A composite gear

Abstract

The present application relates to the technical field of transmission gear, in particular to a kind of composite gear.It includes axle core, support matrix and gear ring, including axle core, support matrix and gear ring, gear ring is formed by injection molding at the outside of support matrix, support matrix includes the outer edge injection molding connecting portion of the circumferential surface of surrounding coverage and the extension to one end face, gear ring includes the circumferential portion of the circumferential surface of the outer edge injection molding connecting portion and the extension part extending to end face and the end face of the outer edge injection molding connecting portion.The inner surface of gear ring and the outer surface of the outer edge injection molding connecting portion are provided with corresponding matched torque resisting bite structure.The support matrix structure used in the present application forms large-area circumferential embedding structure with gear ring, greatly improves circumferential anti-slip ability, avoids relative rotation failure during gear transmission, and effectively prevents axial movement, peeling and falling off of gear ring.

Description

Technical Field

[0001] This invention relates to the field of transmission gear technology, and more specifically to a composite gear. Background Technology

[0002] Currently, the steering wheel transmission mechanism of new energy vehicles generally adopts a composite gear structure to transmit steering torque. The entire transmission pair is made of non-metallic materials to achieve low noise and lightweight effect. There is no metal gear meshing. The composite gear is mainly composed of a steering input shaft, a plastic support base and an outer nylon gear ring.

[0003] Existing structures such as Figure 9 , 10 As shown, the overall structure is columnar, with a constricted fitting section in the middle. This fitting section contains numerous short protrusions and grooves. On one hand, the short size of the protrusions and grooves, and the narrow cavities, result in high flow resistance for the molten nylon during secondary injection molding. This easily leads to filling defects such as material shortages, air bubbles, and weld lines. The nylon does not fully fit with the substrate, leaving gaps at the joint surface, and continuously generating frictional and impact noise during steering. On the other hand, the short protrusions have insufficient effective bearing height and a small circumferential contact area. When the vehicle frequently changes direction and experiences alternating steering torque, shear stress concentrates at the root of the protrusion, significantly reducing the overall circumferential anti-slip capability. Long-term use can easily lead to protrusion wear and breakage, and relative circumferential slippage between the nylon gear ring and the supporting substrate. Once the protrusion fails, relative circumferential slippage will occur between the nylon gear ring and the supporting substrate, resulting in lag in steering torque transmission and severely affecting the steering experience and safety. Summary of the Invention

[0004] This invention provides a composite gear to solve the technical problems in the prior art, such as the short protruding groove in the necked-out fitting part of the support base being prone to material shortage during injection molding, easy slippage in the circumferential direction, and easy movement and delamination of the nylon gear ring, as well as many molding defects.

[0005] To solve the above problems, the present invention provides a composite gear with the following technical solution:

[0006] The device includes a shaft core, a support base, and a gear ring. The gear ring is formed on the outside of the support base by injection molding. The support base includes an outer edge injection-molded connection portion that covers a side peripheral surface and extends to one of its end faces. The gear ring includes a circumferential portion that fits the side peripheral surface of the outer edge injection-molded connection portion and an extension portion that extends to the end face and fits the end face of the outer edge injection-molded connection portion.

[0007] The inner surface of the gear ring and the outer surface of the outer edge injection molding connection are provided with a corresponding anti-torque engagement structure.

[0008] Furthermore, the anti-torque engagement structure includes a plurality of engagement ribs disposed on the outer surface of the outer edge injection molding connection and distributed circumferentially thereon. The engagement ribs extend from the side surface of the outer edge injection molding connection to the bottom surface, and an anti-torque filling groove is formed between adjacent engagement ribs.

[0009] The gear ring is wrapped around the outer edge injection-molded connection part and completely fills the anti-torque filling groove. The anti-torque engagement structure also includes engagement claws provided on the inner wall of the gear ring and matching the anti-torque filling groove.

[0010] Furthermore, the bottom surface of the outer edge injection molding connection is an inclined surface, and the bottom end of the inclined surface approaches the direction of the shaft core. The bottom surface and the side surface of the outer edge injection molding connection are smoothly connected by a circular arc surface.

[0011] Furthermore, the angle between the bottom surface of the outer injection-molded connector and the horizontal plane is α, and 0° < α < 60°.

[0012] Furthermore, the support base is an integral structure fixed to one end of the shaft core by injection molding. The support base includes a connecting sleeve part located at the center and cooperating with the shaft core, and a spoke support part is provided outside the connecting sleeve part.

[0013] The bottom of the spoke support also forms a platform surface parallel to the horizontal plane, and a stepped surface is formed between the platform surface and the bottom surface of the outer edge injection molding connection part, with the bottom inner side of the gear ring abutting against the stepped surface.

[0014] Furthermore, an annular engagement boss is provided on the outer surface of the outer edge injection molding connection near the top, and the top of the engagement rib is connected to the lower end face of the annular engagement boss.

