WO2007098191A2 - Integrated shaft, gear and rotor - Google Patents

Integrated shaft, gear and rotor Download PDF

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Publication number
WO2007098191A2
WO2007098191A2 PCT/US2007/004491 US2007004491W WO2007098191A2 WO 2007098191 A2 WO2007098191 A2 WO 2007098191A2 US 2007004491 W US2007004491 W US 2007004491W WO 2007098191 A2 WO2007098191 A2 WO 2007098191A2
Authority
WO
WIPO (PCT)
Prior art keywords
assembly
output shaft
sensor rotor
output
output gear
Prior art date
Application number
PCT/US2007/004491
Other languages
French (fr)
Other versions
WO2007098191A3 (en
Inventor
Robert D. Keefover
Hal E. Pringle
Michael J. Halsig
John W Duddles
Original Assignee
Borgwarner Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Borgwarner Inc. filed Critical Borgwarner Inc.
Priority to DE112007000281T priority Critical patent/DE112007000281T5/en
Priority to JP2008555418A priority patent/JP2009527697A/en
Publication of WO2007098191A2 publication Critical patent/WO2007098191A2/en
Publication of WO2007098191A3 publication Critical patent/WO2007098191A3/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D9/00—Controlling engines by throttling air or fuel-and-air induction conduits or exhaust conduits
    • F02D9/08—Throttle valves specially adapted therefor; Arrangements of such valves in conduits
    • F02D9/10—Throttle valves specially adapted therefor; Arrangements of such valves in conduits having pivotally-mounted flaps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14336—Coating a portion of the article, e.g. the edge of the article
    • B29C45/14377—Coating a portion of the article, e.g. the edge of the article using an additional insert, e.g. a fastening element
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B37/00—Engines characterised by provision of pumps driven at least for part of the time by exhaust
    • F02B37/12—Control of the pumps
    • F02B37/18—Control of the pumps by bypassing exhaust from the inlet to the outlet of turbine or to the atmosphere
    • F02B37/183—Arrangements of bypass valves or actuators therefor
    • F02B37/186—Arrangements of actuators or linkage for bypass valves
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D9/00—Controlling engines by throttling air or fuel-and-air induction conduits or exhaust conduits
    • F02D9/08—Throttle valves specially adapted therefor; Arrangements of such valves in conduits
    • F02D9/10—Throttle valves specially adapted therefor; Arrangements of such valves in conduits having pivotally-mounted flaps
    • F02D9/1065—Mechanical control linkage between an actuator and the flap, e.g. including levers, gears, springs, clutches, limit stops of the like
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M26/00—Engine-pertinent apparatus for adding exhaust gases to combustion-air, main fuel or fuel-air mixture, e.g. by exhaust gas recirculation [EGR] systems
    • F02M26/11—Manufacture or assembly of EGR systems; Materials or coatings specially adapted for EGR systems
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M26/00—Engine-pertinent apparatus for adding exhaust gases to combustion-air, main fuel or fuel-air mixture, e.g. by exhaust gas recirculation [EGR] systems
    • F02M26/45—Sensors specially adapted for EGR systems
    • F02M26/48—EGR valve position sensors
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D1/00—Couplings for rigidly connecting two coaxial shafts or other movable machine elements
    • F16D1/06—Couplings for rigidly connecting two coaxial shafts or other movable machine elements for attachment of a member on a shaft or on a shaft-end
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16H—GEARING
    • F16H57/00—General details of gearing
    • F16H57/0018—Shaft assemblies for gearings
    • F16H57/0025—Shaft assemblies for gearings with gearing elements rigidly connected to a shaft, e.g. securing gears or pulleys by specially adapted splines, keys or methods
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16H—GEARING
    • F16H57/00—General details of gearing
    • F16H57/02—Gearboxes; Mounting gearing therein
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2015/00—Gear wheels or similar articles with grooves or projections, e.g. control knobs
    • B29L2015/003—Gears
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/748—Machines or parts thereof not otherwise provided for
    • B29L2031/7506—Valves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/752—Measuring equipment
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02D—CONTROLLING COMBUSTION ENGINES
    • F02D11/00—Arrangements for, or adaptations to, non-automatic engine control initiation means, e.g. operator initiated
    • F02D11/06—Arrangements for, or adaptations to, non-automatic engine control initiation means, e.g. operator initiated characterised by non-mechanical control linkages, e.g. fluid control linkages or by control linkages with power drive or assistance
    • F02D11/10—Arrangements for, or adaptations to, non-automatic engine control initiation means, e.g. operator initiated characterised by non-mechanical control linkages, e.g. fluid control linkages or by control linkages with power drive or assistance of the electric type
    • F02D11/106—Detection of demand or actuation
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M26/00—Engine-pertinent apparatus for adding exhaust gases to combustion-air, main fuel or fuel-air mixture, e.g. by exhaust gas recirculation [EGR] systems
    • F02M26/52—Systems for actuating EGR valves
    • F02M26/53—Systems for actuating EGR valves using electric actuators, e.g. solenoids
    • F02M26/54—Rotary actuators, e.g. step motors
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies

