WO2021178337A1

WO2021178337A1 - Tensioner device with elongated arm

Info

Publication number: WO2021178337A1
Application number: PCT/US2021/020364
Authority: WO
Inventors: Yahya Hodjat; P.E. Lynda A. ELSAS; Richard Billings; Xinjian Fan
Original assignee: Gates Corporation
Priority date: 2020-03-02
Filing date: 2021-03-02
Publication date: 2021-09-10

Abstract

Described herein is a tensioner device, and assemblies and methods of manufacture thereof. The tensioner device may include an engagement portion adapted to impart a force to a belt associated with the tensioner device. The tensioner device may further include an elongated member having a first end connected to the engagement portion. The tensioner device may further include a biasing portion, including a biasing element assembly housed therein. The biasing element assembly may be associated with a second end of the elongated member to bias the elongated member about a lever arm axis defined by the biasing portion. The elongated member includes an elongated portion between the first and second ends.

Description

TENSIONER DEVICE WITH ELONGATED ARM

FIELD

[0001] The described examples relate generally to a belt tensioner, and more particularly to systems and techniques for optimizing a mechanical arm of the tensioning device.

BACKGROUND

[0002] Belt tensioners are used to apply a load on a belt. The belt load prevents the belt from slipping on one or more entrained pulleys during operation. Typically the belt is used in an engine application for driving various accessories associated with the engine. For example, an air conditioning compressor and alternator are two of the accessories that may be driven by a belt drive system.

[0003] A belt tensioner may include a pulley mounted to an arm. A spring is connected between the arm and a base. The spring may also engage a damping mechanism. The damping mechanism comprises a frictional surface contacting either the arm or the base and connected to the other. The damping mechanism damps oscillatory movement of the arm caused by engine vibration during operation of the belt drive. The spring and damper combination enhances belt life expectancy, improves the belt operation and allows for take-up of belt tolerance and belt wear.

[0004] Belt tensioners have been used for a very long time in the belt-pulley power transmission industry. For example, in the automotive industry, serpentine drive belts have been used to adjust and optimize the belt tension for target performance. Conventional mechanical tensioners use a torsional spring housed in an aluminum cup with an aluminum arm transmitting the spring load to an idler pulley and to the belt. Cost, weight, strength, or performance considerations have hindered attempts at using alternative materials such as stamped sheet metal, powder metal (sinter metal), different types of plastics, and die cast magnesium. Furthermore, conventional mechanical tensioners have relied on die casting parts without notable departure from this architecture. As such, the need continues for systems and techniques to optimize the performance of tensioner devices, including those that reduce weight and complexity without sacrificing performance.

SUMMARY

[0005] Examples of the present invention are directed to tensioner devices, elongated arms of tensioner devices, and assemblies and methods of manufacture thereof.

[0006] In one example, a tensioner device is disclosed. The tensioner device includes an engagement portion adapted to impart a force to a belt associated with the tensioner device. The tensioner device further includes an elongated member having a first end connected to the engagement portion. The tensioner device further includes a biasing portion, including a biasing element assembly housed therein. The biasing element assembly is associated with a second end of the elongated member to bias the elongated member about a lever arm axis defined by the biasing portion. The elongated member includes an elongated portion between the first and second ends.

[0007] In another example, an arm for a tensioner device is disclosed. The arm includes an elongated member formed from a single piece of material having a first end, a second end, and an elongated region extending there between. The single piece of material defines a first connecting feature at the first end and is configured to secure the elongated member to an engagement portion of the tensioner device. The engagement portion is adapted to impart a force on a belt associated with the tensioner device. The single piece of material further defines a second connecting feature at the second end and is configured to secure the elongated member to a biasing portion of the tensioner device. The biasing portion is adapted to bias the engagement portion about a lever arm axis. The single piece of material further defines a bend arranged between the first and second connecting features such that the first connecting feature is orientated along a first direction and the second connecting feature is orientated along a second direction that is different from the first direction.

[0008] In another example, a method of manufacturing an arm for a tensioner device is disclosed. The method includes first forming a single piece of material by bending the material between a first end and second end, and flattening the second end. The method further includes, after the first forming, second forming the material by forming a first connecting feature at the first end. The first connecting feature is configured to secure the arm to an engagement portion of the tensioner device. The second forming further includes forming a second connecting feature at the second end, the second connecting feature configured to secure the arm to a biasing portion of the tensioner device.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The disclosure will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:

[0010] FIG. 1 depicts a sample tensioner device and belt assembly;

[0011] FIG. 2 depicts an exploded view of the tensioner device;

[0012] FIG. 3 depicts a cross-sectional view of an engagement portion of the tensioner device, including an engagement member and a bearing, taken along line I-I of FIG. 1;

[0013] FIG. 4 depicts a cross-sectional view of the engagement portion of FIG. 3, including a bushing assembly, taken along line I-I of FIG. 1;

[0014] FIG. 5A depicts a cross-sectional view of a biasing portion of the tensioner device, including a base, taken along line I-I of FIG. 1;

[0015] FIG. 5B depicts a bottom isometric view of the biasing portion of FIG. 5 A;

[0016] FIG. 6 depicts a cross-sectional view of the biasing portion of FIG. 5 A, including a biasing element assembly, taken along line I-I of FIG. 1;

[0017] FIG. 7 depicts a cross-sectional view of the biasing portion of FIG. 6, including a bushing, taken along line I-I of FIG. 1;

[0018] FIG. 8 depicts a cross-sectional view of the biasing portion of FIG. 7, including a cap and associated elongated member, taken along line I-I of FIG. 1;

[0019] FIG. 9 depicts an isometric view of a sample elongated member; [0020] FIG. 10 depicts a cross-sectional view of the tensioner device of FIG. 1, taken along line I-I of FIG. 1;

[0021] FIG. 11 depicts another sample tensioner device and belt assembly;

[0022] FIG. 12A depicts an isometric view of an elongated member of the sample tensioner device of FIG. i i;

[0023] FIG. 12B depicts a side view of the elongated member of FIG. 12 A;

[0024] FIG. 13 A depicts an operation of forming an elongated member;

[0025] FIG. 13B depicts another operation of forming an elongated member;

[0026] FIG. 13C depicts another operation of forming an elongated member;

[0027] FIG. 14A depicts a sample cross-sectional area of an elongated member;

[0028] FIG. 14B depicts another sample cross-sectional area of an elongated member;

[0029] FIG. 14C depicts another sample cross-sectional area of an elongated member; and

[0030] FIG. 15 depicts a flow diagram for manufacturing an arm of a tensioner device.

