Rail member and method for manufacturing rail member

Abstract

A rail member (1) for holding a slider of a linear guide rail device is formed by connecting a first member (10) made of thermoplastic resin and forming an upper portion of the rail member (1) and a second member (20) made of thermoplastic resin and forming a lower portion of the rail member (1). Tool withdrawal grooves 34 extending in the longitudinal direction of the rail component 1 are formed in the two side faces of the rail component 1 respectively. The relief groove (34) is formed by connecting the first member (10) and the second member (20), the upper edge (11a) of the relief groove (34) being a part of the first member (10), and the lower edge (24) of the relief groove (34) being a part of the second member (20).

Description

Technical Field

[0001] The present disclosure relates to a rail component and a method for manufacturing the rail component. Background Art

[0002] Patent document 1 discloses a package for accommodating a device for guiding linear motion, generally referred to as a linear guide device. The linear guide device shown in patent document 1 is composed of a moving body called a slider and a track body as a track component. The track component serves as an insertion jig for inserting the slider into a track installed at a specified position. In addition, the track component also has a ball rolling groove, which can be used as a retaining jig for retaining the multiple rolling bodies of the slider before the above-mentioned insertion. This type of track component for retaining the slider is usually manufactured by cutting metal or the like, but the track component in patent document 1 is made of a plastic material such as polyethylene.

[0003] Patent Document 2 discloses a linear guide rail device equipped with a linear rolling element retainer for retaining the multiple rolling elements of a slider. Patent Document 2 also discloses forming a relief groove on the side of the rail to prevent the rolling element retainer from interfering with the side of the rail when the slider moves linearly along the rail.

[0004] Prior art literature

[0005] Patent Document 1: Japanese Patent Application Laid-Open No. 2015-160658

[0006] Patent Document 2: Japanese Patent Application Laid-Open No. 11-82504 Summary of the Invention

[0007] Problems to be solved by the present invention

[0008] According to Patent Document 1, when the rail member used to hold the slider of a linear guide device is made of thermoplastic resin, costs can be better controlled compared to manufacturing by metal cutting. While there are various manufacturing methods using thermoplastic resin as a material, vacuum forming and gas pressure forming are generally more cost-effective than, for example, injection molding. Therefore, from a cost perspective, vacuum forming or gas pressure forming is preferred.

[0009] However, in vacuum forming or air pressure forming, the presence of grooves perpendicular to the product's demolding direction makes it difficult to demold the product, hindering mass production. For example, the track component described in Patent Document 2, which features a relief groove for accommodating the linear rolling element retainer, is difficult to manufacture using vacuum forming or air pressure forming. If this is done, the product may deform during demolding, potentially leading to defective products.

[0010] The present disclosure has been made in view of the above-mentioned problems. Specifically, the present disclosure aims to provide a track component that can be manufactured by vacuum forming or air pressure forming even if a back-off groove is provided on the side of the track component for holding a slider of a linear guide device. Furthermore, the present disclosure also aims to provide a method for manufacturing such a track component.

[0011] According to one aspect of the present invention, a rail component for holding a slider of a linear guide device, wherein the rail component is composed of a first component made of thermoplastic resin forming the upper portion of the rail component and a second component made of thermoplastic resin forming the lower portion of the rail component; the two side surfaces of the rail component are respectively provided with a tool relief groove extending along the longitudinal direction of the rail component; the tool relief groove is formed by connecting the first component and the second component, the upper edge of the tool relief groove is part of the first component, and the lower edge of the tool relief groove is part of the second component.

[0012] According to one aspect of the present invention, a method for manufacturing a rail component for holding a slider of a linear guide device includes: a molding process, forming by vacuum molding or air pressure molding, a first component made of thermoplastic resin forming the upper portion of the rail component and a second component made of thermoplastic resin forming the lower portion of the rail component; a connecting process, connecting the first component with the second component; wherein, through the connecting process, a tool relief groove extending along the longitudinal direction of the rail component is formed on both side surfaces of the rail component, the upper edge of the tool relief groove is part of the first component, and the lower edge of the tool relief groove is part of the second component.

