Overrunning alternator decoupling pulley design

1. A pulley assembly comprising:

a. an inner shaft;

b. a damping element coupled to and disposed about the inner shaft;

c. a one-way overrunning clutch disposed between the inner shaft and the damping element, the one-way overrunning clutch selectively permitting torque to be transferred from the damping element to the inner shaft, and substantially preventing the transfer of torque from the inner shaft to the damping element;

d. an outer pulley housing disposed about and spaced from the damping element such that minimal to no friction exists between the damping element and the outer pulley housing;

e. a torsion spring, situated longitudinally along an axis of the inner shaft between the damping element and an inner portion of the outer pulley housing, the spring having a top end adjacent to the damping element and a bottom end adjacent to an interior section of the outer pulley housing, the top end of the torsion spring matingly coupled to the damping element and the bottom end of the torsion spring matingly coupled to the outer pulley housing, whereby torsional impacts to the pulley assembly are substantially reduced;

f. the damping element and the outer pulley housing include an integral spring pocket for matingly coupling to the torsion spring, the spring pocket having the same or similar helical profile as the torsion spring to prevent the spring from becoming dislodged from the damping element or outer pulley housing; and

g. the outer pulley housing includes a plurality of inner surface portions, the inner surface portions comprising a first inner surface portion towards a top of the outer pulley housing having a first radius, a second inner surface portion having a second radius smaller than the first radius, a third inner surface portion joining the first and second inner surface portions, and a fourth annual portion at a bottom of the outer pulley housing having a third radius smaller than the second radius.

2. The pulley assembly of claim 1 , wherein:

a. the damping element includes a plurality of portions, the plurality of portions comprising a tubular top portion having an inner surface of a fourth radius, a tubular bottom portions having an inner surface of a fifth radius smaller than the fourth radius, and an annulus member attaching the tubular top portion to the tubular bottom portion;

b. the annulus member has a top surface and a bottom surface, and an inner radius substantially the same as the fifth radius;

c. a second helical ramp member begins on the bottom surface of the annulus member and spirals downward along the outer surface of the annulus member ending in a bottom end;

d. the bottom end of the second helical ramp member matingly abuts the top end of the torsion spring;

e. the outer pulley housing includes an inner surface, the inner surface comprising the first helical ramp member having a beginning and an end, the end of the first helical ramp member configured to abut the bottom end of the torsion spring; and

f. the damping element includes an outer surface, the outer surface comprising a second helical ramp member having a beginning and an end, the end of the second helical ramp member configured to abut the top end of the torsion spring.

3. The pulley assembly of claim 1 , wherein the torsion spring allows the damping element to rotate up to 60 degrees relative to the outer pulley housing.

4. The pulley assembly of claim 1 , wherein the torsion spring has a circular cross-section.

5. The pulley assembly of claim 1 , wherein the torsion spring has a square cross-section.

6. The pulley assembly of claim 1 , wherein the one-way overrunning clutch utilizes needle roller bearings.

7. The pulley assembly of claim 1 , further comprising a plurality of ball bearings allowing the inner shaft to rotate independently from the damping element when the rotational speed of the inner shaft is greater than the rotational speed of the damping element.

8. The pulley assembly of claim 1 , wherein the torsion spring unwinds as the rotational speed of the outer pulley housing is greater than, and increases relative to, the rotational speed of the damping element.

9. A pulley assembly comprising:

a. an inner shaft;

b. a damping element coupled to and disposed about the inner shaft;

c. a one-way overrunning clutch disposed between the inner shaft and the damping element, the one-way overrunning clutch selectively permitting torque to be transferred from the damping element to the inner shaft, and substantially preventing the transfer of torque from the inner shaft to the damping element;

d. an outer pulley housing disposed about and spaced from the damping element such that minimal to no friction exists between the damping element and the outer pulley housing;

e. a torsion spring, situated longitudinally along an axis of the inner shaft between the damping element and an inner portion of the outer pulley housing, the spring having a top end adjacent to the damping element and a bottom end adjacent to an interior section of the outer pulley housing, the top end of the torsion spring matingly coupled to the damping element and the bottom end of the torsion spring matingly coupled to the outer pulley housing, whereby torsional impacts to the pulley assembly are substantially reduced;

f. the outer pulley housing includes a plurality of inner surface portions, the inner surface portions comprising a first inner surface portion towards a top of the outer pulley housing having a first radius, a second inner surface portion having a second radius smaller than the first radius, a third inner surface portion joining the first and second inner surface portions, and a fourth annual portion at a bottom of the outer pulley housing having a third radius smaller than the second radius; and

g. an inner diameter of a portion of the outer pulley housing disposed about the torsion spring is sized to limit the amount the torsion spring may expand such that damage to the torsion spring is avoided when the pulley assembly is subjected to torsional loads that cause the torsion spring to expand.