DETAILED DESCRIPTION

[0031] The description that follows includes sample systems, methods, and apparatuses that embody various elements of the present disclosure. However, the described disclosure may be practiced in a variety of forms in addition to those described herein.

[0032] Before referring to the Figures, a brief explanation is required. The present disclosure describes tensioner devices, and assemblies and methods of manufacture thereof. A sample tensioner device of the present disclosure may include an elongated member, such as a rod, to define an arm of the tensioner device. As used herein, “arm” or “mechanical arm” refers to a mechanical structure that carries a load over a distance, and generally rotates or pivots about a lever arm axis of the tensioner device. For example, a sample tensioner device may include a biasing portion at the lever arm axis that is used to induce a load, such as with a biasing element or the like. The arm is associated with the biasing portion and used to carry the induced load to an engagement portion, which in turn imparts the load or force on an associated belt. Conventional die-cast arms often include relatively large, plate-like structures that may establish pronounced failure of the mechanism or sites. Die-cast aluminum, for example, may be prone to porosity-based weaknesses that may facilitate fatigue-related failures, and generally define an unacceptable large envelope within a motor assembly.

[0033] The tensioner devices, assemblies, and methods of manufacture thereof of the present disclosure may mitigate such hindrances by implementing an elongated member, such as a rod, to define the tensioner device. The elongated member may be formed from a single piece of material that may be forged, and generally machined and processed, to define a one-piece, integral structure that transmits a load from the biasing portion to the engagement portion of the tensioner device. The elongated member may define an elongated portion that has a cross dimension that is substantially less than a length of the elongated member to help define a low- weight, small-footprint tensioner arm architecture. For example, a cross-dimension at the elongated portion may be a diameter of a substantially circular cross-section with a value of around 5 mm to 8 mm, as compared to a length of the elongated member of around 80 mm to 100 mm. It will be appreciated that these are sample numerical ranges, and as described in greater detail below, other numerical ranges and geometries are contemplated herein, and defined in part by the materials and methods of manufacture used to form the elongated member. The reduced-sized cross-section may reduce an overall footprint of the tensioner device within an engine or other application, which may increase the adaptability of the tensioner device to work in a wider array of systems.

[0034] The elongated member may also simplify tensioner device assembly and installation.

In one example, the single piece of material may be used to define a first connecting feature at a first end of the elongated member, and a second connecting feature at a second, opposing end of the elongated member. The first connecting feature, as one example, may include a protrusion or post having a size and shape to establish a press-fit with the engagement portion of the tensioner device. The second connecting feature, continuing the non-limiting example, may include an engagement surface for seating and securing various force-inducing features or assemblies of the biasing portion, such as a biasing element assembly having a spring or other biasing element. A bend may be formed in the single piece of material between the first and second ends, such as a substantially 90 degree bend, thus allowing the first and second connecting features to be orientated along different directions.

[0035] The elongated member may help reduce overall component count and simplify installation while providing enhanced strength and durability to the tensioner device. For example, the protrusion of the first connecting member may be press fit into a bearing of the engagement portion, with the protrusion extending through some or substantially all of a height of the engagement portion to increase strength. Continuing the non-limiting example, the engagement surface of the second connecting feature may define a locating feature for securing a biasing element in a desired configuration, including in a desired angular displacement. A series of dimples or other landmarks may be formed into a flattened region of the single piece of material at the second end, and a portion of the biasing element may be welded or otherwise connected to the region with respect to the dimples. Caps may be used to shield the first and second connecting features from dust and debris.

[0036] The elongated member may be formed from a ferrous material having a fatigue limit. This may prolong a tensioner device lifecycle, especially for high-force, cyclic loading applications. Sample materials include certain low carbon steels that have a high formability. In this regard, a cold forging or hot forgoing process may be used to form the elongated member from a single piece of material. It will be appreciated, however, that other materials may be used to form the elongated member and are contemplated herein, including certain other high strength metals, which may be sufficiently formable to establish the connecting features and other arrangements described herein. In other cases, non-metals can be used including ceramic and/or composite-type materials.

[0037] In one example, the elongated member may be formed from multiple press-hits using transfer tooling that adapts a working component to a desired shape. For example, a single piece of material may be provided as a rod of uniform cross-section formed from a ferrous material. A first press or “hit” may be used to first form or first shape the rod by forming a bend in the rod, and flatten one end of the rod (e.g., the end for forming the second connecting feature). The first press may optionally include forming dimples or other locating features in the flattened end. A second press or “hit” may be used to second form or second shape the rod to form the first and second connecting features. This may include ironing out or otherwise defining a distinct protrusion and lip opposite the flattened end of the rod. In addition, the flattened end of the rod may be trimmed for removing flash, and further manipulated to define an aperture there through for alignment on the lever arm axis. Machining may also be incorporated. In certain examples, corrosion protection may be desirable, including electro-deposition coating or other technique that may be compatible with metallic parts formed for press-fit tolerances.

[0038] Reference will now be made to the accompanying drawings, which assist in illustrating various features of the present disclosure. The following description is presented for purposes of illustration and description. Furthermore, the description is not intended to limit the inventive aspects to the forms disclosed herein. Consequently, variations and modifications commensurate with the following teachings, and skill and knowledge of the relevant art are within the scope of the present inventive aspects.

[0039] FIG. 1 depicts an assembly 100. The assembly 100 includes a belt 102 and a tensioner device 106, such as the tensioner device discussed above and described in greater detail below. The tensioner device 106 may generally include an engagement portion 110, a biasing portion 160, and an elongated member 130. The engagement portion 110 may be adapted to impart a force on the belt 102 to facilitate tensioning the belt to a target tension. For example, the engagement portion 110 may include an engagement member 112 having an engagement surface 113 that contacts the belt 102 to induce a target tension therein. The belt 102 may be an accessory belt, such as that used in an engine application or otherwise for driving various accessories. It will be appreciated that the belt 102 may be defined by a continuous loop, and that a section of the belt 102 is shown in FIG. 1 for clarity.

[0040] The engagement portion 110 may be configured to impart a force to the belt 102 using force induced by the biasing portion 160. The biasing portion 160 may include a biasing element assembly 170 housed therein. The biasing element assembly 170 may be manipulated to store and release energy, such as using a spring, and be calibrated to release energy in a desired quantity, e.g., including a quantity tailored to the parameters of the belt 102.

