Stamped hub for cast plastic

Abstract

A gear includes an inner hub formed of metal material, the inner hub having an outer surface defining a plurality of outer teeth. The gear also includes an outer ring formed of non-metal material, the outer ring having an inner diameter that is smooth. The outer ring is disposed in an interference fit with the outer teeth of the inner hub.

What is claimed is: 
     
         1 . A gear comprising:
 an inner hub formed of metal material, the inner hub having an outer surface defining a plurality of outer teeth;   an outer ring formed of non-metal material, the outer ring having an inner diameter that is smooth;   wherein the outer ring is disposed in an interference fit with the outer teeth of the inner hub; and   wherein at least some of the plurality of outer teeth have a dovetail geometry, wherein each dovetail geometry tooth has a pair of outer tooth sidewalls and an outer tooth top wall, each of the pair of outer tooth sidewalls extending away from each other as each sidewall extends away from the outer surface of the inner hub, wherein the outer tooth top wall connects the pair of outer tooth sidewalls.   
     
     
         2 . A gear comprising:
 an inner hub formed of metal material, the inner hub having an outer surface defining a plurality of outer teeth;   an outer ring formed of non-metal material, the outer ring having an inner diameter that is smooth;   wherein the outer ring is disposed in an interference fit with the outer teeth of the inner hub; and   wherein at least some of the plurality of outer teeth have a tapered geometry, wherein each tapered geometry tooth has a pair of outer tooth sidewalls and an outer tooth top wall, each of the pair of outer tooth sidewalls extending toward each other as each sidewall extends away from the outer surface of the inner hub, wherein the outer tooth top wall connects the pair of outer tooth sidewalls.   
     
     
         3 . A method of forming a gear comprising:
 forming an inner hub from a metal material and defining a plurality of outer teeth on an outer diameter of the inner hub;   forming an outer ring formed of non-metal material and defining a smooth inner diameter of the outer ring; and   interference fitting the smooth inner diameter of the outer ring to the outer teeth of the inner hub.   
     
     
         4 . The method of  claim 3 , wherein forming the inner hub comprises stamping a metal component. 
     
     
         5 . The method of  claim 3 , wherein forming the inner hub comprises casting a metal component. 
     
     
         6 . The method of  claim 3 , wherein forming the inner hub comprises forging a metal component. 
     
     
         7 . The method of  claim 3 , wherein forming the inner hub comprises machining a metal component.