belt tensioner of claim 3 , wherein the spring plate and the damper bushing are stationary as the arm rotates relative thereto.

5. The high-off-set belt tensioner of claim 4 , wherein the spring plate has a bore therethrough defining an inner periphery and the inner periphery is seated between the pivot tube and an end cap with the damper bushing in contact with the lower surface of the first end of the arm; wherein the arm plate is conically shaped, thereby biasing the damper bushing into frictional engagement with the arm.

6. The high-offset belt tensioner of claim 2 , wherein the damper bushing is seated in the cup of the first end of the arm, wherein the spring plate is present and is fixedly attached to the pivot tube and holds the damper bushing in operative engagement for rotation with the arm.

7. The high-offset belt tensioner of claim 6 , wherein the damper bushing has a flange extending axially toward the support base, and the flange is seated against the pivot tube.

8. The high-offset belt tensioner of claim 7 , wherein a wear surface of a main body of the damper bushing is seated against the spring plate and the main body includes a plurality of troughs for retention of grease.

9. The high-offset belt tensioner of claim 8 , comprising a ring seal member seated juxtaposed to an outermost surface of the flange of the damper bushing.

10. The high-offset belt tensioner of claim 2 , wherein the arm has a radially protruding enclosure in its radially outermost surface at a position that locates the enclosure in a protective orientation around the outer spring hook; wherein the enclosure has an open bottom.

11. The high-offset belt tensioner of claim 10 , wherein the pivot bushing has an axially extending main body and either a radially inward or radially outward extending flange at a first end of the main body.

12. The high-offset belt tensioner of claim 11 , wherein the pivot bushing has a slit extending axially through the main body, thereby allowing expansion of at least a second end thereof.

13. The high-offset belt tensioner of claim 12 , wherein the pivot bushing is seated with the flange between the support base and the lower surface of the first end of the arm.

14. The high-offset belt tensioner of claim 13 , wherein the pivot bushing has a key protruding from an outer surface of the main body and the key is seated in a keyway of the arm for rotation therewith.

15. The high-offset belt tensioner of claim 14 , wherein the pivot bushing has a radially outward extending tab opposite the key; wherein the enclosure has received therein the radially outward extending tab.

16. The high-offset belt tensioner of claim 14 , wherein the slit is positioned through the key of the pivot bushing.

17. The high-offset belt tensioner of claim 11 , wherein the pivot bushing is seated with the flange between the cup of the arm and an end cap.

18. The high-offset belt tensioner of claim 1 , wherein the support base has an arm travel limiting feature defining a preselected number of degrees for a maximum rotation of the arm and the arm has a mating feature engage with the arm travel limiting feature; wherein the arm travel limiting feature is an arcuate slot in the pivot tube or a base of the support base.

19. A high-offset belt tensioner comprising:

a support base having a pivot tube that defines a pivot axis;

an arm coupled to the support base for rotation about the pivot axis, the arm having a pivot tube-receiving first end defining a cup and having a second end offset axially from the first end, wherein the second end defines a pulley rotation axis;

an end cap seated within the cup of the arm;

a flat wire torsion spring having an inner spring hook operatively attached to the pivot tube and an outer spring hook operatively attached to the first end of the arm at a position that counterbalances a hub load force; and

a damper bushing in operative engagement with the first end of the arm;

a spring plate or an axially biasing member urging the damper bushing into engagement with the first end of the arm; and

a pivot bushing having a radially outward extending flange seated with the radially outward extending flange between the arm and the end cap; and

a ring seal member seated juxtaposed to an outermost surface of the radially outward extending flange of the pivot bushing.