Definitions

  • the present invention generally relates to the forming of sensors on shaft and gear components.
  • Conventional motor/gear drive actuators typically require an output shaft, generally comprised of plated steel, stainless steel and the like, an output gear, and a sensor rotor, typically required for position sensing.
  • the output gear and the sensor rotor are mounted in proximity to one another to an appropriate end of the output shaft by various means.
  • a shaft and gear component having an output shaft member; a sensor rotor member disposed on an end of the output shaft member; and an output gear member overmolded about at least a portion of the output shaft member and the sensor rotor member.
  • FIG. 1 is a perspective view of a shaft and gear component, in accordance with the general teachings of the present invention.
  • Figure 2 is a sectional view of a shaft and gear component, in accordance with the general teachings of the present invention
  • Figure 3 is a top plan view of a shaft and gear component, in accordance with the general teachings of the present invention
  • Figure 4 is an elevational view of an output shaft member of a shaft and gear component, in accordance with one embodiment of the present invention
  • Figure 5 is a top plan view of a sensor rotor member of a shaft and gear component, in accordance with a second embodiment of the present invention.
  • Figure 6 is a sectional view of an alternate embodiment of the invention.
  • FIG. 1 there is generally shown an assembly 10 for a shaft and gear component in accordance with the general teachings of the present invention.
  • the assembly can be used in any type of application using motor gear driven actuafors such as, but not limited to exhaust gas recirculation valves, throttle bodies, turbo actuators, bypass valves, position sensors etc.
  • the assembly 10 includes an output shaft member, generally shown at 12, a sensor rotor member, generally shown at 14, and an output gear member, generally shown at 16. At least two or more of these members are fastened together, as will be described in detail herein.
  • the output shaft member 12 preferably includes ah optional area defining a throttle plate aperture 120 for receiving a throttle plate member (not shown), as well as at least one optional area defining fastener receiving slots 122, 124, respectively, for fastening the throttle plate member to the output shaft member 12. Additionally, an optional knurled section 126 may be provided on an external surface of the output shaft member 12. Further features may be provided in conjunction with the output shaft member 12, as is known in the art. Referring specifically to the Figures generally, and specifically to Fig.
  • an area, generally shown at 128, in proximity to one end, generally shown at 130, of the output shaft member 12 is provided with an area defining a notch 132 in communication with an adjacent throughbore 134, as well as a flat surface 136, the purpose of all of which will be explained in detail herein.
  • the sensor rotor member 14 is shown as being a substantially circular member. It should be appreciated that the sensor rotor member 14 can be configured in any number of shapes, including but not limited to a substantially flat or planar member.
  • the sensor rotor member 14 is preferably disposed about the extreme portion of the end 130 of the output shaft member 12 and is preferably fastened thereto, either directly or indirectly, as will be explained in detail herein.
  • a printed circuit board 140 is connected to the sensor rotor member 14 and has a conductor loop 144 operably associated therewith for a non- contacting (e.g., inductive) position sensor that can be piloted directly to the output shaft member 12 during a molding process, which will be explained in detail herein, so as to ensure that the sensor rotor member 14 and the output shaft member 12 remain concentrically aligned with respect to one another.
  • a non- contacting e.g., inductive
  • At least one, area defines apertures (e.g., such as but not limited to chamfered holes) 146, 148, 150, respectively, are formed on surface 140, the purpose of which will be explained in detail herein.
