Patent Description:
Gears are used in various machinery. Typical applications of the gears include industrial robots, automobiles, various large or small industrial machines, precision equipments, toys, and the like. In particular, the gears for the industrial robots, the gears for the industrial machines, the gears for the automobiles, and the like are required to have a high strength. In general, metal gears are used as such gears. For example, Patent Document <NUM> discloses a gear entirely made of a steel.

The <CIT> discloses an annular gear component that comprises tooth portions, groove portions and a support portion, wherein the tooth portions are located on an annular outer surface of the support portion and the groove portions are located on an annular inner surface of the support portion, and wherein each groove bottom of each groove portion is located below and inside the tooth root circle.

<CIT> discloses a toothed transmission pulley comprising a surface ring formed of metal strip shaped to define the requisite teeth and recesses therebetween, and a rigid inner body moulded from plastics material whose outer surface conforms to the inner surface of sail metal ring.

<CIT> shows a gear comprising a hub adapted to rotate about an axis, the hub being made of a hub material, and a crown attached to the hub and made of a crown material that is softer than the hub material, the crown having a sprocket teeth adapted to engage with teeth on an endless drive member such as a timing belt.

With recent energy saving promotion, weight reduction of various components is required for the reduction of the energy consumption. Gears are also not exception, and lighter gears are required. Moreover, in the industrial robots, weight reduction of the gears has been required from the viewpoint in that weight reduction of the gears used in the joints is effective for the smooth movement of the robots. In the automobile field, the demand for the electric vehicles is increasing, and the weight reduction of various components of the vehicles is promoted in order to increase the travel distance.

The present inventor studied the reduction of the weight of the gear, and has found that the weight can be reduced by using a resin material for the gear. However, it is difficult to increase the strength of the gear formed of the resin material. Low strength can cause problems in reliability and safety of the gears, especially when the gears are subjected to high loads. For example, if the strength of the gear is low in a surgical robot or the like, there is a concern that an error may occur in the movement of the robot. Since a transmission gear or the like of the automobiles receives a large torque, a trouble may be caused if the strength is low.

An object of the present invention is to provide a gear that enables weight reduction thereof while maintaining a high strength. That is, the object is to provide a lightweight gear having a sufficient strength.

The present inventor has conducted extensive studies and found that at least an outer peripheral portion and a central portion of a gear are formed of a metal, and at least a part of the other portion is formed of a resin material, and thereby reducing a weight of the gear while maintaining a strength of the gear, so that the inventor has reached the present invention.

According to a first aspect of the present invention, there is provided a gear which has a wholly annular metal outer peripheral portion that is a gear component according to a second aspect of the present invention and a metal central portion wherein a resin portion is present between the outer peripheral portion and the central portion, and connects the metal outer peripheral portion and the metal central portion.

According to a second aspect of the present invention, there is provided an annular metal gear component including a plurality of tooth portions and a support portion that supports the plurality of tooth portions wherein.

This gear component can be used in manufacturing the gear according to the present invention, and the gear component functions as the metal outer peripheral portion.

According to the present invention, the strength of the gear can be ensured by forming an outer side of the gear, i.e. the outer peripheral portion, and an inside of the gear, i.e. the central portion with the metal, and the weight of the gear can be reduced by forming the other portion with the resin material. Therefore, according to the present invention, the gear that achieves both of its high strength and its light weight can be provided.

Hereinafter, the embodiments of the gear according to the present invention will be further described with reference to the drawings. It is noted that the shapes and arrangement and the components for the gears of those embodiments are not limited to the illustrated examples.

<FIG> schematically shows a perspective view of the gear 1a not according to the invention, <FIG> schematically shows a perspective view of a metal part of the gear 1a not according to the invention, and <FIG> schematically shows a perspective view of a resin part of the gear 1a not according to the invention.

As shown in <FIG>, the gear 1a not according to the present invention includes an annular outer peripheral portion <NUM>, an annular central portion <NUM>, and a resin portion <NUM> located between the outer peripheral portion <NUM> and the central portion <NUM>. The gear of the present invention can have a high strength because the outer peripheral portion <NUM> and the central portion <NUM> are formed of a metal. Such high strength allows for use of the gear in mechanical devices where strength is required, for example, transmissions in the automobiles. In addition, since the region between the outer peripheral portion <NUM> and the central portion <NUM> is made of a resin instead of a metal, the weight of the gear can be reduced, which can contribute to the weight reduction of a mechanical device using the gear.

The outer peripheral part <NUM> described above is made of a metal. The metal constituting the outer peripheral portion is preferably a metal having an excellent strength, for example, iron or an alloy of iron, for example, steel. In a preferred embodiment, the outer periphery <NUM> is formed of a steel, preferably S45C.

The outer peripheral portion <NUM> described above has tooth portions <NUM> of the gear on its annular outer surface. That is, the outer peripheral portion <NUM> described above is a gear component having the tooth portions <NUM> and a support portion <NUM> that supports the tooth portions <NUM>. It is noted here that the "support portion" refers to a part between the annular outer surface <NUM> and the annular inner surface <NUM>. The "annular outer surface" refers to a plane defined by the tooth root circle <NUM> (i.e. an imaginary plane of the outer peripheral portion which plane includes a tooth root <NUM> defined by the adjacent tooth portions between them), and the "annular inner surface" refers to an inner surface of the outer peripheral portion <NUM> when there is no convex portion or protruding portion which will be described below. That is, the support portion <NUM> corresponds to an annular portion <NUM> defined by the annular outer surface <NUM> and the annular inner surface <NUM>.