[0013] Beneficial effects of the present invention

[0014] According to one embodiment of the present disclosure, a guide rail component can be provided that can be manufactured by vacuum forming or air pressure forming even if a back-off groove is provided on the side of the rail component for holding the slider of the linear guide device. In addition, according to one embodiment of the present disclosure, a method for manufacturing such a rail component can also be provided. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 is a perspective view showing a state of the rail member before connection in the first embodiment;

[0016] Figure 2 yes Figure 1 a rear perspective view of the middle track component;

[0017] Figure 3 Show Figure 1 A perspective view of the middle track component after connection;

[0018] Figure 4 It is along Figure 3 Cross-section along line AA;

[0019] Figure 5 It shows Figure 3 A perspective view of the middle track component in a state where the slider is retained;

[0020] Figure 6 It is along Figure 5 Partial cross-section along line BB;

[0021] Figure 7 It is a perspective view showing a modified example of the rail member in the first embodiment. DETAILED DESCRIPTION

[0022] The following describes a track component and a method for manufacturing a track component in accordance with an embodiment of the present disclosure with reference to the accompanying drawings. Identical elements are denoted by the same reference numerals in the various drawings, and duplicate descriptions are omitted as appropriate. The dimensions of the components shown in the drawings are for ease of description and may vary in actual dimensions.

[0023] In the figures, "F" stands for "front," "B" for "back," "L" for "left," "R" for "right," "U" for "up," and "D" for "down." These directions are relative directions for ease of explanation and do not limit the present invention. In the following description, "front-back" refers to a direction encompassing both the front and back directions; "left-right" refers to a direction encompassing both the left and right directions; and "up-down" refers to a direction encompassing both the up and down directions.

[0024] [First embodiment]

[0025] (Track components)

[0026] The track component in this embodiment is a product used to hold the slider of a linear guide device. The track component in this embodiment can, for example, serve as an insertion jig for inserting the slider into a track installed at a specified position. Furthermore, the track component in this embodiment can also serve as a retaining jig for holding the multiple rolling elements of the slider before the slider is inserted into the track installed at a specified position. In this specification, the term "linear guide device" does not refer to a specific product but rather a general term for devices that guide linear motion.

[0027] The track member in this embodiment is composed of a first member and a second member connected to each other. Figure 1 and Figure 2 , the rail component 1 before connection is described. Figure 1 1 is a perspective view showing a state before connection of the rail member 1 in the first embodiment. Figure 2 yes Figure 1 A rear perspective view of the track component 1.

[0028] like Figure 1 and Figure 2 As shown, the rail component 1 includes a first component 10, a second component 20 and a connecting component 31. The first component 10, the second component 20 and the connecting component 31 are made of thermoplastic resin, for example, thin-walled components formed by vacuum forming or air pressure forming. In this embodiment, these components are integrally formed by vacuum forming or air pressure forming, but they can also be formed separately. When they are formed separately, the connecting component 31 may not be provided. In addition, the first component 10 and the second component 20 are provided as shown in FIG. Figure 1 The draft angle shown widens downward (see Figure 4 ) to facilitate demoulding during vacuum forming or air pressure forming.

[0029] The resin used for the first component 10, the second component 20 and the connecting component 31 is not particularly limited as long as it is a thermoplastic resin. For example, conventionally known resins such as polyethylene terephthalate, polypropylene (PP), polystyrene, polyvinyl chloride, ABS (Acrylonitrile-Butadiene-Styrene) resin, polycarbonate or acrylic resin can be used. From the perspective of balancing the strength required for the track component 1 and the cost, it is preferred to use, for example, polyethylene terephthalate or polypropylene, and more preferably polyethylene terephthalate. In addition, it is also possible to form them by stacking two or more resins. In addition, when the first component 10 and the second component 20 are molded as separate components, the resins used for each component may also be different.

[0030] The first member 10 includes a first facing surface 11, a first fitting portion 12, a first rolling groove 13, and an undercut upper edge 14. The second member 20 includes a second facing surface 21, a second fitting portion 22, a second rolling groove 23, and an undercut lower edge 24.

[0031] The first member 10 has a substantially rectangular shape when viewed from above. The first member 10 forms the upper portion of the rail member 1 when connected to the second member 20. Figure 1 In FIG, the first opposing surface 11 is a substantially rectangular surface facing upward. When the first component 10 and the second component 20 are connected, the first opposing surface 11 faces the second opposing surface 21 of the second component 20.