[0015] Furthermore, the end of the anti-torque filling groove is formed with a recessed hook locking section.

[0016] Furthermore, a radial locking groove is provided on the bottom surface of the outer edge injection molding connection.

[0017] Furthermore, the radial locking slots are a plurality of those spaced apart along the circumference, with protrusions provided between adjacent radial locking slots, and protruding posts provided on the lower surface of the protrusions.

[0018] Furthermore, the spoke support includes a plurality of spoke stiffeners extending radially outward, the plurality of spoke stiffeners being evenly distributed along the circumference, and a reinforcing plate being provided between adjacent spoke stiffeners.

[0019] The beneficial effects of the composite gear provided by this invention are:

[0020] 1. The present invention adopts an integrated base structure formed by connecting sleeve part, spoke support part and outer edge injection molding connection part. By setting an annular engagement boss, axially penetrating engagement rib and anti-torque filling groove on the outer side of the outer edge injection molding connection part, matching engagement claws are formed on the inner side of the gear ring, forming a large area circumferential fitting structure. The torque is evenly distributed along the circumference, which greatly improves the circumferential anti-slip capability and avoids relative rotation failure during gear transmission.

[0021] In addition, a concave hook locking section is provided at the bottom of the anti-torque filling groove, so that the inner side of the nylon molding hooks...

[0022] The claw, in conjunction with the inclined bottom surface, forms a two-way hooking and locking mechanism. Combined with the rigid axial limit of the bottom stepped surface, a multi-segment axial anti-detachment structure is formed from the top, middle, and bottom ends, effectively preventing the gear ring from axially moving, peeling, and falling off.

[0023] 2. In this invention, the use of radial spoke stiffeners and hollowed-out reinforcing plates significantly reduces the material usage and molding shrinkage of the supporting base while ensuring overall torsional stiffness and bending strength, thus achieving lightweight and low-cost production. Attached Figure Description

[0024] The above and other objects, features, and advantages of exemplary embodiments of the present invention will become readily apparent upon reading the following detailed description with reference to the accompanying drawings. In the drawings, several embodiments of the invention are illustrated by way of example and not limitation, and like or corresponding reference numerals denote like or corresponding parts, wherein:

[0025] Figure 1 This is one of the structural schematic diagrams of the present invention;

[0026] Figure 2 This is the second structural schematic diagram of the present invention;

[0027] Figure 3 This is a cross-sectional view of the structure of the present invention;

[0028] Figure 4 This is one of the structural schematic diagrams of the supporting substrate in this invention;

[0029] Figure 5 This is the second schematic diagram of the supporting substrate structure in this invention;

[0030] Figure 6 This is a cross-sectional view of the supporting substrate in this invention;

[0031] Figure 7 This is a schematic diagram of the cross-sectional structure of the supporting substrate in this invention;

[0032] Figure 8 This is a schematic diagram of the gear ring structure in this invention;

[0033] Figure 9 This is a schematic diagram of the structure of a composite gear in the prior art;

[0034] Figure 10 This is a partial structural diagram of a composite gear in the prior art.

[0035] Explanation of reference numerals in the attached figures:

[0036] 1. Shaft core; 2. Support base; 21. Connecting sleeve; 22. Spoke support; 221. Spoke rib; 222. Reinforcing plate; 23. Outer edge injection molded connection; 231. Engaging rib; 232. Torque-resistant filling groove; 233. Annular engagement boss; 234. Hook locking section; 235. Radial locking slot; 236. Protrusion; 237. Protruding post; 3. Gear ring; 3a. Circumferential part; 3b. Extension part; 31. Engaging claw; 4. Platform surface; 5. Stepped surface. Detailed Implementation

[0037] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Those skilled in the art should understand that the embodiments described below are only some, not all, of the embodiments disclosed. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0038] The number of any elements in the accompanying drawings is for illustrative purposes only and not as a limitation, and any naming is for distinction only and has no limiting meaning.

[0039] The principles and spirit of the present invention will be explained in detail below with reference to several representative embodiments.

[0040] An embodiment of a composite gear provided by the present invention:

[0041] like Figures 1 to 8 As shown,

[0042] It includes a shaft core 1, a support base 2, and a gear ring 3. The support base 2 is fixed to one end of the shaft core 1 through a single injection molding process, forming a one-piece plastic base structure. The gear ring 3 is fixed to the outside of the support base 2 through a secondary injection molding process, so that the three components constitute an integral composite transmission gear.

[0043] In this embodiment, the gear ring 3 is a nylon gear ring. In other embodiments, the gear ring can also be an injection-molded polyester elastomer, polyethylene material, etc.

[0044] The supporting base 2 consists of a connecting sleeve part 21, a spoke support part 22, and an outer edge injection molded connecting part 23, which are integrally formed from the inside to the outside.