As to the outer peripheral portion <NUM>, the number of the tooth portions <NUM>, a pitch of the tooth portions, a height of the tooth portions (tooth depth), a width of the tooth portions, and the like constituting the gear can be appropriately set according to the intended application of the gear.

The thickness of the support portion <NUM> is not particularly limited and can be appropriately selected depending on the application of the gear. For example, the thickness may be not less than <NUM> and not more than <NUM>, not less than <NUM> and not more than <NUM>, or not less than <NUM> and not more than <NUM>. By increasing the thickness of the support portion, the strength of the gear can be further increased. Further, by making the thickness of the support portion smaller, the weight of the gear can be further reduced.

0001The width "w1" of the outer peripheral portion <NUM> (a length in the axial direction of the gear) is not particularly limited, and can be appropriately selected depending on the application of the gear. For example, it may be not less than <NUM> and not more than <NUM>, not less than <NUM> and not more than <NUM>, not less than <NUM> and not more than <NUM>, or not less than <NUM> and not more than <NUM>.

0002The diameter of the annular outer surface of the outer peripheral portion <NUM> is not particularly limited and can be appropriately selected depending on the application of the gear. For example, it may be not less than <NUM> and not more than <NUM>, not less than <NUM> and not more than <NUM>, not less than <NUM> and not more than <NUM>, or not less than <NUM> and not more than <NUM>.

The outer peripheral portion <NUM> described above has a convex portion <NUM> on its annular inner surface. In the present embodiment, the convex portions <NUM> protrude toward the center of the gear, and are provided uniformly over the entire width of the outer peripheral portion <NUM>, and they are provided for example, at the same interval or at the same angle. By providing the convex portions on the annular inner surface of the outer peripheral portion, it is possible to prevent the outer peripheral portion <NUM> from moving as to the resin portion <NUM> in the circumferential direction. This makes it possible to rotate the gear with a stronger force.

<NUM> In the present embodiment, the convex portions <NUM> are provided over the entire width of the outer peripheral portion <NUM> as shown in the drawing, but they are not limited to as shown, and they may be provided over a part of the width of the gear, for example, not less than <NUM>% and not more than <NUM>%, or not less than <NUM>% and not more than <NUM>% of the width of the gear.

In the present embodiment, three of the convex portions <NUM> are provided evenly on the annular inner surface of the outer peripheral portion <NUM>, that is, at an interval of every <NUM>°. By thus providing a plurality of the convex portions and arranging them evenly, it is possible to more efficiently prevent the circumferential portion <NUM> from moving as to the resin portion <NUM> in the circumferential direction. It is noted here that providing the convex portions "evenly" means that when a straight line is drawn from the center of each convex portion to the center of the outer peripheral portion, the angles formed by two adjacent straight lines are all substantially the same.

<NUM> It is noted that in the present invention, the number of the convex portions is not particularly limited, and it may be preferably not less than <NUM> and not more than <NUM>, more preferably not less than <NUM> and not more than <NUM>, still more preferably not less than <NUM> and not more than <NUM>, and further more preferably three. It is noted that the convex portion is not an essential component, and may not be present.

0005The height of the convex portion <NUM> described above is not particularly limited, but may be preferably not less than <NUM> % and not more than <NUM> %, and for example not less than <NUM> % and not more than <NUM> % of the distance from the center of the outer peripheral portion <NUM> (i.e. the center of the ring defining the outer peripheral portion <NUM>) to the annular inner surface of the outer peripheral portion <NUM>.

In one embodiment, the height of the convex portion <NUM> may be for example, not less than <NUM> and not more than <NUM>, not less than <NUM> and not more than <NUM>, not less than <NUM> and not more than <NUM>, or not less than <NUM> and not more than <NUM>. By increasing the height of the convex portion, it is possible to more efficiently prevent the outer peripheral portion <NUM> from moving as to the resin portion <NUM> in the circumferential direction. Further, by making the height of the convex portion lower, an increase in the weight of the gear due to the formation of the convex portion can be suppressed.

The outer peripheral portion <NUM> described above has a wall-shaped (or corrugated-shaped or ridge-shaped) protruding portion <NUM> on its annular inner surface along the circumferential direction of the gear. In the present embodiment, the protruding portion <NUM> protrudes toward the center of the gear, and is provided over the entire circumference of the annular inner surface of the outer peripheral portion <NUM> or partially provided at the same interval or angle as illustrated. By providing the protruding portion <NUM> on the annular inner surface of the outer peripheral portion, it is possible to prevent the outer peripheral portion <NUM> from moving as to the resin portion <NUM> in the width direction of the gear.

In the present embodiment, totally three of the protruding portions <NUM> are provided partially in the circumferential direction on the annular inner surface of the outer peripheral portion <NUM>, but the present invention is not limited to this embodiment. For example, a plurality of the protruding portions <NUM> may extend with separated in the same interval or angle over a part of the circumference of the annular inner surface of the outer peripheral portion <NUM>, for example, over not less than <NUM>% and not more than <NUM>%, over not less than <NUM>% and not more than <NUM>%, or over not less than <NUM>% and not more than <NUM>% of the circumference of the annular inner surface of the outer peripheral portion. Further, the protruding portion is not an essential component, and may not necessarily be present.