[0032] The first interlocking portion 12 interlocks with the second interlocking portion 22 when the first component 10 is connected to the second component 20. The shape of the first interlocking portion 12 is not particularly limited, as long as it can interlock with the second interlocking portion 22. In the present embodiment, the first interlocking portion 12 is a cylindrical protrusion, but it can also be, for example, a prismatic protrusion, an elliptical protrusion or other shapes. The number of the first interlocking portions 12 is not particularly limited. In the present embodiment, the number of the first interlocking portions 12 is two, but it can also be one, three or more than four. The position of the first interlocking portion 12 is not particularly limited, for example, it can be appropriately determined according to the number of the first interlocking portions 12. In the present embodiment, the first interlocking portion 12 is respectively arranged near the rear end and the front end of the first relative surface 11.

[0033] When the first member 10 and the second member 20 are connected, the first rolling groove 13 forms a track-side rolling path 33 together with the second rolling groove 23 (see FIG. Figure 4 The first rolling grooves 13 extend along the longitudinal direction (front-rear direction) of the first member 10 and are formed on the left side surface and the right side surface of the first member 10 , respectively.

[0034] When the first component 10 and the second component 20 are connected, the upper edge 14 of the undercut forms a undercut 34 together with the lower edge 24 of the undercut (see FIG. Figure 4 The undercut upper edge 14 is a portion of the first opposing surface 11 , and refers to the left and right ends of the first opposing surface 11 . The undercut upper edge 14 extends along the longitudinal direction of the first component 10 .

[0035] The second member 20 has a substantially rectangular shape when viewed from above. When the second member 20 is connected to the first member 10, it forms the lower portion of the rail member 1. Figure 1 In FIG, the second opposing surface 21 is a substantially rectangular surface facing upward. When the first component 10 and the second component 20 are connected, the second opposing surface 21 faces the first opposing surface 11 of the first component 10.

[0036] The second interlocking portion 22 interlocks with the first interlocking portion 12 when the first component 10 and the second component 20 are connected. The shape of the second interlocking portion 22 is not particularly limited, as long as it can interlock with the first interlocking portion 12. In this embodiment, the second interlocking portion 22 is a cylindrical hollow hole, but the shape can be modified appropriately based on the shape of the first interlocking portion 12. The number and position of the second interlocking portions 22 can also be determined based on the number and position of the first interlocking portions 12.

[0037] When the first member 10 and the second member 20 are connected, the second rolling groove 23 forms a track-side rolling path 33 together with the first rolling groove 13 (see FIG. Figure 4The second rolling grooves 23 extend along the longitudinal direction of the second member 20 and are formed on the left side surface and the right side surface of the second member 20, respectively.

[0038] When the first component 10 and the second component 20 are connected, the lower edge 24 of the undercut forms a undercut 34 together with the upper edge 14 of the undercut (see FIG. Figure 4 The undercut lower edge 24 is a stepped portion extending further to the left from the left end of the second opposing surface 21, and a stepped portion extending further to the right from the right end of the second opposing surface 21. Furthermore, the undercut lower edge 24 extends along the longitudinal direction of the second component 20.

[0039] The connecting member 31 is a member used to connect the first member 10 and the second member 20 when the first member 10 and the second member 20 are integrally formed. Furthermore, the longitudinal length of the connecting member 31 is, for example, substantially equal to the height of the rail member 1 when the first and second members 10, 20 are connected. Therefore, the connecting member 31 also contributes to positioning the first and second members 10, 20 when connected. Furthermore, when the first and second members 10, 20 are connected, the connecting member 31 may or may not be arranged so that at least a portion of it abuts against the front surface of the second member 20.

[0040] Next, refer to Figure 3 and Figure 4 , the rail member 1 after the first member 10 and the second member 20 are connected will be described. Figure 3 It shows Figure 1 A perspective view of the middle rail component 1 after connection. Figure 4 It is along Figure 3 Cross-section along line AA.