  • apertures e.g., such as but not limited to chamfered holes
  • the output gear member 16 is shown as being a substantially circular member. It should be appreciated that the output gear member 16 can be configured in any number of 'shapes, including but not limited to a substantially flat or planar member.
  • the output gear member 16 is disposed about the extreme portion of the end 130 of the output shaft member 12 and is fastened to the output shaft member 12 and/or the sensor rotor member 14, as will be explained in detail herein.
  • the output gear member 16 is preferably provided with a gear tooth section 160 formed on a surface thereof, the purpose of which is well-known in the art.
  • the output gear member 16 is formed of a moldable material, such as plastic, and could be, but is not limited to, high temperature thermoplastic materials.
  • Fastening at least two of either the output shaft member 12, the sensor rotor member 14, and/or the output gear member 16, can be accomplished by overmolding the material comprising the output gear member 16 using injection-molding technology.
  • the output shaft member 12 can be placed in an injection molding machine and the sensor rotor member 14 can theri be placed into the mold relative to the output shaft member 12.
  • the sensor rotor member 14 can be placed on the flat surface 136 of the output shaft member 12, and then both components can be placed into the injection-molding machine.
  • the machine can be sealed (e.g., both mold portions are brought together to form a space or cavity therebetween).
  • a portion of the mold provides a surface operable to form the various contours and configurations of the output gear member 16.
  • Plastic material is then preferably injected into the space or cavity in a sufficient amount to form the output gear member 16 as well as to form a connection among any of the output shaft member 12, the sensor rotor member 14, and/or the output gear member 16.
  • the plastic material preferably infiltrates, at least partially and more preferably substantially, the area proximate to the notch 132 and/or throughbore 134, as well as the apertures 146, 148, 150, respectively.
  • the hardened plastic material in the throughbore 134 fastens the output gear member 16 to the shaft member 12.
  • the plastic hardens and/or cures, it functions to serve as an overmold fastener between the output shaft member 12, the sensor rotor member 14, and/or the output gear member 16.
  • the overmold fastens the sensor rotor member 14 to the output shaft member 12, as well as providing the output gear member 16.
  • the overmold functions to prevent the sensor rotor member 14 from both independently rotating about and/or lifting away from the surface of the output shaft member 12.
  • the sensor rotor member 14 is preferably aligned angularly in the mold by an area defining an optional aperture 152 formed on the surface 140 of the sensor rotor member 14, wherein the aperture 152 is unfilled by the plastic material comprising the output gear member 16.
  • an area defining another optional aperture can be formed on the surface 140 of the sensor rotor member 14, wherein the aperture is also unfilled by the plastic material comprising the output gear member 16.
  • the intended purpose of this aperture which is preferably of a different size of the previously described apertures, 146, 148, 150 and/or 152, respectively, is to ensure that the sensor rotor member 14 is properly oriented onto the output shaft member 12 when being assembled in the mold in preparation for the injection-molding process.
  • a gear and shaft assembly 200 is shown with the shaft 12 having a knurled portion 202.
  • the knurled portion 202 can be diamond shaped knurls, straight knurls or any other suitable design.
  • the output gear member 16 has a mold area 204 that during the forming of the assembly 200 the molten plastic will come into contact with the knurled area 202. The molten plastic will flow into the various grooves on the surface of the knurled area 202 and fasten the gear member 16 to the shaft 12.