0006The height of the protruding portion <NUM> is not particularly limited, but may be preferably not less than <NUM>% and not more than <NUM>%, and for example, not less than <NUM>% and not more than <NUM>% of the distance from the center of the outer peripheral portion <NUM> to the annular inner surface of the outer peripheral portion <NUM>. In one embodiment, the height of the protruding portion <NUM> may be, for example, not less than <NUM> and not more than <NUM>, not less than <NUM> and not more than <NUM>, not less than <NUM> and not more than <NUM>, or not less than <NUM> and not more than <NUM>. By increasing the height of the protruding portion, it is possible to more efficiently prevent the outer peripheral portion <NUM> from moving as to the resin portion <NUM> in the width direction of the gear. Further, by making the height of the protruding portion lower, it is possible to suppress the increase in the weight of the gear due to the formation of the protruding portion.

0007The width of the protruding portion <NUM> is not particularly limited as long as it is smaller than the width of the outer peripheral portion <NUM>, but a width w2 (a length in the axial direction of the gear) of the protruding portion may be not less than <NUM>% and not more than <NUM>%, and for example not less than <NUM>% and not more than <NUM>%, or not less than <NUM>% and not more than <NUM>% of the width of the outer peripheral portion <NUM>. In one embodiment, the width of the protruding portion <NUM> may be, for example, not less than <NUM> and not more <NUM>, not less than <NUM> and not more than <NUM>, not less than <NUM> and not more than <NUM>, or not less than <NUM> and not more than <NUM>. By making the width of the protruding portion <NUM> wider, it is possible to more effectively prevent the displacement of the outer peripheral portion <NUM> as to the resin portion <NUM> in the width direction. Further, by making the width of the protruding portion <NUM> narrower, it is possible to suppress the increase in the weight of the gear due to the formation of the protruding portion.

In the present embodiment, the protruding portion <NUM> is provided as a single ridge in the circumferential direction of the annular inner surface of the outer peripheral portion <NUM>, but the present invention is not limited to this. For example, not less than two or more, for example, two, three, or four ridges may be provided in parallel with each other (not necessarily with facing to each other). Increasing the number of the protruding portions <NUM> can prevent more effectively the displacement of the outer peripheral portion <NUM> as to the resin portion <NUM> in the width direction.

The central portion <NUM> described above is made of a metal. The metal constituting the central portion is preferably a metal having an excellent strength, and for example, iron or an alloy of iron, for example, a steel may be exemplified. In a preferred embodiment, the central portion <NUM> is formed of a steel, preferably S45C.

In a preferred embodiment, the metal material forming the central portion <NUM> is the same as the metal material forming the outer peripheral portion <NUM> as described above, and it is for example, a steel.

In the present embodiment, the central portion <NUM> is annular. Since the central portion <NUM> is annular, it becomes easy to ensure the strength of the gear.

The thickness of the central portion <NUM> is not particularly limited, but may be, for example, not less than <NUM> and not more than <NUM>, not less than <NUM> and not more than <NUM>, or not less than <NUM> and not more than <NUM>. By increasing the thickness of the central portion, the strength of the gear can be further increased. Further, by making the thickness of the central portion smaller, the weight of the gear can be further reduced.

The diameter of an annular outer surface of the central portion <NUM> is not particularly limited, but may be, for example, not less than <NUM> and not more than <NUM>, not less than <NUM> and not more than <NUM>, not less than <NUM> and not more than <NUM>, or not less than <NUM> and not more than <NUM>.

The central portion <NUM> described above may have a concave portion <NUM> on its annular outer surface. In the present embodiment, a hole may be provided instead of the concave portion <NUM> which hole passes through the ring portion of the central portion <NUM>. By providing the concave portion or the hole in the central portion <NUM>, the resin penetrates into the concave portion or the hole, and thereby preventing the central portion <NUM> from moving as to the resin portion <NUM> in the circumferential direction. This makes it possible to rotate the gear with a stronger force. It is noted that in <FIG>, the protruding portion <NUM> of the resin which is formed by the through-hole <NUM> and has a form corresponding to the through-hole is omitted to be shown.

In the present embodiment, four of the concave portions <NUM> are provided evenly on the ring of the central portion <NUM>, that is, four concave portions are formed at an interval of every <NUM>°. By providing a plurality of the concave portions and arranging them evenly in this way, it is possible to more efficiently prevent the central portion <NUM> from moving as to the resin portion <NUM> in the circumferential direction.

In the present invention, the number of the concave portions is not particularly limited, and may be preferably not less than one and not more than eight, more preferably not less than two and more more than six, and further preferably not less than two and not less than five. Further, the concave portion is not an essential component and may not be present. Further, the concave portion does not need to pass through the central portion <NUM> and may be provided as a depression.

The resin portion <NUM> described above is located between the outer peripheral portion <NUM> and the central portion <NUM>. In a conventional gear, a part corresponding to the resin portion of the gear of the present invention is also formed of a metal, so that the weight of the gear is large. On the other hand, the weight of the gear according to the present invention can be reduced by providing the resin portion as compared with the conventional gear.

The resin part <NUM> described above is made of a resin. As the resin constituting the resin portion is not particularly limited, but for example, a liquid crystal polymer (LCP), a polyphenylene sulfide resin (PPS), a polyetheretherketone resin (PEEK) and the like may be exemplified. When oil resistance and heat resistance are required, the PEEK is preferred as the resin.