[0041] The elongated member 130 may be connected to each of the engagement portion 110 and the biasing portion 160, as shown in FIG. 1. More specifically, the elongated member 130 may be associated with the biasing portion 160 in a manner that allows for transmission of force induced by the biasing element assembly 170. In this regard, the elongated member 130 may carry the force over a distance and transmit the force to the engagement portion 110. As shown in FIG. 1, the elongated member 130 defines an elongated portion 132 between the engagement portion 110 and the biasing portion 160, along which the force induced by the biasing portion 160 is transmitted. This elongated portion 132 facilitates a low-weight, reduced-footprint construction of the tensioner device 106, increasing the adaptability of the tensioner device 106 to various engine designs, including compact, high-performance applications. The typically ferrous material construction and single-piece formation facilitate a high-strength design, with simplified assembly.

[0042] Turning to FIG. 2, an exploded view of the tensioner device 106 is shown. The tensioner device 106 includes the engagement portion 110, the elongated member 130, and the biasing portion 160. The engagement portion 110 includes the engagement member 112 having an engagement surface 113. The engagement member 112 may be a pulley or other structure that is adapted to engage a run of the belt 102. In this manner, the engagement member 112 may define a circumferential contour 114 about which a portion of the belt 102 may conform and move relative to during tensioning. The engagement portion 110 may further include a bearing assembly 122 that is received within the engagement member 112. The bearing assembly 122 may define an aperture 124 and facilitate attachment and/or relative movement of the engagement member 112 with respect to the elongated member 130.

[0043] For example, the engagement portion 110 may further include a bushing assembly 118 that is associable with the bearing assembly 122 to facilitate such attachment and movement.

The bushing assembly 118 may define a mechanical connection between the bearing assembly 122 and the elongated member 130. In the example of FIG. 2, the bushing assembly 118 may include a bearing portion 120 that defines a connecting feature for connecting the bushing assembly 118 to the bearing assembly 122. The bushing assembly 118 may also include a cap portion 119 that defines a dust or debris shield along an end of the engagement portion 110.

[0044] The elongated member 130, as described herein, may be at least partially inserted into the engagement portion 110 via the bushing assembly 118. For example, the bushing assembly 118 may define a through portion 129 and an end of the elongated member 130 may be inserted into the through portion 129. A cap 126 may also be provided at an end of the engagement portion 110 opposing the cap portion 119 that also may function as a dust or debris shield. An aperture 127 may be defined through the cap 126 and aligned with the aperture 124 of the bearing assembly 122 and the through portion 129 of the bushing assembly 118.

[0045] The engagement portion 110 is adapted to impart a force on the belt in cooperation with the biasing portion 160 and associated elongated member 130, as shown in FIG. 2. The biasing portion 160 may include a variety of components and assemblies that facilitate inducing or otherwise generating a force. In the example of FIG. 2, the biasing portion 160 includes a base 162. The base 162 may generally function to enclose the component and assemblies of the biasing portion 160. The base 162 may also provide an interface between the tensioner device 106 and one or more components of an engine assembly or other application. In this regard, the base 162 is shown in FIG. 2 as including an anti-rotation feature 163, which may be a nub or protrusion extending from an exterior surface of the base 162. The anti-rotation feature 163, in certain examples, may be received or otherwise engaged with an engine assembly to mitigate or prevent rotation of the biasing portion 160 relative to the assembly. Further shown in FIG. 2, the base 162 includes a through portion 166 extending through the base 162 and arranged along a lever arm axis L-L. The through portion 166 may be adapted to receive or otherwise engage with a complementary component of the engine assembly, and thus mitigate rotation of the biasing portion 160 within the engine assembly in cooperation with the anti -rotation feature 163.

[0046] Received within the base 162, FIG. 2 shows a biasing element assembly 170. Broadly, the biasing element assembly 170 may include a collection of components that may store a force, and subsequently release the stored force. The biasing element assembly 170 may also be associated with various other components of the biasing portion 160 in a manner to release the stored force in a controlled or predictable manner, such as releasing the force at a value tuned to impart a desired tension on the belt 102. To facilitate the foregoing, the biasing element assembly 170 may include a biasing element 172, an insert 176, and a shoe 180. In other examples, more or fewer components may be used. For example, the insert 176 and the shoe 180 may collectively define a damping assembly, as explained in greater detail with respect to FIGS. 5A-6. However, it will be appreciated that in certain other examples, the insert 176 and the shoe 180 may be omitted.

[0047] In the example of FIG. 2, the biasing element 172 is shown with a first biasing element portion 173a and a second biasing element portion 173b. The first biasing element portion 173a may be connected with the base 162, such as via the insert 176 and/or shoe 180, and the second biasing element portion 173b may be connected with the elongated member 130. The first and second biasing element portions 173a, 173b are manipulatable relative to one another in order to store and release energy. For example, the elongated member 130 may be moveable relative to the base 162, and thus cause the manipulation of the first and second biasing element portions 173a, 173b.

[0048] In the particular implementation of FIG. 2, the biasing element 172 may be a torsion spring and the first biasing element portion 173 a may include a first end of the torsion spring, and the second biasing element portion 173b may include a second opposing end of the torsion spring. The first and second biasing element portions 173a, 173b may be manipulated to an angular offset, relative to one another, to store energy in the torsion spring. As explained in greater detail herein, in cooperation with the elongated member 130 and associated connecting features, the first and second biasing element portions 173a, 173b may be manipulated to a predetermined angular offset from one another to define a set bias for creating a target tension in the belt 102.

[0049] As shown in FIG. 2, the biasing portion 160 includes a bushing 185, a shaft 189, and a biasing portion cap 193. The bushing 185, the shaft 189, and the biasing portion cap 193 may be each arranged along the lever arm axis L-L. The bushing 185 may facilitate connection of the elongated member 130 to the biasing portion 160, and more specifically to the lever arm axis L- L. For example, the elongated member 130 may be fitted around the bushing 185 and allowed to rotate or pivot about the lever arm axis L-L, as defined by the bushing 185. The biasing portion cap 193 may define a dust or debris shield to enclose or partially enclose the components of the biasing portion 160, such as the biasing element assembly 170, within the base 162. The shaft 189 may define a pivot pin or other feature that is generally receivable through the biasing portion cap 193 for engagement with the bushing 185 within the base 162. The shaft 189 may therefore establish a surface about which the bushing 185 and elongated member 130 more generally may rotate along for rotation about the lever arm axis L-L. The shaft 189, in certain examples, may also help secure the biasing portion cap 193 to the base 162 or otherwise prevent exit of the biasing portion cap 193 from the biasing portion 160; however, this is not required.