10. The pulley assembly of claim 9 , wherein:

a. the damping element includes a plurality of portions, the plurality of portions comprising a tubular top portion having an inner surface of a fourth radius, a tubular bottom portions having an inner surface of a fifth radius smaller than the fourth radius, and an annulus member attaching the tubular top portion to the tubular bottom portion;

b. the annulus member has a top surface and a bottom surface, and an inner radius substantially the same as the fifth radius;

c. a second helical ramp member begins on the bottom surface of the annulus member and spirals downward along the outer surface of the annulus member ending in a bottom end;

d. the bottom end of the second helical ramp member matingly abuts the top end of the torsion spring;

e. the outer pulley housing includes an inner surface, the inner surface comprising the first helical ramp member having a beginning and an end, the end of the first helical ramp member configured to abut the bottom end of the torsion spring; and

f. the damping element includes an outer surface, the outer surface comprising a second helical ramp member having a beginning and an end, the end of the second helical ramp member configured to abut the top end of the torsion spring.

11. The pulley assembly of claim 9 , wherein the torsion spring allows the damping element to rotate up to 30 degrees relative to the outer pulley housing.

12. The pulley assembly of claim 9 , wherein the torsion spring allows the damping element to rotate up to 60 degrees relative to the outer pulley housing.

13. The pulley assembly of claim 9 , wherein the torsion spring has a circular cross-section.

14. The pulley assembly of claim 9 , wherein the torsion spring has a square cross-section.

15. The pulley assembly of claim 9 , wherein the one-way overrunning clutch utilizes needle roller bearings.

16. The pulley assembly of claim 9 , further comprising a plurality of ball bearings allowing the inner shaft to rotate independently from the damping element when the rotational speed of the inner shaft is greater than the rotational speed of the damping element.

17. The pulley assembly of claim 9 , wherein the torsion spring unwinds as the rotational speed of the outer pulley housing is greater than, and increases relative to, the rotational speed of the damping element.

18. A pulley assembly comprising:

a. an inner shaft;

b. a damping element coupled to and disposed about the inner shaft;

c. a one-way overrunning clutch disposed between the inner shaft and the damping element, the one-way overrunning clutch selectively permitting torque to be transferred from the damping element to the inner shaft, and substantially preventing the transfer of torque from the inner shaft to the damping element;

d. an outer pulley housing disposed about and spaced from the damping element such that minimal to no friction exists between the damping element and the outer pulley housing;

e. a torsion spring, situated longitudinally along an axis of the inner shaft between the damping element and an inner portion of the outer pulley housing, the spring having a top end adjacent to the damping element and a bottom end adjacent to an interior section of the outer pulley housing, the top end of the torsion spring matingly coupled to the damping element and the bottom end of the torsion spring matingly coupled to the outer pulley housing, whereby torsional impacts to the pulley assembly are substantially reduced;

f. the damping element and the outer pulley housing include an integral spring pocket for matingly coupling to the torsion spring, the spring pocket having the same or similar helical profile as the torsion spring to prevent the spring from becoming dislodged from the damping element or outer pulley housing;

g. the outer pulley housing includes a plurality of inner surface portions, the inner surface portions comprising a first inner surface portion towards a top of the outer pulley housing having a first radius, a second inner surface portion having a second radius smaller than the first radius, a third inner surface portion joining the first and second inner surface portions, and a fourth annual portion at a bottom of the outer pulley housing having a third radius smaller than the second radius; and

h. an inner diameter of a portion of the outer pulley housing disposed about the torsion spring is sized to limit the amount the torsion spring may expand such that damage to the torsion spring is avoided when the pulley assembly is subjected to torsional loads that may cause the torsion spring to expand.

19. The pulley assembly of claim 18 wherein:

a. the damping element includes a plurality of portions, the plurality of portions comprising a tubular top portion having an inner surface of a fourth radius, a tubular bottom portions having an inner surface of a fifth radius smaller than the fourth radius, and an annulus member attaching the tubular top portion to the tubular bottom portion;

b. the annulus member has a top surface and a bottom surface, and an inner radius substantially the same as the fifth radius;

c. a second helical ramp member begins on the bottom surface of the annulus member and spirals downward along the outer surface of the annulus member ending in a bottom end;

d. the bottom end of the second helical ramp member matingly abuts the top end of the torsion spring;

e. the outer pulley housing includes an inner surface, the inner surface comprising the first helical ramp member having a beginning and an end, the end of the first helical ramp member configured to abut the bottom end of the torsion spring; and

f. the damping element includes an outer surface, the outer surface comprising a second helical ramp member having a beginning and an end, the end of the second helical ramp member configured to abut the top end of the torsion spring.

20. The pulley assembly of claim 18 , wherein the torsion spring allows the damping element to rotate up to 60 degrees relative to the outer pulley housing.