The resin portion <NUM> has a ring form. The annular outer surface of the resin portion <NUM> has a shape corresponding to the shape of the annular inner surface of the outer peripheral portion <NUM>. The annular inner surface of the resin portion <NUM> has a shape corresponding to the shape of the annular outer surface of the central portion <NUM>. By making the annular outer surface and the annular inner surface of the resin portion correspond to the shapes of the annular inner surface of the outer peripheral portion <NUM> and the annular outer surface of the central portion <NUM>, respectively, the adhesions of the resin portion to the outer peripheral portion and also to the central portion are improved. Thus, the displacement of the resin portion as to the outer peripheral portion and the central portion can be prevented. Further, since no gap is formed between the resin portion <NUM> and the outer peripheral portion <NUM> or between the resin portion <NUM> and the central portion <NUM>, the strength of the gear is further improved.

<FIG> shows a perspective view of the gear 1b not according to the present invention, and <FIG> shows a schematic perspective view of a metal portion of the gear 1b not according to the invention.

As shown in <FIG> and <FIG>, the gear 1b of the present embodiment includes an annular outer peripheral portion <NUM>, an annular central portion <NUM>, connecting portions <NUM> which connect the outer peripheral portion <NUM> and the central portion <NUM>, and a resin part <NUM> located between the annular outer peripheral portion <NUM> and the central portion <NUM>. The gear 1b of the present embodiment has a higher strength by providing the connecting portions <NUM> connecting the outer peripheral portion <NUM> and the central portion <NUM>.

The connecting part <NUM> described above is preferably formed of a metal. The metal constituting the connecting portion is preferably a metal having an excellent strength, and for example, iron or an alloy of iron, for example, a steel. In a preferred embodiment, the connecting portions <NUM> are formed from a steel, preferably S45C.

In a preferred embodiment, the metal material forming the connecting portion <NUM> is the same as the metal material forming the outer peripheral portion <NUM> and the central portion <NUM> as described above, and preferably a steel.

The connecting portion <NUM> described above may be separately formed and joined to the outer peripheral portion <NUM> and the central portion <NUM> or may be formed integrally with the outer peripheral portion <NUM> and the central portion <NUM>. The connecting portion <NUM> is preferably formed integrally with the outer peripheral portion <NUM> and the central portion <NUM> because the strength can be further increased.

In the present embodiment, the three connecting portions <NUM> are provided evenly on the annular inner surface of the outer peripheral portion <NUM>, that is, at an interval of every <NUM>°. By providing a plurality of the connecting portions and arranging them evenly in this way, the strength of the gear can be further increased.

In the present invention, the number of the connecting portions is not particularly limited, but may be preferably not less than <NUM> and not more than <NUM>, more preferably not less than <NUM> and not more than <NUM>, still more preferably not less than <NUM> and not more <NUM>, and most preferably three.

The shape of the connecting portion <NUM> described above is not particularly limited, but it is preferable that a part close to the central portion <NUM> is relatively thicker and a part close to the outer peripheral portion <NUM> is relatively thinner. For example, as shown in the drawing, it is preferable that a part on the side of the central portion <NUM> has a relatively larger width and a part on the side of the outer peripheral portion <NUM> has a relatively smaller width. It is noted that the width of the connecting portion means a length or width in a direction perpendicular to the axis of the gear and also orthogonal to the radial direction of the gear. By adopting such a shape of the connecting portion, a high strength can be secured while reducing the volume occupied by the connecting portion, that is, increasing the effect of the weight reduction.

In a preferred embodiment, a planar shape of the connecting portion <NUM> is preferably a substantially trapezoidal shape in which a vertex of an approximately isosceles triangle is cut off. With regard to the connecting portion <NUM>, a ratio of a width of the side of the outer peripheral portion (that is, a width of an upper base of the substantially trapezoidal shape) to a width of the side of the central portion <NUM> (that is, a width of a lower base of the substantially trapezoidal shape) is not particularly limited, but it is in the range from <NUM>:<NUM> to <NUM>:<NUM>, preferably in the range from <NUM>:<NUM> to <NUM>:<NUM>, and more preferably in the range from <NUM>:<NUM> to <NUM>:<NUM>. It is noted that the width of the side of the outer peripheral portion of the connecting portion <NUM> refers to a distance between two contacts formed by two side surfaces (that is, the two substantially trapezoidal legs) of such connecting portion respectively with the annular inner surface of the outer periphery portion in a planar shape of the connecting portion (that is, substantially the trapezoidal shape). Similarly, the width of the connecting portion <NUM> on the side of the central portion means a distance between two contacts formed by the two side surfaces (i.e. two substantially trapezoidal legs) of the connecting portion respectively with an annular outer surface of the central portion in the planar shape of the connecting portion (that is, substantially the trapezoidal shape).

In the present embodiment, the outer peripheral portion <NUM>, the central portion <NUM>, and the connecting portions <NUM> constitute a single component. Therefore, the present invention also provides a gear component including the tooth portions, the support portion which supports the tooth portion, the central portion, and the connecting portions which connect the support portion and the central portion, wherein the support portion has an annular shape, and the gear component is entirely made of the metal.

In the present embodiment, the other portions except the connecting portions <NUM>, the outer peripheral portion <NUM>, the central portion <NUM>, and the resin portion <NUM> may be the same as those of the gear 1a.

Further, at least one of the features of the gear 1a of the above-described embodiment and a gear 1c which will be described below may be incorporated in the gear 1b of the present embodiment if necessary.