[0050] Force induced by the biasing portion 160 is transmitted to the engagement portion 110 via the elongated member 130. The elongated member 130 may include a rod or other elongated structure having a cross-dimension that is smaller than a length of the elongated member 130. For example, the elongated member 130 may have a cross-dimension that is around 10% of the value of the length of elongated member 130, as shown in greater detail below with respect to FIG. 9. The elongated member 130 includes an elongated portion 132 extending between the biasing portion 160 and the engagement portion 110. The elongated portion 132 may exhibit the cross-dimension, such as a diameter of a substantially circular shape that is around 10% or the value of the length of the elongated portion 132. Such cross-dimension may be exhibited by the elongated portion 132 along a substantial entirety of the length, and in some cases, be substantially constant. In other example, the cross-dimension may vary, and be defined by a variety of shapes, such as the patterns and contours depicted in FIGS. 14A-14C herein.

[0051] The elongated member 130 is shown in FIG. 2 as having a first end 131a and a second end 131b. The first and second ends 131a, 131b may be opposing ends of the elongated member 130. The engagement portion 110 may be associated with elongated member 130 at the first end 131a. The biasing portion 160 may be associated with the elongated member 130 at the second end 131b. In the example of FIG. 2, the elongated member 130 includes a bend 139 between the first and second ends 131a, 131b. The bend 139 may allow the first and second ends 131a, 131b to be orientated along different directions, such as substantially perpendicular directions, which may in turn facilitate the association of the engagement portion 110 and the biasing portion 160 to the elongated member 130.

[0052] For example, the elongated member 130 is shown in FIG. 2 as including a first connecting feature 134a at the first end 131a and a second connecting feature 134b at the second end 131b. The first connecting feature 134a may be orientated along a direction that is different from an orientation of the second connecting feature 134b, in part due to the construction of the bend 139. The first connecting feature 134a may include a protrusion 133a that is adapted to be received into the engagement portion 110. For example, the protrusion 133a may be specifically manufactured with a dimension and tolerance to form a press-fit connection between the elongated member 130 and the engagement portion 110. The through portion 129, as an illustration, of the bushing assembly 118 may receive the protrusion 133a of the first connecting feature 134a, and the through portion 129 and the protrusion 133a may have complementary dimensions in order to establish a press-fit connection between the components when connected. A lip 133b may be established on the elongated member to demarcate the protrusion 133a from the remainder of the elongated member 130. The lip 133b may also define a limit for the advancement of the engagement portion 110 onto the elongated member 130.

[0053] The second connecting feature 134b may include an engagement surface 140. The engagement surface 140 may generally be a flattened portion of the elongated member 130 at the second end 131b. The engagement surface 140 may be used to connect the biasing element assembly 170 to the elongated member 130. For example, the engagement surface 140 may be used to connect the second biasing element portion 173b to the elongated member 130. This may be accomplished via a weld, such as a laser weld; however, other attachment techniques are contemplated herein, including mechanical-type attachment techniques, which may be facilitated by certain high-performance adhesives. The engagement surface 140 may also help orientate the biasing element assembly 170 with the biasing portion 160. In the example of FIG. 2, the engagement surface includes dimples 142. The dimples 142 may be bumps, ridges, curved and raised lines, or other features that cooperate to define a locating feature of the elongated member for determining proper positioning of the biasing element 172 at the second end 13 lb of the elongated member 130. For example, the second biasing element portion 173b may be welded to the engagement surface 140 relative to the dimples 142. This in turn may define an angular orientation or angular offset of the second biasing element portion 173b to the first biasing element portion 173a, such as an angular offset of the biasing element 172 in a loaded state for tuning the desired force to create a desired force in the belt 102.

[0054] FIG. 3 depicts a cross-sectional view of the engagement member 112 and the bearing assembly 122, taken along line I-I of FIG. 1. The engagement member 112 includes the engagement surface 113 for contacting the belt 102. The engagement surface 113 may define the circumferential contour 114 of the engagement member 112. The circumferential contour 114 may help the engagement surface 113 conform to a portion of the belt 102, and allow for movement of the belt 102 relative to the engagement member 112. The engagement member 112 may be constructed having a wall 116. The wall 116 may be a substantially continuous structural component that defines both the engagement surface 113 and a through portion 115.

In other cases, the wall 116 may be formed from two or more components as may be appropriate for a given application. In the example of FIG. 3, the wall 116 extends from the engagement surface 113 to define the through portion 115 and form a cavity 117 therebetween.

[0055] The bearing assembly 122 may be received by the engagement member 112. In one example, the engagement member 112 may be formed from a moldable material, and the engagement member 112 may be molded over the bearing assembly 122. The bearing assembly 122 may also be associated with the engagement member 112 via a press-fit connection. For example, the bearing assembly 122 may include an exterior surface 125 that is adapted for association with the wall 116 of the engagement member 112 at the through portion 115. The bearing assembly 122 also includes the aperture 124 shown in FIG. 3, which may facilitate association of the engagement member 112 with the tensioner device 106.

[0056] For example and with respect to FIG. 4, a cross-sectional view of the engagement portion 110 is shown including the bushing assembly 118 and cap 126. In the cross-sectional view of FIG. 4, the bushing assembly 118 is received by the bearing assembly 122. For example, the bushing assembly 118 may include the bearing portion 120, and the bearing portion 120 may be insertable at least partially into the bearing assembly 122 at the aperture 124. At least a portion of the bearing assembly 122 may therefore be rotatable about the bushing assembly 118 via the association of the bearing portion 120 with the aperture 124.

[0057] FIG. 4 also shows the cap portion 119 of the bushing assembly 118 installed substantially within the cavity 117. The cap portion 119 may close the bearing assembly 122 within the engagement member 112 in cooperation with the cap 126. For example, the cap portion 119 may be fitted at a first end of the bearing assembly 122, and the cap 126 may be fitted at a second, opposing end of the bearing assembly 122. This may mitigate the intrusion of dust and debris into rotational components of the engagement portion 110. To facilitate, the cap portion 119 may also include a lip feature 121 that is adapted for engagement with the wall 116 of the engagement member 112. The bushing assembly 118 is also shown in FIG. 4 as including the through portion 129 for association of the bushing assembly 118 with the elongated member 130.

