Polymer-Coated Metal Gear Teeth for Torque and NVH Balance
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Solution Overview
Problem
Conventional worm gear systems with plastic teeth face durability limitations as customer demand for output torque increases, necessitating a more robust gear solution.
Innovation Solution
A metallic gear hub with smaller metallic gear teeth that are co-planar and non-orthogonal to the axis, coated with a polymer layer to form the final gear teeth size, enhancing both durability and noise, vibration, and harshness (NVH) performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If plastic teeth are used in worm gear systems, then noise, vibration and harshness (NVH) performance is improved, but durability is limited
Solution Approach 1:
The patent applies composite materials by combining a metallic core structure with a polymer outer layer. The metallic core (steel or aluminum) provides durability and torque capacity, while the polymer layer (molded or coated) provides NVH performance. This composite construction resolves the contradiction by integrating the advantages of both materials: the metal substrate ensures structural integrity and load-bearing capacity, while the polymer exterior reduces noise and vibration.
2Object-affected harmful factors
If all-gear teeth are made from plastic, then NVH performance is improved, but the gear solution becomes insufficient for increased torque demands
Solution Approach 1:
The patent uses composite materials with a metallic core providing high strength for torque capacity and a polymer layer providing NVH performance. The metal substrate (steel or aluminum) with appropriate yield strength handles the increased torque demands, while the polymer coating maintains quiet operation.
Solution Approach 2:
The patent applies local quality by giving different parts of the gear tooth different material properties. The core region uses metal for strength and torque capacity, while the outer surface uses polymer for NVH performance. This spatial differentiation of material properties allows the gear to simultaneously handle high torque and maintain low noise levels.
3Reliability
If a metallic gear hub with metallic teeth is used, then durability and torque capacity are improved, but NVH performance deteriorates
Solution Approach 1:
The patent resolves this contradiction by creating a composite structure where a metallic gear hub with metallic teeth is coated or molded with a polymer layer. The metal core maintains durability and torque capacity, while the polymer exterior reduces noise and vibration, achieving both high reliability and good NVH performance simultaneously.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a robust gear system capable of handling increased torque demands while maintaining satisfactory NVH performance, thereby addressing the durability limitations of conventional plastic teeth worm gear systems.
Implementation Method 1
dipping the metallic gear teeth in a fluidized bed of polymer powder and forming a polymer coating on the metallic gear teeth
Data Source
AI summary
Embodiments of a system, method and apparatus for a gear are disclosed. For example, a metallic gear hub can include an axis of rotation and metallic gear teeth. The metallic gear teeth can be smaller than a final gear teeth size of the gear. The metallic gear teeth can be co-planar with the axis. In addition, the metallic gear teeth can be non-orthogonal to the axis. A polymer layer can be located on the metallic gear teeth to form polymer gear teeth on the metallic gear teeth. The polymer gear teeth can form the final gear teeth size of the gear.