<FIG> shows a perspective view of the gear 1c according to the present embodiment, and <FIG> shows a schematic perspective view of a metal part of the gear 1c, that is, a gear component of the gear 1c. <FIG> schematically shows an enlarged plan view of a part of an outer peripheral portion <NUM> of the gear of <FIG>.

As shown in <FIG> and <FIG>, the gear <NUM> c of the present embodiment comprises an annular outer peripheral portion <NUM>, an annular central portion <NUM>, and a resin portion <NUM> located between the outer peripheral portion <NUM> and the central portion <NUM>. The outer peripheral portion <NUM> of the present embodiment has groove portions <NUM> along the gear width direction (in other words, the gear thickness direction, that is, the direction of the arrow A in <FIG>) on its annular inner surface <NUM>. The resin portion <NUM> extends also inside the groove portions <NUM>. By providing the groove portions <NUM> on the annular inner surface <NUM> of the support portion <NUM> of the outer peripheral portion <NUM>, it is possible to prevent the outer peripheral portion <NUM> from moving as to the resin portion <NUM> in the circumferential direction. This makes it possible to rotate the gear with a stronger force. It is preferable that a large number of the groove portions <NUM> exist over the entire width of the periphery of the outer peripheral portion <NUM> as shown in the drawing, that is, along entirely a width of the outer peripheral portion, but they may also exist along a part of the width.

The gear 1c has a plurality of, usually a large number of tooth portions <NUM> uniformly over the entire circumference of the annular outer surface <NUM>, that is, at an every equal angle with respect to the center of the annular ring. The number of the tooth portions can be appropriately selected depending on the application of the gear, and may be, for example, at least <NUM>, at least <NUM>, at least <NUM> or more. A plurality of the groove portions <NUM> are present evenly over the entire circumference of the annular inner surface <NUM>, that is, at an every equal angle with respect to the center of the annular ring. The number of the groove portions can be appropriately selected according to the application of the gear, and the number of the tooth portions may be for example, at least <NUM>, at least <NUM>, at least <NUM> or more. The number of the tooth portions and the number of the groove portions are not necessarily the same as described below, but in one preferred embodiment they are the same, and there is one groove potion inside each tooth portion as shown.

The cross-sectional shape of the groove portion <NUM> described above (cross-sectional shape in a plane perpendicular to the width direction of the gear) is preferably a shape which follows the cross-section of the tooth portion <NUM> of the gear (that is, substantially geometrically similar to the cross-sectional shape of the tooth portion) with respect to the plan view in <FIG>. However, in other embodiment, it is preferable that the shape of the tooth portion is one which does not follow the shape of the tooth portion, and for example it is preferable that the shape is substantially a tetragon such as a rectangle. When the cross section of the groove portion follows the cross section of the tooth portion of the gear, the strength of the gear may be insufficient depending on the application. However, when the generally tetragon shape is employed so that a thickness of the tooth portion is ensured, the strength of the gear is relatively improved. Further, by making the shape approximately tetragon, it is possible to further prevent the circumferential direction sliding between the outer peripheral portion <NUM> and the resin portion <NUM>.

<FIG> is referred to which is a plan view schematically showing a part of the outer peripheral portion <NUM> with enlarged. The groove portion <NUM>, particularly its cross-section may have any suitable shape (one of such cross-section is shown as hatched in <FIG>). For example, the cross-section is substantially rectangle shape having a frontage length "a1", a groove bottom length "a2" and a depth length "b" as shown. It is noted that the cross section means a section perpendicular to the width direction "A" of the gear. However, the portion <NUM> corresponding to the annular inner surface <NUM> is in an open state (that is, such portion is open, and the side (or surface) <NUM> is imaginary). The cross-sectional shape of the groove portion <NUM> may be substantially a tetragon, in which case, it is for example, a rectangle (in case of a square: a1=a2=b, and in case of a rectangular: a1=a2≠b), or a trapezoid (a1<a2, and "b" is arbitrary, and particularly, isosceles trapezoidal). In addition to such a shape, the cross-sectional shape of the groove portion <NUM> may be a triangle ("a1" is arbitrary, and a2 ≒ <NUM>), a semicircle, a semi-ellipse, or the like.

In the embodiment shown in <FIG>, the cross section of the groove portion <NUM> is substantially rectangular (a1 = a2 < b). In a preferred embodiment, the cross-section of the groove portion <NUM> is line-symmetric, and the groove portion <NUM> is arranged in the tooth <NUM> such that the axis <NUM> of the tooth portion <NUM> and the axis <NUM> of the groove portion <NUM> coincide. This is advantageous because the tooth flanks <NUM> and <NUM> on both sides of the tooth portion <NUM> have the same strength. When the cross section of the groove portion has a corner portion, that portion may be chamfered.

The groove portion <NUM> described above is preferably formed in the annular inner surface <NUM> so as to correspond to the position where the tooth portion <NUM> of the outer peripheral portion <NUM> of the gear is present (i.e. such that the groove portion <NUM> is located inside the tooth portion <NUM>). In other words, the axis of symmetry of the tooth portion and the axis of symmetry of the groove portion are configured to coincide with each other as described above, and as a result, the groove portion <NUM> faces to the tooth portion as illustrated.