[0058] FIG. 5 A depicts a cross-sectional view of the biasing portion 160, including the base 162, taken along line I-I of FIG. 1. The base 162 may define an internal volume 161 for receiving the various components and assemblies of the tensioner device 106, such as for receiving the biasing element assembly 170. The base 162 is also shown as including a duct 165. The duct 165 defines a through portion 166 that extends into the internal volume 161. The through portion 166 is arrangeable along the lever arm axis L-L. The biasing element assembly 170 may be positioned substantially within the internal volume 161 and surround or partially surround the duct 165. The biasing element assembly 170 may be adapted for movement within the internal volume 161 about the lever arm axis L-L.

[0059] The biasing element assembly 170 may also be connected to the base 162. For example, the biasing element assembly 170 may be connected to the base to mitigate or limit rotation of the biasing element assembly 170 beyond a threshold or specified location. With reference to FIG. 5B, a bottom isometric view of the base 162 is shown, including features that may facilitate the association of the biasing element assembly 170 and the base 162 and/or define relative movement between these components. For example, the base 162 may include a stop feature 164. The stop feature 164 may be an indented portion of the base 162 that is configured for engagement with the biasing element assembly 170. The stop feature 164 may define a landing 167, and the landing may prevent rotation of the biasing element assembly 170 upon contact. More specifically, the biasing element assembly 170 may include the shoe 180, and the landing 167 may be configured to contact the shoe 180 upon rotation of the biasing element assembly 170 within the internal volume 161 of the base 162. This arrangement of the landing 167 and shoe 180 may help dampen the operation of the biasing element assembly 170, for example, by constraining the rotation of the biasing element assembly 170 to a threshold value within the base 162. [0060] FIG. 6 depicts a cross-sectional view of the biasing portion 160 of FIG. 5 A, including the biasing element assembly 170, taken along line I-I of FIG. 1. In FIG. 6, the biasing element assembly 170 is arranged within the internal volume 161. The duct 165 is positioned at least partially extending into or through a center of the biasing element assembly 170. In this manner, where the biasing element assembly 170 includes a torsion spring, the duct 165 may extend at least partially through the spring, allowing the ends of the torsion spring to be angularly offset about the duct 165 and lever arm axis 1-1. FIG. 6 also shows the first biasing element portion 173a connected to the insert 176. The insert 176 is received within the shoe 180. In this regard, the insert 176 and the shoe 180 may define an interface between the biasing element 172 and the base 162 to allow for the association of the first biasing element portion 173a with the base 162. The second biasing element portion 173b is also shown, opposite the first biasing element portion 173a. The second biasing element portion 173b is angularly displaceable relative to the first biasing element portion 173a, and associable with the elongated member 130.

[0061] To facilitate the foregoing and with reference to FIG. 7, the biasing portion 160 is shown as including the bushing 185. The bushing 185 is received at least partially through the through portion 166 of the base 162. The bushing 185 may therefore connect the base 162 to other components of the biasing portion 160. For example, the bushing 185 may extend through the duct 165 and through an entirety of the biasing element assembly 170. The bushing 185 may, as shown in FIG. 7, extend past the biasing element assembly 170 to allow the connection of additional components of the biasing portion 160 to the bushing 185 proximate the second biasing element portion 173b.

[0062] Turning to FIG. 8, a cross-sectional view of the biasing portion 160 is depicted, in which the elongated member 130 and the shaft 189 are associated with the bushing 185 and biasing element assembly 170. For example, the elongated member 130 may be associated with the bushing 185 at the second end 131b. At the second end 131b, the elongated member 130 is shown as defining an aperture 150. The bushing 185 may be extendable through the aperture 150, securing the position of the elongated member 130 relative to lever arm axis L-L. The bushing 185 may extend through the aperture 150 to facilitate relative movement between the elongated member 130 and the bushing 185. [0063] The elongated member 130 may also be secured at the biasing portion 160 via the shaft 189. For example and as shown in FIG. 8, the shaft 189 may be received by the bushing 185, such as being received by a through portion 186 of the bushing 185, and include a lip portion 191. The lip portion 191 may press against the elongated member 130, opposite the biasing element assembly 170, when the shaft 189 is in an installed configuration. The shaft 189 also defines a through portion 190, which may be adapted to receive one or more features of an engine or other application of the tensioner device 106.

[0064] FIG. 8 also shows the association of the elongated member 130 with the biasing element assembly 170. In the cross-sectional view of FIG. 8, the second biasing element portion 173b is associated with the elongated member 130 at the second end 131b. More specifically, the second biasing element portion 173b is associated with the second connecting feature 134b. As described herein, the second connecting feature 134b may define an engagement surface 140 and the second biasing element portion 173b may be welded to the engagement surface. In this regard, the second biasing element portion 173b may be displaced with the movement or rotation of the elongated member relative to the bushing 185. The cross-sectional view of FIG. 8 also shown the dimples 142. The second biasing element portion 173b is weldable to the engagement surface 140 with respect to the dimples 142. For example, the dimples 142, or other curved ridges, or raised portion may collectively define a locating feature for locating a proper position of the biasing element 172 at the engagement surface 140, such as a position that corresponds to a predetermined or engineer angular offset of the first and second biasing element portion 173a, 173b in a loaded configuration of the tensioner device 106.

[0065] FIG. 9 depicts an isometric view of the elongated member 130. The elongated member 130 includes the first connecting feature 134a at the first end 131a, and the second connecting feature 134b at the second end 131b. The bend 139 described herein is arranged in the elongated member 130, such as adjacent or in the elongated portion 132 and operates to orientate the first and second connecting features 134a, 134b along different directions. As shown in FIG. 9, the first connecting feature 134a is orientated along a first direction 135a, and the second connecting feature 134b is orientated along a second direction 135b. The first and second directions 135a, 135b may be substantially perpendicular directions, as defined by the bend 139. [0066] The orientation of the first and second connecting features 134a, 134b may facilitate a simplified and secure connection of the elongated member 130 to the engagement portion 110 and the biasing portion 160. For example, the post or protrusion 133a of the first connecting feature 134a may extend along the first direction 135a, which may be a direction that is substantially perpendicular to a direction of the force imparted on the belt 102 by the engagement member 112. The engagement portion 110 may be press-fit with the first connecting feature 134a along the direction 135a allowing all or some of the protrusion 133a to be inserted through the engagement portion 110, reinforcing and stabilizing the engagement member 112 as it imparts force along a substantially perpendicular direction to that of the first direction 135a. As another example, the engagement surface 140 may extend along the second direction 135b, which is a direction that intersects the lever arm axis L-L. This allows the aperture 150 to extend through a complete thickness of the elongated member 130 at the engagement surface 140. Thus the elongated member 130 is rotatable about the lever-arm axis, while also providing a substantially flat contour for welding of the biasing element assembly 170 around the lever arm axis L-L.