[0041] Here, in this specification, "connection" between the first component 10 and the second component 20 means that the first component 10 and the second component 20 are fixed together in a state where the first opposing surface 11 and the second opposing surface 21 face each other. Figure 3 and Figure 4 In the example shown, the protrusion of the first engaging portion 11 engages with the hole of the second engaging portion 21, thereby connecting the first component 10 and the second component 20. However, the connection method is not limited to this example. Other conventional connection structures or adhesives can also be used for connection. The connection can be releasable or non-releasable.

[0042] like Figure 3As shown, the width w3 of the central portion of the rail component 1 in the longitudinal direction is longer than the width w1 and the width w2 of the two end portions of the rail component 1 in the longitudinal direction. The size of the width w3 should, for example, preferably be greater than 105% and less than 115% of the widths w1 and w2, and more preferably greater than 105% and less than 110%. When a product of the shape of the rail component 1 of this embodiment is manufactured by vacuum forming or air pressure forming, the central portion in the longitudinal direction is more likely to swell than the end portions when demolding from the mold. Therefore, the rail component 1 having a width w3 within the above range can be obtained, for example, by vacuum forming or air pressure forming. Specifically, the width w3 can be controlled to be within the above range by adjusting the resin heating temperature and cooling temperature during vacuum forming, etc.

[0043] like Figure 4 As shown, in this embodiment, when the first component 10 and the second component 20 are connected, the first relative surface 11 and the second relative surface 21 are opposite to each other and abut against each other. However, for example, a predetermined gap can be set between the first relative surface 11 and the second relative surface 21 by adjusting the shapes of the first interlocking portion 12 and the second interlocking portion 22.

[0044] In addition, if Figure 4 As shown, the first rolling groove 13 and the second rolling groove 23 form a track-side rolling path 33. When the track member 1 holds the slider, the rolling elements contained in the slider can roll within the rolling path formed by the track-side rolling path 33 and the slider-side rolling path (not shown). The shape and position of the track-side rolling path 33 are determined by the shape of the rolling elements and the position of the rolling elements in the slider, respectively.

[0045] In addition, if Figure 4 As shown, the back-off groove 34 is formed by the upper edge 14 of the back-off groove which is a part of the first component 10 and the lower edge 24 of the back-off groove which is a part of the second component 20. The back-off groove 34 is a groove provided to prevent the linear rolling element retainer contained in the slider from interfering with the rail component 1 when the slider is retained in the rail component 1. The shape and position of the back-off groove 34 are determined according to the shape of the rolling element retainer and the position of the rolling element retainer in the slider, respectively. There is no special restriction on the depth d of the back-off groove 34, which is determined according to the size of the rolling element retainer. The depth d of the back-off groove 34 is, for example, not less than 0.5 mm.

[0046] Next, refer to Figure 5 and Figure 6 , an example of use of the rail component 1 is described. Figure 5 It shows Figure 3 A perspective view of the rail component 1 holding the slider 50. Figure 6 It is along Figure 5 Partial cross-sectional view of line BB. In addition, Figure 6 The slider 50 shown in FIG. 1 shows only a portion of the rolling element 51 and the rolling element retainer 52 as a cross section, and other internal structures are omitted in the figure, and only the outer edge is shown.

[0047] The slider 50 comprises at least a plurality of rolling elements 51 and a rolling element retainer 52 for retaining the rolling elements 51. The rolling elements 51 may be spheres or rollers. The rolling element retainer 52 may be linear, plate-shaped, or have other shapes. The slider 50 may also have other conventionally known structures.

[0048] like Figure 6 As shown, a portion of the rolling element 51 is located inside the track side rolling path 33. In addition, the rolling element retainer 52 is located inside the undercut 34. Figure 5 In the illustrated state, the slider 50 is held on the rail member 1 and can move in the front-rear direction on the rail member 1 .

[0049] (Manufacturing method of track component)

[0050] The method for manufacturing the rail member 1 in this embodiment includes at least a molding step and a connecting step. The molding step involves forming the first member 10 made of thermoplastic resin at the upper portion of the rail member 1 and the second member 20 made of thermoplastic resin at the lower portion of the rail member 1 by vacuum molding or air pressure molding. Since vacuum molding and air pressure molding are conventionally known techniques, their description will be omitted.