The present invention does not exclude an embodiment in which the groove portion <NUM> is formed inside the location where the tooth root <NUM> exists (that is, an embodiment in which the symmetry axis of the groove portion is located in the middle of the symmetry axes of the adjacent tooth portions). In such an embodiment, the thickness "t" of the annular portion <NUM> (corresponding to the support portion <NUM> as described above) of the outer peripheral portion <NUM> is reduced by the depth "b" of the groove portion (that is, the depth length "b"), as a result of which the strength of the outer peripheral portion <NUM> may be reduced. This reduction of the strength means that the thickness "t" of the annular portion <NUM> is sacrificed. In some cases, the strength is insufficient, so that it is not necessarily preferable. Therefore, in order to compensate for the reduction of the strength, it is necessary to increase the thickness "t" of the annular portion <NUM> of the outer peripheral portion. Increasing the thickness increases an amount of metal in the outer peripheral portion <NUM>, and eventually increases the weight of the gear, which may not be preferable in some cases.

On the other hand, with respect to the outer peripheral portion <NUM>, in the portion where the tooth portion <NUM> exists, the tooth portion <NUM> can function as if it were a part of the annular portion as to the strength of the outer peripheral portion <NUM>. Specifically, even if the thickness of the annular portion <NUM> is reduced, there is the tooth portion <NUM> which can also function as the annular portion, so that this can suppress or compensate for the decrease in the strength of the outer peripheral portion. Therefore, in the case where the groove portion <NUM> is formed at the location which corresponds to the location of the tooth portion <NUM> as described above, even if a part of the thickness "t" of the annular portion <NUM> is used for the depth "b" of the groove portion, the strength of the outer peripheral portion is ensured since there still exist a balance of the annular portion outside the groove potion and also the tooth portion outside the balance.

Further, in an embodiment in which the depth "b" of the groove portion <NUM> is larger than the thickness "t" of the annular portion <NUM> (this embodiment corresponds to an "intruding" embodiment described below), an amount of the metal forming the outer peripheral portion is reduced, so that the weight of the gear can be preferably reduced. In this case, since the substantially sufficient tooth portion <NUM> exists outside the groove portion, the strength of the outer peripheral portion <NUM> can be appropriately secured. In this embodiment, by making at least one of the groove width, the groove bottom, and the groove depth (or the degree of intruding) of the groove portion as large as possible, the outer peripheral portion can be made lighter while securing appropriate strength of the outer peripheral portion. As will be described later, when the number of the groove portions is increased, the force acting on each groove portion can be reduced, so that the groove portions can be configured accordingly. As a result, at least one of the groove width and the groove bottom and the groove depth (or the degree of intruding) can be made larger.

When the groove portions are formed corresponding to the tooth portions as described above, the expense of the thickness of the annular portion can be minimized or compensated, so that the decrease in the strength of the outer peripheral portion <NUM> due to the formation of the groove portions can be suppressed as much as possible. Since the formation of such groove portions does not require the thickness "t" of the annular portion of the outer peripheral portion <NUM> to be increased, it is effective in reducing the weight of the outer peripheral portion and hence the gear.

By forming the groove portions <NUM> so as to correspond to the tooth portions <NUM> as described above, it is possible to form the groove portions while suppressing or compensating for the decrease in the strength of the outer peripheral portion <NUM>, and/or it is possible to make the depth of the groove portions longer (compared to the case where the groove portions <NUM> are formed inside the locations where the tooth roots are present), so that it is possible to efficiently prevent the circumferential movement between the outer peripheral portion <NUM> and the resin portion <NUM>. Conversely, the formation of the groove portions can avoid the formation of a part of the annular portion <NUM> of the outer peripheral portion <NUM> which part has an excessively small thickness "t", and thereby facilitating an appropriate strength to be maintained.

In a preferred embodiment, as shown in <FIG>, the outer peripheral portion is formed such that the groove portions <NUM> intrude into the tooth portions <NUM>, and the resin portion <NUM> is formed so that the resin penetrates into such groove portions <NUM>. In this specification, the embodiment of "intruding" means that the positions of the groove bottoms <NUM> of the groove portions <NUM> are located outside the root circle <NUM> (shown with a dotted line in <FIG>) of the tooth portions <NUM> of the gear. The degree of intruding may be expressed by a ratio of a distance "d" by which the groove bottom <NUM> extends beyond the root circle <NUM> (which is referred to as "intruding length") to a height of the tooth portion <NUM>, that is, a tooth depth "h" (which is equal to (diameter "da" of tip circle <NUM> - diameter "df" of root circle <NUM>) x <NUM>), and such ratio is referred to as "intrusion degree". That is, the intrusion degree = "d/h". If the intrusion degree is too large, the depth "b" of the groove portion becomes excessively large, so that the distance between the groove portion and the tooth tip <NUM> or the tooth flank <NUM> or <NUM> (substantially the thickness of the outer peripheral portion) becomes too small, which may lead to insufficient strength of the outer periphery portion.

Further, when the bottom length "a2" of the groove potion is excessively long, the thickness of a part of the tooth portion <NUM> adjacent to the groove portion (that is, the distance between the tooth flank <NUM> or <NUM> and the groove portion <NUM>) becomes too small, the strength of the outer peripheral potion may be reduced similarly. In this regard, it is preferable to consider a ratio of the groove bottom length "a2" to the tooth thickness of the tooth portion <NUM>, particularly a chordal tooth thickness "s" based on a reference circle <NUM> (shown with a dashed-dotted line in <FIG>). Such ratio (= 2a/s) is referred to as a "groove bottom length ratio" of the tooth portion.