[0067] For example and with continued reference to FIG. 9, the engagement surface 140 is shown as having a substantially flat contour 141. The substantially flat contour 141 is arranged about the aperture 150 and thus defines a feature for welding the biasing element assembly 170 to the elongated member 130. FIG. 9 also shows the dimples 142. More specifically, FIG. 9 shows a first dimple 142a, a second dimple 142b, a third dimple 142c, and a fourth dimple 142d. The dimples 142a-142d are arranged about the aperture 150 and define a location feature for the welding of the biasing element assembly 170 at a specified location on the engagement surface 140. For example, the second biasing element portion 173b may be an end of a torsion spring, and the end of the torsion spring may be welded relative to one or more of the dimples 142a- 142d. In some cases, the dimples 142a-142d may define a location for welding the end of the torsion spring to define an angular offset between spring ends in a loaded configuration of the tensioner device 106.

[0068] The elongated member 130 helps reduce an overall weight and footprint of the tensioner device 106. In this manner, the elongated member 130 is shown in FIG. 9 as including an elongated portion 132. The elongated portion 132 has an elongated portion length 138 and an elongated portion width 136. The elongated portion length 138 is greater than the elongated portion width 136, such as being substantially greater than the elongated portion width 136. While many constructions are possible, the elongated portion width 136 may be in a range of about 5 mm to 8 mm. For example, the elongated portion 132 may be a rod of a substantially circular cross-section for an automotive application, and having a diameter of about 5 mm to 8 mm along the elongated portion length 138. In other examples, other diameters may be desirable, such as a diameter of less than 5 mm or greater than 8 mm. The elongated portion length 138 is greater than the elongated portion width 136, and depending on the application may be at least 70 mm, at least 80 mm, at least 90 mm, or at least 100 mm or greater.

[0069] The ratio of the elongated portion length 138 to the elongated portion width 136 may be tuned based on the performance criteria of the tensioner device 106, including the anticipated load transmitted by the elongated member 130. The ratio may also be based at least in part on the material, construction, and manufacturing of the elongated member 130. For example, the elongated member 130 may be formed from a single piece of material having high strength and high formability. Ferrous materials may be used such as low carbon steel. Such materials may have a fatigue limit, enhancing their use in cyclic loading applications. Fastener grade materials may also be used to facilitate formability during forging.

[0070] FIG. 10 depicts a cross-sectional view of the tensioner device 106 of FIG. 1, taken along line I-I of FIG. 1. In FIG. 10, the tensioner device 106 is shown in an assembled configuration. For example, the first connecting feature 134a is shown associated with the engagement portion 110 via a press fit with the bearing assembly 122. Further, the second connecting feature 134b is shown associated with the biasing portion 160 via the bushing 185 and the welding of the engagement surface 140 and the second biasing element portion 173b to one another.

[0071] FIG. 11 depicts another sample tensioner device and belt assembly 1100. In the example of FIG. 11, a tensioner device 1106 is depicted engaging a belt 1102. The tensioner device 1106 includes an elongated member 1130 adapted to transmit force between a biasing portion 1160 and an engagement portion 1110. The tensioner device 1106 may be substantially analogous to the tensioner device 106, and may be adapted to impart a force on the belt 1102 for inducing a target tension in the belt 1102. In this regard, the engagement portion 1110 is shown in FIG. 11 as including an engagement member 1112 with an engagement surface 1113 that contacts the belt 1102. Further, the biasing portion 1160 is shown in FIG. 11 as including a base 1162 that houses a biasing element assembly 1170 therein. The biasing element assembly 1170 is configured to store and subsequently release a value of force for tensioning the belt 1102. It will be appreciated that the tensioner device 1106 may also include various other components, such as various busing assemblies, bearing assemblies, caps, and so on, which may be similar to those illustrated in the examples of FIGS. 1-10, and not shown in FIG. 11 for the interest of clarity.

[0072] The elongated member 1130 may transmit force released by the biasing element assembly 1170 to the engagement portion 1110. The elongated member 1130 may have a cross- sectional dimension that is smaller, such as being substantially smaller than a length of the elongated member 1130. The elongated member 1130 may include an offset section 1146 that may define a transition between a first elevation of the elongated member 1130 and a second elevation of the elongated member 1130. The offset section 1146 may therefore allow the tensioner device 1106 to accommodate a wider and/or different variety of engines and other tensioning application.

[0073] FIGS. 12A and 12B illustrate the elongated member 1130 and the offset section 1146. Broadly, the elongated member 1130 may be substantially similar to the elongated member 1130, and may include an elongated portion 1132, a first end 1131a, a second end 113 lb, a first connecting feature 1134a, a second connecting feature 1134b, a protrusion 1133a, a lip 1133b, a first direction 1135a, a second direction 1135b, an elongated portion width 1136, an elongated portion length 1138, a bend 1139, an engagement surface 1140, a substantially flat contour 1141, dimples 1142, including a first dimple 1142a, a second dimple 1142b, a third dimple 1142c, a fourth dimple 1142d, and an aperture 1150.

[0074] In the side view of FIG. 12B, the offset section 1146 is shown as defining a transition between a first elevation 1147a and a second elevation 1147b of the elongated member 1130.

The offset section 1146 may therefore define an offset 1148 of the elongated member 1130 corresponding to the change in elevation between the first elevation 1147a and the second elevation 1147b. The first and second elevations 1147a, 1147b may be along the same direction, such as the second direction 1147b shown in FIG. 12B.

[0075] The elongated portion 1132 may include the offset section 1146. The offset section 1146 may segment or divide the elongated portion 1132 between a first rod portion 1149a of the elongated portion 1132 and a second rod portion 1149b of the elongated portion 1132. In the example shown in FIG. 12B, the first and second rod portions 1149a, 1149b may be substantially linear, rod-like sections of the elongated member 1130. The offset section 1146 may therefore function to transition the elevation of the elongated member between the first and second rod portions 1149a, 1149b. The first rod portion 1149a may extend from the bend 1139, and may be longer than the second rod portion 1149b. This difference in length may account for specific engine designs and applications, such as where a majority of the length of the elongated member 1130 may be positioned along the first elevation 1147a for optimized performance and/or integration with an engine. In other cases, the offset section 1146 may be arranged at any appropriate location of the elongated portion 1132.