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  • Engineering & Computer Science (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Manufacturing & Machinery (AREA)
  • Analytical Chemistry (AREA)
  • Connection Of Motors, Electrical Generators, Mechanical Devices, And The Like (AREA)
  • Control Of Throttle Valves Provided In The Intake System Or In The Exhaust System (AREA)
  • Gears, Cams (AREA)

Abstract

A shaft and gear assembly and method for forming the same are described, wherein the assembly includes an output shaft member (12), a sensor rotor member (14) disposed on an end of the output shaft member (12), and an output gear member (16) overmolded about at least a portion of the output shaft member (12) and the sensor rotor member (16).

Description

INTEGRATED SHAFT, GEAR AND ROTOR
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/775,183 filed February 21 , 2006.
FIELD OF THE INVENTION
The present invention generally relates to the forming of sensors on shaft and gear components.
BACKGROUND OF THE INVENTION
Conventional motor/gear drive actuators typically require an output shaft, generally comprised of plated steel, stainless steel and the like, an output gear, and a sensor rotor, typically required for position sensing. Typically, the output gear and the sensor rotor are mounted in proximity to one another to an appropriate end of the output shaft by various means.
However, current methods of assembling electronic throttle bodies are not entirely satisfactory in that they may lead to damage to the sensor rotor and/or other components. Accordingly, there exists a need for new and improved shaft and gear components and methods for making the same.
SUMMARY OF THE INVENTION
In accordance with the general teachings of the present invention, new and improved shaft and gear components and methods for making the same are provided.
In accordance with a first embodiment of the present invention, a shaft and gear component is provided, having an output shaft member; a sensor rotor member disposed on an end of the output shaft member; and an output gear member overmolded about at least a portion of the output shaft member and the sensor rotor member. Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:
Figure 1 is a perspective view of a shaft and gear component, in accordance with the general teachings of the present invention;
Figure 2 is a sectional view of a shaft and gear component, in accordance with the general teachings of the present invention; Figure 3 is a top plan view of a shaft and gear component, in accordance with the general teachings of the present invention;
Figure 4 is an elevational view of an output shaft member of a shaft and gear component, in accordance with one embodiment of the present invention; Figure 5 is a top plan view of a sensor rotor member of a shaft and gear component, in accordance with a second embodiment of the present invention; and
Figure 6 is a sectional view of an alternate embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. Referring to the Figures generally, and specifically to Figs. 1-3, there is generally shown an assembly 10 for a shaft and gear component in accordance with the general teachings of the present invention. The assembly can be used in any type of application using motor gear driven actuafors such as, but not limited to exhaust gas recirculation valves, throttle bodies, turbo actuators, bypass valves, position sensors etc.
The assembly 10 includes an output shaft member, generally shown at 12, a sensor rotor member, generally shown at 14, and an output gear member, generally shown at 16. At least two or more of these members are fastened together, as will be described in detail herein.
The output shaft member 12 preferably includes ah optional area defining a throttle plate aperture 120 for receiving a throttle plate member (not shown), as well as at least one optional area defining fastener receiving slots 122, 124, respectively, for fastening the throttle plate member to the output shaft member 12. Additionally, an optional knurled section 126 may be provided on an external surface of the output shaft member 12. Further features may be provided in conjunction with the output shaft member 12, as is known in the art. Referring specifically to the Figures generally, and specifically to Fig. 4, an area, generally shown at 128, in proximity to one end, generally shown at 130, of the output shaft member 12 is provided with an area defining a notch 132 in communication with an adjacent throughbore 134, as well as a flat surface 136, the purpose of all of which will be explained in detail herein. Referring to the Figures generally, and specifically to Fig. 5, the sensor rotor member 14 is shown as being a substantially circular member. It should be appreciated that the sensor rotor member 14 can be configured in any number of shapes, including but not limited to a substantially flat or planar member. The sensor rotor member 14 is preferably disposed about the extreme portion of the end 130 of the output shaft member 12 and is preferably fastened thereto, either directly or indirectly, as will be explained in detail herein.
