Anti-kickback clutch for starter gear

In a permanently engaged starter system (20), a roller type one-way clutch (40) located between a permanently engaged starter motor (21) and a starter ring gear (34), the starter motor (21) rotating a driving shaft (25) with respect to a rotational axis, and the starter ring gear (34) for imparting torque from the roller type one-way clutch (40) to an internal combustion engine, the improvement of the roller type one-way clutch (40) comprising:

• a starter gear (54) mounted for rotation and operably engageable with the starter ring gear (34), the starter gear having an outer race surface (56) connected thereto;
• a roller cage (42) mounted for rotation independent of the starter gear (54), the roller cage having a cylindrical wall portion with a plurality of recesses (44) for receiving a corresponding plurality of roller disks (46), the roller cage (42) having a radially outwardly extending flange portion (48) connected to the cylindrical wall portion supporting an inertia ring adjacent to an outer peripheral edge (50) of the flange portion (48) for retarding rotational movement of the roller cage (42) during acceleration of the starter motor (21);
• an inner race (60) defined by a nut-shaped portion having a plurality of generally flat planar surfaces with central portions spaced a greater distance from the outer race surface (56) than edges formed between two adjacent flat planar surfaces, the edges of the inner race (60) trapping the plurality of roller disks (46) in wedged non-rolling engagement between the nut-shaped surface of the inner race (60) and the outer race surface (56) in response to acceleration of the starter motor (21) for engaging the one-way clutch to start the engine;
• and
• at least one spring (52) secured between the roller cage (42) and the nut-shaped surface of the inner race (60) for biasing the plurality of roller disks (46) toward a disengaged position with respect to the outer race surface (56).

A method of assembling a roller type one-way clutch (40) engageable between a permanently engaged starter motor (21) and a starter ring gear (34), the starter motor (21) having a driving shaft (25) with an axis of rotation, and the starter ring gear (34) for imparting torque from the roller type one-way clutch assembly (40) to an internal combustion engine, the method comprising:

• providing a starter gear having an outer race surface (56);
• inserting a roller cage (42) within the outer race surface (56), the roller cage (42) having a cylindrical wall portion with a plurality of recesses (44) for receiving a corresponding plurality of cylindrical rollers (46) and a flange portion connected to the cylindrical wall portion supporting an enlarged inertia ring adjacent an outer peripheral edge of the flange portion;
• installing an inner race (60) defined by a nut-shaped portion having a plurality of generally flat planar surfaces with central portions spaced a greater distance from the outer race surface (56) than edges formed between two adjacent flat planar surfaces, the edges of the inner race (60) trapping the plurality of roller disks (46) in wedged non-rolling engagement between the nut-shaped surface of the inner race (60) and the outer race surface (56) in response to acceleration of the starter motor (21) for engaging the one-way clutch to start the engine;
• and
• biasing the roller disks (46) supported by the roller cage (42) with at least one spring (52) toward a disengaged position with the cylindrical rollers (46) positioned in contact with a central portion of the generally flat planar surfaces of the nut-shaped surface of the inner race (60) and spaced radially from contact with the outer race surface (56) of the starter gear to prevent transfer of rotation from the starter gear through the nut-shaped portion of the inner race (60) to the starter motor (21).

A roller type one-way clutch (40) for isolating a starter motor (21) from kickback rotation, the starter motor (21) having a driving shaft (25) with an axis of rotation for startup torque transmission to an internal combustion engine, the roller type one-way clutch (40) comprising:

• an outer race surface (56);
• an inner race (60) having a nut-shaped surface with a plurality of generally flat planar surfaces;
• a roller cage (42) having a cylindrical wall portion with a plurality of recesses (44) supporting a corresponding plurality of roller disks (46) for engagement between the outer race surface (56) and the inner race (60), the roller cage (42) having a radially outwardly extending flange portion (48) adjacent one end of the cylindrical wall portion supporting an enlarged inertia ring adjacent an outer peripheral edge (50) of the flange portion (48) for retarding rotational movement of the roller cage (42) during acceleration of the starter motor (21);
• and
• at least one spring (52) secured between the roller cage (42) and the nut-shaped surface of the inner race (60) for biasing the plurality of roller disks (46) toward a disengaged position with respect to the outer race surface (56);
• wherein the at least one spring (52) further comprises a leaf spring member extending between the roller cage (42) and the inner race (60).