In a particularly preferred embodiment of the present invention, the cross-sectional shape of the groove portion <NUM> is an isosceles trapezoid (wherein a1 > a2). This embodiment will be described in detail with reference to <FIG>, which schematically shows a part of a single tooth portion in a plan view. In the shown embodiment, the tooth portion <NUM> has a tip <NUM> as a part of a tip circle <NUM>, and on both sides thereof, tooth flanks <NUM> and <NUM> rising from a root circle <NUM>. As shown in the drawing, the tip of the groove portion <NUM>, that is, the groove bottom <NUM> is located outside the root circle <NUM>. That is, the groove portion is in the state of being intruding into the tooth portion.

It is noted that the both end portions of each of the tooth flanks (<NUM> and <NUM>) of the tooth portion <NUM> as well as the trapezoidal leg portions (<NUM> and <NUM>) of the groove portion are chamfered. In other words, both end portions of the tooth tip <NUM> and the groove bottom <NUM> are chamfered. When chamfered as shown, the distance between intersections p1 and p2 of the substantially straight extension of the trapezoidal leg portions (<NUM> and <NUM>) and the substantially straight extension of the groove bottom <NUM> corresponds to the groove bottom length "a2". The distance between intersections p3 and p4 between the circle <NUM> defining the annular inner surface and the extension of the leg portions (<NUM> and <NUM>) corresponds to the frontage length "a1". The distance between the groove bottom <NUM> and the straight line connecting the intersections "p5" and "p6" between the extension lines of the tooth flanks <NUM> and <NUM> and the root circle <NUM> (the intersections are referred to as "root points") corresponds to a length by which the groove bottom <NUM> substantially extends beyond the tooth root circle <NUM>, that is, the intruding length "d". In addition, it is preferable that the chamfer in the tooth tip <NUM> is rounded with a large radius as much as possible.

In the embodiment in which the groove portion <NUM> has an isosceles trapezoidal cross section as described above, it is preferable that the cross sectional shape of the groove portion <NUM> and the cross sectional shape of the tooth portion <NUM> are substantially in a geometrically similar relationship or a relationship close thereto. It is noted that the geometrically similar relationship means that a ratio of the distance "g1" between the intersection points "p7" and "p8" of the extension lines of the tooth flanks <NUM> and <NUM> with the tip circle <NUM> and the distance "g2" between "p5" and "p6" is close or preferably substantially equal to the ratio of "a2" and "a1". That is, this preferred embodiment is represented by the following equation: <MAT>.

When the dimensions of the tooth portion and the groove portion are geometrically similar or close to being geometrically similar as described above, it is possible to avoid the occurrence of an excessively thin thickness part in the outer peripheral portion, so that it is convenient because the strength of the outer peripheral portion is easily ensured as uniformly as possible. Excessive intruding of the groove portion <NUM> is particularly preferably to be avoided because the thickness of the outer peripheral portion <NUM> is reduced near the groove bottom <NUM>. As a guide, when an intersection "p11" of a straight line <NUM> connecting the pitch point "p9" of the tooth portion <NUM> and the tooth root point "p6" and a straight line <NUM> connecting the other pitch point "p10" of the groove portion and the tooth root point "p5" is obtained, it is preferable that the groove bottom <NUM> does not does not exist outside beyond the point "p11", and it is more preferable that the groove bottom <NUM> is as close to the point "p11" as possible. It is desirable to appropriately select the depth length "b" and the groove bottom length "a2" of the groove portion <NUM> so that the groove bottom <NUM> becomes close to the point "p11" as much as possible.

In any embodiment of the gear 1c, the number of the groove portions <NUM> is not particularly limited, but it is preferable to arrange the tooth portions uniformly around the outer peripheral portion <NUM>, that is, at an every equal angle with respect to the center of the outer peripheral portion. The number of groove portions is plural, and preferably many (for example, the number of the groove portions and the number of the tooth portions are the same, so that one groove portion is formed in each tooth portion), and thereby the movement of the outer peripheral portion <NUM> as to the resin portion in the circumferential direction is more effectively avoided. As to the embodiment in which the groove portions <NUM> are formed corresponding to the tooth portions <NUM> so that the groove portions <NUM> are located inside the tooth portions <NUM>. In a particularly preferred embodiment, one groove portion is provided for a plurality of the tooth portions, preferably for <NUM> to <NUM> or more adjacent tooth portions, for example, for five adjacent tooth portions. More preferably, one groove portion is uniformly provided for adjacent <NUM> or <NUM> tooth portions. In the most preferred embodiment, at least one groove portion, usually one groove portion is provided for one tooth portion <NUM>. That is, the groove portions <NUM> are provided so that each of them corresponds to the respective tooth portion <NUM> (that is, one tooth portion and one groove portion are paired). As a result, each tooth portion <NUM> has the groove portion <NUM> inside thereof, and the number of the tooth portions <NUM> and the number of the groove portions <NUM> are the same. In this embodiment, it is particularly preferred that the groove portions <NUM> intrudes into the tooth portions <NUM>. That is, each groove portion provided in each tooth portion can share and resist a circumferential force that can cause relative circumferential displacement between the outer peripheral portion <NUM> and the resin portion <NUM>, so that a resistance capacity of each groove portion can be smaller. Therefore, in some embodiments, the formation of shallow (i.e. smaller "b") and/or narrow (i.e. smaller "a1" and/or "a2") groove portions may be sufficient, which simplifies manufacture of the outer periphery portion <NUM>, and also, the formation of the resin portion <NUM> by molding can be simplified.