A printed circuit board 140 is connected to the sensor rotor member 14 and has a conductor loop 144 operably associated therewith for a non- contacting (e.g., inductive) position sensor that can be piloted directly to the output shaft member 12 during a molding process, which will be explained in detail herein, so as to ensure that the sensor rotor member 14 and the output shaft member 12 remain concentrically aligned with respect to one another. - A -
At least one, area defines apertures (e.g., such as but not limited to chamfered holes) 146, 148, 150, respectively, are formed on surface 140, the purpose of which will be explained in detail herein.
Referring tb the Figures generally, and specifically to Fig. 3, the output gear member 16 is shown as being a substantially circular member. It should be appreciated that the output gear member 16 can be configured in any number of 'shapes, including but not limited to a substantially flat or planar member. The output gear member 16 is disposed about the extreme portion of the end 130 of the output shaft member 12 and is fastened to the output shaft member 12 and/or the sensor rotor member 14, as will be explained in detail herein.
The output gear member 16 is preferably provided with a gear tooth section 160 formed on a surface thereof, the purpose of which is well-known in the art. The output gear member 16 is formed of a moldable material, such as plastic, and could be, but is not limited to, high temperature thermoplastic materials.
Fastening at least two of either the output shaft member 12, the sensor rotor member 14, and/or the output gear member 16, can be accomplished by overmolding the material comprising the output gear member 16 using injection-molding technology.
By way of a non-limiting example, the output shaft member 12 can be placed in an injection molding machine and the sensor rotor member 14 can theri be placed into the mold relative to the output shaft member 12. Alternatively, the sensor rotor member 14 can be placed on the flat surface 136 of the output shaft member 12, and then both components can be placed into the injection-molding machine.
Once the components are properly positioned and fixtured within the injection-molding machine, the machine can be sealed (e.g., both mold portions are brought together to form a space or cavity therebetween). Preferably, a portion of the mold provides a surface operable to form the various contours and configurations of the output gear member 16. Plastic material is then preferably injected into the space or cavity in a sufficient amount to form the output gear member 16 as well as to form a connection among any of the output shaft member 12, the sensor rotor member 14, and/or the output gear member 16. By way of a non-limiting example, the plastic material preferably infiltrates, at least partially and more preferably substantially, the area proximate to the notch 132 and/or throughbore 134, as well as the apertures 146, 148, 150, respectively. The hardened plastic material in the throughbore 134 fastens the output gear member 16 to the shaft member 12.
As the plastic hardens and/or cures, it functions to serve as an overmold fastener between the output shaft member 12, the sensor rotor member 14, and/or the output gear member 16. In this manner, the overmold fastens the sensor rotor member 14 to the output shaft member 12, as well as providing the output gear member 16. Additionally, the overmold functions to prevent the sensor rotor member 14 from both independently rotating about and/or lifting away from the surface of the output shaft member 12. In accordance with an alternative embodiment of the present invention, the sensor rotor member 14 is preferably aligned angularly in the mold by an area defining an optional aperture 152 formed on the surface 140 of the sensor rotor member 14, wherein the aperture 152 is unfilled by the plastic material comprising the output gear member 16. In accordance with a second alternative embodiment of the present invention, an area defining another optional aperture (not shown) can be formed on the surface 140 of the sensor rotor member 14, wherein the aperture is also unfilled by the plastic material comprising the output gear member 16. The intended purpose of this aperture, which is preferably of a different size of the previously described apertures, 146, 148, 150 and/or 152, respectively, is to ensure that the sensor rotor member 14 is properly oriented onto the output shaft member 12 when being assembled in the mold in preparation for the injection-molding process.
Referring now to Figure 6 an alternative embodiment of the invention is shown. Like reference numeral are used where applicable. As shown a gear and shaft assembly 200 is shown with the shaft 12 having a knurled portion 202. The knurled portion 202 can be diamond shaped knurls, straight knurls or any other suitable design. The output gear member 16 has a mold area 204 that during the forming of the assembly 200 the molten plastic will come into contact with the knurled area 202. The molten plastic will flow into the various grooves on the surface of the knurled area 202 and fasten the gear member 16 to the shaft 12.
The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.

