Gear Ring Carrier Ribs and Pockets for Torque-Stable Molding
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Solution Overview
Problem
Existing two- or multi-component gears face issues with inhomogeneities and reduced load-bearing capacity due to non-uniform material flow during injection molding, leading to potential detachment and increased deformations under high torques, which results in poor running behavior and premature damage.
Innovation Solution
The gear ring carrier part design features a circular ring section with radially aligned ribs and pockets on extension faces, forming a form-fit interface that enhances material flow uniformity and load-bearing capacity, reducing the formation of inhomogeneities and stress peaks, and includes annular walls for radial stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If projections and recesses are provided for form-fitting interaction, then slippage resistance is improved, but material flow uniformity deteriorates causing inhomogeneities and weld seams
Solution Approach 1:
The patent applies preliminary action by providing a flow guide at the gate that pre-directs the material flow path before the material encounters the projections and recesses. This preliminary flow guidance ensures uniform material distribution throughout the mold cavity, preventing inhomogeneities and weld seams while maintaining the form-fitting projections and recesses for slippage resistance
2Manufacturing precision
If excessively high holding pressures are used to achieve acceptable part quality, then manufacturing precision is improved, but device complexity and stress on injection molds increase
Solution Approach 1:
The patent changes the flow distribution parameters by introducing a flow guide that optimizes material flow patterns. This allows achieving acceptable part quality with reduced holding pressures, thereby decreasing stress on injection molds and simplifying the overall device design while maintaining manufacturing precision
3Strength
If wall thicknesses are increased to raise maximum load capacity, then strength is improved, but productivity deteriorates due to longer process cycle times and increased material consumption
Solution Approach 1:
The patent applies local quality by providing localized reinforcement through projections and recesses that create form-fitting interfaces only where needed for torque transmission and slippage prevention. This allows maintaining high load capacity at critical interfaces while keeping overall wall thicknesses optimized for productivity, avoiding unnecessary material consumption and long cycle times
Data Source
AI summary
The present invention relates to a gear ring carrier part (10) for a two- or multi-component gear (11), the gear ring carrier part (10) having a circular ring section (12) rotating in the circumferential direction about an axis of rotation (A), a gear ring (14) arranged radially on the outside of the circular ring section (12), and an extension (16) extending radially inward from the circular ring section (12), the extension (16) having a first extension face (30) and a second extension face (32), a number of first ribs (34) and an equal number of first pockets (36) being arranged on the first extension face (30), and/or a number of second ribs (38) and an equal number of second pockets (40) being arranged on the second extension face (30), the first ribs (34) and the first pockets (36) and/or the second ribs (38) and the second pockets (40) each extending radially and being arranged adjacent to one another in the circumferential direction. The invention also relates to a two-component or multi-component gear (11) with such a gear ring carrier part (10).