[0045] The outer injection-molded connecting portion 23 covers the side circumferential surface of the supporting base 2 and extends to one of its end faces. The gear ring 3 includes a circumferential portion 3a that fits the side circumferential surface of the outer injection-molded connecting portion 23 and an extension portion 3b that extends to the end face and fits the end face of the outer injection-molded connecting portion 23. Overall, the injection molding bonding strength is improved, preventing the gear ring 3 from slipping circumferentially or separating axially.

[0046] Specifically, the connecting sleeve portion 21 is located at the center, and the inner hole of the connecting sleeve portion 21 is tightly fitted with the outer wall of the shaft core 1. The end of the shaft core 1 is provided with a spline structure, and the inner wall of the hole of the connecting sleeve portion 21 forms an interlocking structure that mates with the spline structure. This achieves circumferential positioning and synchronous torque transmission between the support base 2 and the shaft core 1.

[0047] In this embodiment, the spoke support portion 22 is formed by radially extending outward from the outer wall of the connecting sleeve portion 21, and is used to bear and transmit torque and achieve lightweight design. The outer edge injection molded connection portion 23 is formed on the outer side surface and bottom area of ​​the spoke support portion 22, and serves as a dedicated connecting base for engaging and locking with the gear ring 3.

[0048] Specifically, the spoke support 22 includes a plurality of spoke stiffeners 221 extending radially outward, the plurality of spoke stiffeners 221 being evenly distributed along the circumference, and a reinforcing plate 222 being provided between adjacent spoke stiffeners 221.

[0049] The spoke stiffener 221 and the reinforcing plate 222 together form a hollowed-out groove structure, which achieves lightweight design while ensuring the overall torsional stiffness and bending strength of the supporting base 2.

[0050] The support base 2 includes a connecting sleeve portion 21 located at the center and cooperating with the shaft core 1. A spoke support portion 22 is provided outside the connecting sleeve portion 21. An outer edge injection molded connecting portion 23 is formed on the side and bottom surface of the spoke support portion 22.

[0051] In this embodiment, an annular engagement boss 233 is provided on the outer surface of the outer edge injection molding connection portion 23 near the top. The annular engagement boss 233 is continuously arranged around the entire circumference of the outer edge injection molding connection portion 23.

[0052] A corresponding anti-torque engagement structure is provided between the inner surface of the gear ring 3 and the outer surface of the outer edge injection molding connection part 23.

[0053] The anti-torque engagement structure includes a plurality of engagement ribs 231 arranged in an array on the outer surface of the outer injection-molded connecting portion 23 and distributed circumferentially. The top of the engagement ribs 231 is integrally connected to the lower end face of the annular engagement boss 233. The engagement ribs 231 extend from the side surface of the outer injection-molded connecting portion 23 to the bottom surface, and an anti-torque filling groove 232 is formed between adjacent engagement ribs 231.

[0054] The gear ring 3 is wrapped around the outer injection-molded connecting part 23, and the molten nylon completely fills the anti-torque filling groove 232. The anti-torque engagement structure also includes engagement claws 31 formed on the inner wall of the gear ring 3 and matching the anti-torque filling groove 232. Through the circumferential engagement of the engagement ribs 231 and the engagement claws 31, the circumferential slippage of the gear ring 3 relative to the supporting base 2 can be effectively restricted, thereby achieving stable torque transmission.

[0055] In this embodiment, a recessed hook-locking section 234 is formed at the end of the anti-torque filling groove 232.

[0056] The hook-locking section 234 creates a concave structure at the bottom of the anti-torque filling groove 232. During the secondary injection molding, the nylon completely fills the hook-locking section 234, forming an inwardly bent claw structure. This claw can hook onto the bottom of the support base 2 from the inside, forming an axial reverse locking effect, effectively inhibiting the gear ring 3 from axially peeling outward and loosening.

[0057] In this embodiment, the bottom surface of the outer injection molding connection 23 is an inclined slope, and the bottom end of the slope converges towards the shaft core 1. The bottom surface and the side surface of the outer injection molding connection 23 are smoothly connected by a curved arc. This eliminates sharp corners with right-angle stress and reduces injection molding defects and the risk of cracking under stress.

[0058] Specifically, the angle between the bottom surface of the outer injection molding connection 23 and the horizontal plane is α, and α is 15°. This angle range ensures that the secondary injection molding melt flows smoothly along the inclined surface and the slots are fully filled, while also allowing a sufficiently wide coating layer to be formed at the bottom of the gear ring 3 to improve axial pull-out resistance.

[0059] The bottom of the spoke support 22 is formed with a platform surface 4 parallel to the horizontal plane. A stepped surface 5 is formed between the platform surface 4 and the bottom surface of the outer edge injection molding connection 23. The inner side of the bottom of the gear ring 3 abuts against the stepped surface 5. This forms a rigid axial limit, further restricting the gear ring 3 from moving outward toward the shaft core.