As to the groove portions <NUM>, when the groove bottom length "a2" of the groove portion <NUM> is excessively large, the thickness of the metal part of the outer peripheral portion <NUM> adjacent to the groove portion may be reduced, so that the strength of the outer peripheral portion may be insufficient as described above. In such case, it is preferable to set the "groove bottom length ratio" within an appropriate range. Furthermore, when the cross-sectional shape of the groove portion is too thin and long or too thick and short, it is often not preferable in consideration of the strength of the outer peripheral portion and the weight of the outer peripheral portion. In such case, it is preferable that an aspect ratio of the cross-sectional shape of the groove portion (that is, a1/b) is set in an appropriate range. In addition, when the groove portion <NUM> excessively intrudes into the tooth portion <NUM>, the outer peripheral portion may be similarly reduced in its strength. In such case, it is preferable that the "intruding degree" is within an appropriate range. Therefore, although it depends on the materials to be used, it is generally appropriate that the gear 1c of the present invention, particularly the gear in which the cross-sectional shape of the groove portion <NUM> is a rectangular or isosceles trapezoid satisfies for example the ratios shown in the following table in relation to the dimensions of the groove portion <NUM> and other dimensions related to the tooth portion <NUM>.

In a preferred embodiment, the distance from the tooth surface of the gear to the groove portion, that is, the length between the tooth tip and the groove bottom can be appropriately selected according to the application of the gear and the materials constituting the gear, and it is for example not less than <NUM>, preferably not less than <NUM>, and for example, not less than <NUM>.

The depth of the groove (that is, the depth "b") is not particularly limited, and an appropriate depth can be selected according to the application of the gear and the materials constituting the gear, and it may be preferably not less than <NUM> and not more than <NUM>, for example not less than <NUM> and not more than <NUM>, or not less than <NUM> and not more than <NUM>. By increasing the depth of the groove portion, it is possible to more efficiently prevent the movement in the circumferential direction of the peripheral portion <NUM> as to the resin portion <NUM>, and further reduce the weight of the gear. Also, by making the groove depth shallower, it becomes easier to keep the strength of the gear.

In the present embodiment, other portions except the groove portion <NUM> of the outer peripheral portion <NUM>, the central portion <NUM>, and the resin portion <NUM> can be the same as those of the gear 1a or 1b.

Further, similarly to the above, in the gear 1c of the present embodiment, at least one of the features of the gear 1a and the gear 1b of the above embodiments may be incorporated as necessary.

Although the gears according to the present invention have been described in detail while showing several embodiments, the present invention is not limited to the gears of the above-described embodiments, and various design changes are possible without departing from the scope of the present invention.

For example, in the above-described embodiments, all of the central portions are annular, but the present invention is not limited to this, and the inside of the annular portion may be filled.

Further, if possible, the convex portion and the concave portion for preventing the movement between the outer peripheral portion and the resin portion, and also the movement between the central portion and the resin portion may have the opposite forms, that is, the concave portion and the convex portion respectively.

The gear of the present invention is preferably manufactured by integral molding. For example, it can be obtained by placing the outer peripheral portion and the central portion in a mold, then pouring a liquid resin into the mold, and curing or solidifying the resin. By using the integral molding, a gear having a more precise structure can be manufactured with higher accuracy, and thereby the strength of the gear is further improved.

Claim 1:
An annular metal gear component comprising a plurality of tooth portions (<NUM>) and a support portion (<NUM>) that supports the plurality of tooth portions (<NUM>), wherein
the plurality of tooth portions (<NUM>) are provided on an outside of the support portion (<NUM>) along its entire circumference,
a plurality of groove portions (<NUM>) are provided along a width direction of the annular metal gear component evenly on an annular inner surface (<NUM>) of the support portion (<NUM>),
the plurality of groove portions (<NUM>) are present such a ratio that at least one groove portion (<NUM>) is provided per one tooth portion (<NUM>) or adjacent two or more of the plurality of tooth portions (<NUM>), and
each of the plurality of groove portions (<NUM>) is formed such that it is located to correspond to a position where the tooth portion (<NUM>) is present on the support portion (<NUM>), characterized in that
the plurality of groove portions (<NUM>) intrudes into the plurality of tooth portions (<NUM>) such that a groove bottom (<NUM>) of the groove portion (<NUM>) is located beyond and outside a tooth root circle (<NUM>),
a cross-sectional shape of the groove portion (<NUM>) is a isosceles trapezoid, and wherein a ratio of a distance (g1) between intersection points (p7, p8) of extension lines of tooth flanks (<NUM>, <NUM>) of the tooth portion (<NUM>) with a tip circle (<NUM>) of the tooth portion (<NUM>), and a distance (g2) between tooth root points (p5, p6) of the tooth portion (<NUM>) is substantially equal to a ratio of a groove bottom length (a2) of the groove portion (<NUM>) and a frontage length (a1) of the groove portion (<NUM>),
a groove bottom (<NUM>) of the groove portion (<NUM>) is located inside an intersection of two straight lines each connecting a pitch point (p9, p10) of one tooth flank (<NUM>, <NUM>) and a root point (p5, p6) of the other tooth flank (<NUM>, <NUM>).