Claims

CLAIMSWhat is claimed is:
1. An assembly comprising: an output shaft member having an end with a notch in communication with an adjacent throughbore; an output gear member molded onto said end of said output shaft member, wherein a portion of said output gear member is molded into said notch and said throughbore for fastening said output gear member to said end of said output shaft member; and v a sensor rotor member having a conductor loop, said sensor rotor member being operably connected to said output gear member.
2. The assembly of claim 1, wherein said output gear member has a gear tooth section.
3. The assembly of claim 1 wherein said sensor rotor member has one or more apertures, and a portion of said moldable material of said output gear member is disposed within said series of apertures to fasten said rotor to said output gear member.
4. The assembly of claim 3, said sensor rotor member further comprises an aperture formed substantially in the center of said sensor rotor member, said aperture centrally locating said sensor rotor member relative to said output shaft member as said sensor rotor member is attached to said output shaft member.
5. The assembly of claim 1 wherein said assembly is a portion of a motor driven actuator.
6. The assembly of claim 1 wherein said assembly is a portion of one selected from the group comprising exhaust gas recirculation valves, throttle bodies, turbo actuators, bypass valves and position sensors.
7. An assembly comprising: an output shaft member; an output gear member molded onto said end of said output shaft member; and a sensor rotor member having a conductor loop, wherein said sensor rotor member has one or more apertures, wherein a portion of said output member is molded through said one ore more apertures for attaching said sensor rotor to said output shaft member.
8. The assembly of claim 7, said output gear member further comprising a geared section, said geared section circumscribing a portion of said output shaft member.
9. The assembly of claim 7, wherein a portion of said moldable material of said output gear member is disposed within said output shaft member for connecting said output gear member to said output shaft member.
10. The assembly of claim 7, said sensor rotor further comprising an aperture located substantially in the center of said sensor rotor.
11. The assembly of claim 7 wherein said assembly is a portion of a motor driven actuator.
12. The assembly of claim 7 wherein said assembly is a portion of one selected from the group comprising exhaust gas recirculation valves, throttle bodies, turbo actuators, bypass valves and position sensors.
13. An assembly comprising: an output shaft member having an end with a notch in communication with an adjacent throughbore; a throttle plate aperture disposed on said output shaft member and having one or more fastener receiving slots; an- output gear member molded onto said end of said output shaft member, wherein a portion of said output gear member is molded into said notch and said throughbore for fastening said output gear member to said end of said output shaft member; and a sensor rotor member having a printed circuit board with a conductor loop contained within said printed circuit board, wherein said sensor rotor member has one ore more apertures, wherein a portion of said output member is molded through said one ore more apertures for attaching said sensor rotor to said output shaft member.
14. The assembly of claim 13, wherein said output gear member has a gear tooth section.
15. The assembly of claim 13 wherein said sensor rotor member has one or more apertures, and a portion of said moldable material of said output gear member is disposed within said series of apertures to fasten said rotor to said output gear member.
16. The assembly of claim 13, said sensor rotor member further comprises an aperture formed substantially in the center of said sensor rotor member, said aperture centrally locating said sensor rotor member relative to said output shaft member as said sensor rotor member is attached to said output shaft member.
17. The assembly of claim 13 wherein said assembly is a portion of a motor driven actuator.
18. The assembly of claim 13 wherein said assembly is a' portion of one selected from the group comprising exhaust gas recirculation valves, throttle bodies, turbo actuators, bypass valves and position sensors.
19. A method for making an assembly for an shaft and gear assembly, comprising the steps of: providing an output shaft member having an end with a through bore, and a notch; providing a sensor rotor member; providing an output gear member; overmolding said output gear member about said end of said output shaft member such that a portion of said output gear member is disposed within said bore and said notch; and connecting said sensor rotor member to said output shaft member when said output gear member is overmolded onto at least a portion of said output member.
20. The method of claim 19 further comprising the steps of: providing one or more apertures on said sensor rotor member; and infiltrating a portion of said overmolded gear member into said one or more apertures during said step of connecting for fastening said rotor to said gear member.
21. A method for making an assembly for an shaft and gear assembly, comprising the steps of: providing an output shaft member having a knurled portion; providing a sensor rotor member having a mold area; providing an output gear member; overmolding said output gear member about said knurled portion of said output shaft member such that said mold area is disposed about said knurled portion to moldably fasten said output shaft to said output gear member; and connecting said sensor rotor member to said output shaft member When said output gear member is overmolded onto at least a portion of said output member.
22. The method of claim 21 further comprising the steps of: providing one or more apertures on said sensor rotor member; and infiltrating a portion of said overmolded gear member into said one or more apertures during said step of connecting for fastening said rotor to said gear member..
23. An assembly comprising: an output shaft member having a kurled portion; an output gear member molded onto said end of said output shaft member, wherein said output gear member has a mold area that is moided onto said knurled portion of said output shaft member for fastening said output gear member to said end of said output shaft member; and a sensor rotor member having a conductor loop, said sensor rotor member being operably connected to said output gear member.
24. The assembly of claim 23 wherein said output gear member has a gear tooth section.
25. The assembly of claim 23 wherein said sensor rotor member has one or more apertures, and a portion of said moldable material of said output gear member is disposed within said series of apertures to fasten said rotor to said output gear member.
26. The assembly of claim 23, said sensor rotor member further comprises an aperture formed substantially in the center of said sensor rotor member, said aperture centrally locating said sensor rotor member relative to said output shaft member as said sensor rotor member is attached to said output shaft member.
27. The assembly of claim 23 wherein said assembly is a portion of a motor driven actuator.
28. The assembly of claim 23 wherein said assembly is a portion of one selected from the group comprising exhaust gas recirculation valves, throttle bodies, turbo actuators, bypass valves and position sensors.
PCT/US2007/004491 2006-02-21 2007-02-21 Integrated shaft, gear and rotor WO2007098191A2 (en)

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JP2008555418A JP2009527697A (en) 2006-02-21 2007-02-21 Integrated shaft, gear and rotor

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US60/775,183 2006-02-21

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FR2992046A1 (en) * 2012-06-15 2013-12-20 Valeo Sys Controle Moteur Sas Fluid flow valve i.e. exhaust gas recirculation valve for diesel engine of car, has control shaft for controlling flap for closing conduit, and drive element for rotating control shaft, where drive element is molded onto control shaft
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WO2007098191A3 (en) 2007-11-01
KR20080106179A (en) 2008-12-04
CN101384412A (en) 2009-03-11
JP2009527697A (en) 2009-07-30
DE112007000281T5 (en) 2009-03-12

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