[0060] Furthermore, a radial locking groove 235 is provided on the bottom surface of the outer injection molding connection part 23.

[0061] Furthermore, there are multiple radial locking slots 235 distributed at intervals along the circumference, and protrusions 236 are provided between adjacent radial locking slots 235, with protrusions 237 on the lower surface of the protrusions 236.

[0062] During the injection molding process, molten nylon flows into the radial locking slot 235, while the protrusion 237 is embedded inside the gear ring 3 to form a multi-point rivet locking structure, which further improves the bonding strength between the gear ring 3 and the bottom of the support base 2 and prevents radial delamination and bottom debonding.

[0063] Based on the above description in this specification, those skilled in the art will also understand that the following terms, such as "upper," "lower," "front," "rear," "left," "right," "width," "horizontal," "top," "bottom," "inner," and "outer," which indicate orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings of this specification. They are only for the purpose of facilitating the explanation of the present invention and simplifying the description, and do not explicitly or implicitly suggest that the device or element involved must have the specific orientation, or be constructed and operated in a specific orientation. Therefore, the above-mentioned orientation or positional relationship terms should not be understood or interpreted as limitations on the present invention.

[0064] In addition, in the description of this specification, "multiple" means at least two, such as two, three or more, etc., unless otherwise expressly and specifically defined.

Claims

1. A composite gear, comprising a shaft core (1), a support base (2), and a gear ring (3), wherein the gear ring (3) is formed on the outside of the support base (2) by injection molding, characterized in that, The support base (2) includes an outer edge injection-molded connection (23) that covers the side peripheral surface and extends to one of the end faces. The gear ring (3) includes a circumferential portion (3a) that fits the side peripheral surface of the outer edge injection-molded connection (23) and an extension portion (3b) that extends to the end face and fits the end face of the outer edge injection-molded connection (23). A corresponding anti-torque meshing structure is provided between the inner surface of the gear ring (3) and the outer surface of the outer edge injection molding connection part (23).

2. The composite gear according to claim 1, characterized in that, The anti-torque engagement structure includes a plurality of engagement ribs (231) provided on the outer surface of the outer edge injection molding connection (23) and distributed along its circumference. The engagement ribs (231) extend from the side of the outer edge injection molding connection (23) to the bottom surface, and an anti-torque filling groove (232) is formed between adjacent engagement ribs (231). The gear ring (3) covers the outer edge injection molding connection part (23) and completely fills the anti-torque filling groove (232). The anti-torque engagement structure also includes an engagement claw (31) provided on the inner wall of the gear ring (3) and matched with the anti-torque filling groove (232).

3. The composite gear according to claim 1, characterized in that, The bottom surface of the outer edge injection molding connection part (23) is an inclined surface, and the bottom end of the inclined surface approaches the direction of the shaft core (1). The bottom surface and the side surface of the outer edge injection molding connection part (23) are smoothly connected by a circular arc surface.

4. The composite gear according to claim 2, characterized in that, The angle between the bottom surface of the outer injection molding connection part (23) and the horizontal plane is α, and 0° < α < 60°.

5. The composite gear according to claim 1, characterized in that, The support base (2) is an integral structure fixed to one end of the shaft core (1) by injection molding. The support base (2) includes a connecting sleeve part (21) located in the center and cooperating with the shaft core (1). A spoke support part (22) is provided outside the connecting sleeve part (21). The bottom of the spoke support (22) is also formed with a platform surface (4) parallel to the horizontal plane. A step surface (5) is formed between the platform surface (4) and the bottom surface of the outer edge injection molding connection (23). The bottom inner side of the gear ring (3) abuts against the step surface (5).

6. The composite gear according to claim 2, characterized in that, The outer surface of the outer injection molding connection part (23) is provided with an annular engagement boss (233) near the top, and the top of the engagement rib (231) is connected to the lower end face of the annular engagement boss (233).

7. The composite gear according to claim 2, characterized in that, The end of the anti-torque filling groove (232) is formed with a recessed hook locking section (234).

8. The composite gear according to claim 1, characterized in that, The bottom surface of the outer edge injection molding connection part (23) is provided with a radial locking groove (235).

9. The composite gear according to claim 8, characterized in that, The radial locking slots (235) are a plurality of those spaced apart along the circumference, and a protrusion (236) is provided between adjacent radial locking slots (235), and a protrusion (237) is provided on the lower surface of the protrusion (236).

10. The composite gear according to claim 5, characterized in that, The spoke support (22) includes a plurality of spoke stiffeners (221) extending radially outward. The plurality of spoke stiffeners (221) are evenly distributed along the circumference, and a reinforcing plate (222) is provided between adjacent spoke stiffeners (221).

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