[0076] Turning to FIGS. 13A-13C, various operations of processing a single piece of material for forming an elongated member are shown, such as the elongated member 130 and/or 1130 described herein. With reference to FIG. 13A, a first operation 1300a is shown. In the first operation 1300a, a single piece of material 1304 is provided. The single piece of material 1304 may have a first end 1306a and a second end 1306b. The single piece of material 1304 may also have an elongated portion 1308 extending between the first and second ends 1306a, 1306b. The elongated portion 1308 may have a cross-dimension that is substantially smaller than the length of the single piece of material 1304. In this regard, the single piece of material 1304 may be a rod-type shape, and may have a substantially constant cross-section along the entirety or at least some of the length of the material 1304. In other examples, other cross-sections are contemplated, such as those shown in FIGS. 14A-14C.

[0077] The single piece of material 1304 may be a ferrous material. While many ferrous materials are possible, fastener grade materials may be preferred, as are materials with generally high strength and high formability. Low-carbon steel and/or high-alloy steels may be used. The material 1304 may also be pre-lubricated by a dry soap-type lubricant to facilitate subsequent forming.

[0078] With reference to FIG. 13B, a second operation 1300b is shown. In the second operation 1300b, the single piece of material 1304 may undergo a cold forging or hot forging process. In some examples, cold forging may reduce manufacturing expense, and produce sufficiently high material strength in association with work hardening. In this regard, the second operation 1300b may be the result of a “first hit” of a cold or hot forgoing process. During this first hit, a bend 1312 may be formed in the single piece of material 1304. Further during or associated with this first hit, a flattened region 1316 may be formed at the second end 1306b. Additionally or alternatively, the flattened region 1316 may include a dimpled region 1320. As one example, the dimpled region 1320 may be formed by having cavities in a die used to flatten the second end 1306b.

[0079] With reference to FIG. 13C, a third operation 1300c is shown. In the third operation 1300c, the single piece of material 1304 may further undergo a cold forging or hot forging process, and thus may be the result a “second hit”. During this second hit, flash at the second end 1306b may be trimmed, accounting for irregularities in the metal flow. An aperture 1350 may also be formed through the flattened region 1316 for association of the elongated member with a lever arm axis of a tensioner device. The first end 1306a may be ironed out. Ironing or sizing dies may flow the metal slightly to create an accurate diameter for the press-fit connection.

[0080] The single piece of material 1304 shown in FIG. 13C may thus include a first connecting feature 1332a including a protrusion 1333 at the first end 1306a. The protrusion 1333 may be the result of the cold and/or hot forgoing described herein in operations 1300b, 1300c. Machining may also be used. Further as shown in FIG. 13C, the single piece of material 1304 may include the second connecting feature 1332b including an engagement surface 1342. The engagement surface 1342 may be the result of the cold and/or hot forgoing described herein in operations 1300b, 1300c, such as where the second end 1306b is flattened.

[0081] Corrosion protection may also be applied to the single piece of material 1304. For example, subsequent to the third operation 1300c, an electro-deposition coating, also known as an e-coating, may be applied. The thickness of the coating may be substantially small and generally uniform over an application side. The coating may also have a sufficiently high hardness in comparison with alternative methods of coating. Accordingly, such e-coating may provide corrosion protection without detracting from the ability of the single piece of material to press-fit with other components of a tensioner device, such as a bearing assembly.

[0082] FIGS. 14A-14C depicts different cross-section views of a sample elongated member.

As described herein, the elongated members of the present disclosure may be rod-like structures with an elongated portion where a cross-dimension of the member is substantially less than a length of the member. The examples of FIGS. 1-13C show a substantially circular cross-section; however, other cross-sections are possible. For example and with reference to FIG. 14A, an elongated member 1430a is shown having a cross-section 1434a at an end 1432a. The cross- section 1434a shown in FIG. 14A may substantially be a rectilinear-type shape, with distinct sides that join one another at an angle or along or forming an edge. For example, this may include a square shape, or may be rectangular, or other shape having four sides. Other rectilinear shapes may also be implemented, including those having three sides, or more than four sides, such as having five sides, six sides, or more sides. The rectilinear-type shape can facilitate manufacturability of the elongated member and may enhance rigidity along a length of the member.

[0083] As a further example and with reference to FIG. 14B, an elongated member 1430b is shown having a cross-section 1434b at an end 1432b. The cross-section 1434b shown in FIG. 14B may substantially resemble a plus “+” sign, with distinct arms that radiate from a center or axial line of the elongated member 1430b. As a further example and with reference to FIG. 14C, an elongated member 1430c is shown having a cross-section 1434c at an end 1432c. The cross- section 1434c shown in FIG. 14C may include additional arms, as compared with the cross- section 1434b of FIG. 14B, that radiate from a center or axial line of the elongated member 1430c. In this regard, the number of arms may be tuned to a particular application, including enhancing flexibility of the elongated member along the length of the member.

[0084] In each of the foregoing examples of FIGS. 14A-14C, the respective cross-section may be maintained along a length of the elongated member. For example, the cross-section 1434a may be substantially constant along a length of the elongated member 1430a, the cross-section 1434b may be substantially constant along a length of the elongated member 1430b, and the cross-section 1434c may be substantially constant along a length of the elongated member 1430c. In other cases, the cross-section may vary along the length of the elongated member. For example, the cross-section may vary in shape and/or dimension along the length of a respective elongated member, as may be appropriate for a given application. As an illustration, any of the elongated members described herein may be tapered in one direction along the length of the member and/or alternate a shape of the cross-section along the length of the member.

[0085] To facilitate the reader’s understanding of the various functionalities of the examples discussed herein, reference is now made to the flow diagram in FIG. 15, which illustrates process 1500. While specific steps (and orders of steps) of the methods presented herein have been illustrated and will be discussed, other methods (including more, fewer, or different steps than those illustrated) consistent with the teachings presented herein are also envisioned and encompassed with the present disclosure.

[0086] In this regard, with reference to FIG. 15, process 1500 relates generally to a method for manufacturing an arm for a tensioner device. The process 1500 may be used with any of the tensioner devices and elongated members, for example, such as the tensioner devices 106, 1106 and/or elongated members 130, 1130, and variations and combinations thereof.

