Injection-Molded Worm Gear Support Ring for Steering Wear Control

The support ring is segmented into multiple support webs that radially penetrate the gear rim, dividing the force transmission path into multiple discrete load-bearing elements. This segmentation allows for more uniform distribution of contact forces across the tooth flanks, preventing concentration of stress at single points and thereby reducing rapid abrasion while maintaining connection strength.

The support webs are strategically positioned to radially penetrate the gear rim at specific locations, creating localized reinforcement zones where force distribution is most needed. This local quality approach ensures that the structural support is provided exactly where the engagement forces are applied, optimizing both connection strength and wear resistance without requiring uniform reinforcement throughout the entire gear rim.

The worm gear combines the metal hub with a plastics material gear rim enhanced by the injected support ring structure. This composite construction allows the metal hub to withstand shock-type stress from maximum torque while the plastics gear rim provides smooth engagement surfaces. The support webs act as a reinforcing interface between these materials, enabling the gear to transmit higher torques without excessive complexity.

The support webs extend radially through the gear rim, adding a third dimension to the force distribution mechanism. Instead of relying solely on the two-dimensional contact surface between worm and gear, the radial penetration of support webs creates a three-dimensional load path that distributes shock-type stresses more effectively throughout the gear structure, enhancing torque transmission capacity.

The injection-molding process replaces traditional mechanical assembly methods with a chemical bonding approach. The support ring is injected as molten material that chemically bonds to both the hub and gear rim in a single operation, eliminating the need for separate mechanical fastening operations. This substitution of chemical bonding for mechanical assembly simplifies manufacturing while maintaining the force-distributing geometry of the penetrating support webs.

The injection-molding process utilizes parameter changes in the plastics material, transitioning from molten state during injection to solidified state after cooling. This phase change allows the support ring to be formed with complex internal geometry including the radially penetrating webs, which would be difficult to machine or assemble mechanically. The material parameters are optimized during injection to ensure proper bonding and structural integrity.