Stacked Steel Plate Gear Sleeve for Lightweight Resin-Coupled Steering Gears
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Solution Overview
Problem
There is a limit to the degree of weight reduction that can be achieved in metal cores used in speed reducers, due to the limitations of equipment and processing methods available for weight reduction processes.
Innovation Solution
A gear is designed with an annular sleeve made of stacked steel plates and an annular tooth portion formed by injection molding, which covers part of the sleeve, allowing for increased weight reduction by processing each plate before stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a weight reduction process is performed on the metal core by hollowing out or shaving, then the weight of the metal core is reduced, but the degree of weight reduction is limited due to equipment capacity and processing method limitations
Solution Approach 1:
The metal core is divided into multiple thin-walled annular sections that are stacked together. Each section can be independently processed with standard equipment, avoiding the need for heavy-duty equipment to process a solid core. The sections are connected by rib portions that provide structural integrity while maintaining weight reduction.
Solution Approach 2:
The invention transitions from processing a three-dimensional solid core to processing two-dimensional thin-walled annular sections. By flattening the structure into thin sections that can be stacked, the processing complexity is reduced to levels achievable with conventional equipment, while still achieving significant weight reduction.
2Weight of moving object
If the metal core is made lighter by hollowing out or shaving, then the weight is reduced, but the strength and coupling capacity between the metal core and synthetic resin member may be compromised
Solution Approach 1:
The metal core is segmented into multiple thin-walled annular sections with rib portions connecting them. These ribs create multiple coupling interfaces with the synthetic resin member, distributing the coupling load across multiple points rather than relying on a single solid core interface.
Solution Approach 2:
The invention creates a composite structure where thin-walled metal sections are stacked and connected to form a lightweight yet strong metal core. The combination of multiple thin sections with rib connections provides both weight reduction and sufficient coupling strength for the synthetic resin member.
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
This approach enables a more significant weight reduction of the sleeve compared to traditional methods, while also enhancing the strength of the coupling between the sleeve and the tooth portion.
Implementation Method 1
The sleeve (50) is a stacked body including a plurality of annular steel plates (70) stacked in an axial direction of the sleeve (50). In adjacent steel plates (70), a plate protrusion (74) of one steel plate (70) is fitted into a plate recess (75) of the other steel plate (70).
Implementation Method 2
an annular tooth portion (60) provided by injection molding to cover a part of the sleeve (50)
Data Source
AI summary
A gear includes an annular sleeve and a tooth portion provided by injection molding to cover a part of the sleeve. The sleeve is a stacked body including a plurality of annular steel plates stacked in an axial direction of the sleeve.