[0087] At operation 1504, a single piece of material is bent between a first end and a second end of the single piece of material. For example and with reference to FIGS. 13A-13C, the single piece of material 1304 may be bent to form the bend 1312 in the material 1304. This may be accomplished using a cold or hot forging process. In addition, with reference to the elongated member 130 of FIG. 9 and analogous bend 139, the bend 139 may orientate the first end 131a of the elongated member 130 along the first direction 135a and the second end 131b of the elongated member 130 along the second direction 135b.

[0088] At operation 1508, a single piece of material is flattened at an end. For example and with reference to FIGS. 13A-13C, the single piece of material 1304 may be flattened to form the flattened region 1316 at the second end 1306b of the material 1304. This may be accomplished using a cold or hot forging process. In some cases, the operation 1508 may also include forming the dimpled region 1320 at the second end 1306b. For example, cavities in a die used to flatten the second end 1306b may form dimples, and establish one or more locating features of the elongated rod at the second end 1306b.

[0089] At operation 1512, a first connecting feature is formed at an end of a single piece of material. For example and with reference to FIGS. 13A-13C, the single piece of material may be ironed out at the first end 1306a. Ironing or sizing dies may flow the metal slightly at the first end 1306a. This may help create a first connecting feature 1332a defined by a protrusion 1333. For example, the ironing may create an accurate diameter calibrated to a dimension of a bearing or other assembly for establishing a press-fit connection during assembly.

[0090] At operation 1516, a second connecting feature is formed at another end of the single piece of material. For example and with reference to FIGS. 13A-13C, the single piece of material may be trimmed and/or punctured at the second end 1306b. This may help create a second connecting feature 1332b defined by an engagement surface 1342. The engagement surface 1342 is used as a surface for welding a component, such as a biasing element, to the elongated member.

[0091] Other examples and implementations are within the scope and spirit of the disclosure and appended claims. For example, features implementing functions may also be physically located at various positions, including being distributed such that portions of functions are implemented at different physical locations. Thus, the foregoing descriptions of the specific examples described herein are presented for purposes of illustration and description. They are not targeted to be exhaustive or to limit the examples to the precise forms disclosed. It will be apparent to one of ordinary skill in the art that many modifications and variations are possible in view of the above teachings.

Claims

CLAIMS What is claimed is:

1. A tensioner device, comprising: an engagement portion adapted to impart a force to a belt associated with the tensioner device; an elongated member having a first end connected to the engagement portion; and a biasing portion including a biasing element assembly housed therein, the biasing element assembly associated with a second end of the elongated member to bias the elongated member about a lever arm axis defined by the biasing portion, wherein the elongated member includes an elongated portion between the first and second ends.

2. The tensioner device of claim 1, wherein: the biasing portion comprises a base; and the biasing element assembly comprises a biasing element arranged with the base, the biasing element having a first biasing element portion connected with the base and a second biasing element portion connected to the elongated member at the second end.

3. The tensioner device of claim 2, wherein: the biasing element is a torsion spring; the first biasing element portion is a first end of the biasing element; the second biasing element portion is a second end of the biasing element; and the first and second ends of the biasing element are manipulatable to a predetermined angular offset from one another to define the bias for creating a target tension in the belt.

4. The tensioner device of claim 2, wherein the biasing element assembly comprises a damping assembly having the biasing element and further comprising: an insert connected to the first biasing element portion; and a shoe adapted to receive the insert and position the damping assembly within the base.

5. The tensioner device of claim 2, wherein the elongated member defines a second connecting feature at the second end, the second connecting feature including an engagement surface for connecting the second biasing element portion to the elongated member.

6. The tensioner device of claim 1, wherein the elongated member defines an aperture at the second end, the aperture configured to receive one or more of a shaft or a bushing of the biasing portion along the lever arm axis for rotation of the elongated member about the lever arm axis.

7. The tensioner device of claim 1, wherein: the elongated portion of the elongated member has an elongated portion length; and the elongated portion has a cross-section that is substantially constant along the elongated portion length.

8. The tensioner device of claim 7, wherein the elongated member defines a first connecting feature at the first end, the second connecting feature including a protrusion for connecting the engagement portion to the elongated member.

9. An arm for a tensioner device, the arm comprising an elongated member formed from a single piece of material having a first end, a second end, and an elongated region extending there between, the single piece of material defining: a first connecting feature at the first end and configured to secure the elongated member to an engagement portion of the tensioner device, the engagement portion adapted to impart a force on a belt associated with the tensioner device; a second connecting feature at the second end and configured to secure the elongated member to a biasing portion of the tensioner device, the biasing portion adapted to bias the engagement portion about a lever arm axis; and a bend arranged between the first and second connecting features, such that the first connecting feature is orientated along a first direction and the second connecting feature is orientated along a second direction that is different than the first direction.

10. The arm of claim 9, wherein the elongated member has a length and a cross-section that varies along the length.

11. The arm of claim 9, further comprising an elongated portion between the first and second ends, wherein: the elongated portion further comprises an offset section between the elongated portion and the second end; and the offset section defines a transition between a first elevation of the single piece of material and a second elevation of the single piece of material, the first and second elevations being defined along the second direction.

12. The arm of claim 9, wherein the first connection feature includes a protrusion, wherein the protrusion is adapted to form a press fit with one or more components of the engagement portion of the tensioner device.

13. The arm of claim 9, where the second connecting feature comprises a series of dimples disposed on the engagement surface, the series of dimples collectively defining a locating feature for positioning the one or more components of the biasing element assembly.

14. The arm of claim 9, wherein the connecting feature comprises an aperture at the lever arm axis and adapted to receive one or more of a shaft or a bushing of the biasing portion.

15. A method of manufacturing an arm for a tensioner device, the method comprising: first forming a single piece of material by bending the material between a first end and second end, and flattening the second end; and after the first forming, second forming the material by: forming a first connecting feature at the first end, the first connecting feature configured to secure the arm to an engagement portion of the tensioner device; and forming a second connecting feature at the second end, the second connecting feature configured to secure the arm to a biasing portion of the tensioner device.

16. The method of claim 15, wherein the bending the material includes forming a 90° bend in the material.

17. The method of claim 15, wherein the flattening of the second end includes establishing a series of dimples in the material at the second end.

18.. The method of claim 15, wherein the forming a first connecting feature at the first end includes defining a protrusion at the first end having a diameter.

19. The method of claim 15, wherein forming a second connecting feature at the second end includes forming an aperture through a portion of the material that was subjected to the flattening.

20. The method of claim 15, further comprising coating the material, after the second forming, using an electro-deposition coating.