Polymer Sprocket with Embedded Textile Reinforcement for High Torque
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Solution Overview
Problem
Conventional metal sprockets are inadequate for high torque applications due to durability issues with non-metal pulleys in smaller pitch sizes, which require more robust solutions for high torque demands.
Innovation Solution
Development of high torque sprockets made from castable polymer materials with embedded textile reinforcements, such as nylon, carbon cordage, or aramid, that are devoid of metal structures, and can engage bushings like QD or taper-lock bushings, providing a continuous toothed structure and optional flanges for enhanced strength and compatibility with various belt types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metal sprockets are used for high torque applications, then durability and strength are improved, but weight increases and corrosion resistance deteriorates
Solution Approach 1:
The sprocket combines a polymeric matrix material with embedded textile reinforcement layers to create a composite structure that achieves metal-level strength and durability while maintaining the weight advantages of non-metallic materials. The textile reinforcement provides tensile strength to resist hoop stresses generated during high torque operation.
2Weight of moving object
If non-metal pulleys are used to reduce weight, then weight decreases, but durability and torque capacity worsen for high torque applications
Solution Approach 1:
The invention transforms a lightweight non-metal pulley into a high-torque-capable component by embedding textile reinforcement within a polymeric matrix, creating a composite structure that simultaneously achieves low weight and high durability for demanding applications.
Solution Approach 2:
The textile reinforcement is strategically positioned within the sprocket body to provide localized strength where hoop stresses are generated during operation, ensuring durability is improved precisely where needed for high torque capacity.
3Object-affected harmful factors
If metal structures are eliminated from the sprocket design, then corrosion resistance improves, but manufacturing precision and structural integrity may worsen
Solution Approach 1:
The invention changes the material parameters by using a polymeric matrix combined with textile reinforcement, achieving corrosion resistance comparable to or exceeding metal while maintaining structural integrity through the composite architecture and proper material selection.
Data Source
AI summary
A high torque sprocket includes a body defining an outer periphery and a hub section defining an inner surface for engaging a bushing. A continuous toothed structure is disposed on the outer periphery of the body, and a textile reinforcement embedded in the body adjacent the inner surface of the hub section. The body is formed of a castable polymer material. In some cases, one or two optional flanges are disposed on side(s) of the body immediately adjacent the continuous toothed structure, in some aspects, a textile reinforcement may be embedded in a surface of the flange(s) immediately adjacent the continuous toothed structure. In some aspects, the high torque sprocket further includes a textile reinforcement embedded in the continuous toothed structure outer surface, and the textile reinforcement is selected from nylon, cotton, aramid, PTFE, and mixtures thereof.