[0051] The connection process is a method of connecting the first component 10 to the second component. In the above-mentioned rail component 1, the first component 10 and the second component 20 are connected by interlocking the first interlocking portion 12 and the second interlocking portion 22. Through the connection process, the backing groove 34 extending in the longitudinal direction of the rail component 1 is formed on both side surfaces of the rail component 1. As described above, the upper edge 14 of the backing groove is a part of the first component 10, and the lower edge 24 of the backing groove is a part of the second component 20. In addition, through the connection process, the track side rolling path 33 extending in the longitudinal direction of the rail component 1 is formed on both side surfaces of the rail component 1.

[0052] [Modification]

[0053] Next, a modification of the rail member 1 in the first embodiment will be described. Figure 7 It is a perspective view showing a modified example of the rail member 1 in the first embodiment. Figure 7 The rail member 100 shown can have the same configuration as the first embodiment except for the shape of the fitting portion and the presence or absence of the rib portion. Therefore, the following description will focus on the differences between the modification and the first embodiment.

[0054] In this modified example, the first component 110 is provided with four first interlocking portions 112. The first interlocking portions 112 are cylindrical protrusions located near the four corners of the first opposing surface 11. Furthermore, the second component 120 is provided with four second interlocking portions 122. The second interlocking portions 122 are rectangular holes located near the four corners of the second opposing surface 21. The first interlocking portions 112 and the second interlocking portions 122 have portions of approximately equal length in the front-to-back direction or the left-to-right direction, for example, and can interlock with each other. The interlocking of the first interlocking portions 112 and the second interlocking portions 122 connects the first component 110 and the second component 120.

[0055] The first opposing surface 11 has at least one rib 115 extending from the first opposing surface 11. The number and shape of the ribs 115 are not particularly limited, but, for example, from the perspective of increasing strength, it is preferable to provide a plurality of ribs 115 extending in the transverse direction (left-right direction), as shown in this example. Furthermore, from the same perspective, it is preferable that the plurality of ribs 115 are arranged in parallel, for example, in the front-to-back direction. Alternatively, the ribs 115 may be provided on the second opposing surface 12 so as to extend from the second opposing surface 12. When the first component 110 and the second component 120 are connected, the ribs 115 may, for example, abut against the second opposing surface 12.

[0056] While the embodiments of the present invention have been described in detail above, the present invention is not limited to the above embodiments and can be appropriately modified, improved, etc. The present invention includes all modifications within the meaning and scope of the claims and equivalents thereof.

[0057] (1) A rail member for holding a slider of a linear guide device, wherein:

[0058] The rail member is formed by connecting a first member made of thermoplastic resin forming an upper portion of the rail member and a second member made of thermoplastic resin forming a lower portion of the rail member;

[0059] Both sides of the track component are provided with a tool-relief groove extending along the longitudinal direction of the track component;

[0060] The undercut is formed by connecting the first member and the second member. An upper edge of the undercut is a portion of the first member, and a lower edge of the undercut is a portion of the second member.

[0061] According to this rail component, even if a side surface of a rail component for holding a slider of a linear guide device is provided with an undercut, it can be manufactured by vacuum forming or gas pressure forming. Specifically, this rail component is formed by connecting a first component including an upper edge of the undercut and a second component including a lower edge of the undercut. Therefore, for example, even if a rail component has an undercut perpendicular to the demolding direction when demolding from a mold or the like, it can be manufactured by vacuum forming or gas pressure forming.

[0062] (2) The rail member according to claim (1), wherein a width of a central portion of the rail member in the longitudinal direction is larger than a width of both end portions of the rail member in the longitudinal direction.

[0063] According to this track member, the central portion of the track member is wider than the width of the two end portions. Therefore, for example, the slider is less likely to fall off from the central portion, thereby improving the retention performance of the slider. In addition, since the width of the two end portions of the track member is narrower than the width of the central portion, for example, it is possible to improve the operability when retaining the slider on the track member.

[0064] (3) The rail component according to claim (1) or (2), wherein the first component has a first engaging portion, and the second component has a second engaging portion, and the first component and the second component are connected by engaging the first engaging portion and the second engaging portion. According to this rail component, for example, positioning is performed by each engaging portion, and the first component and the second component can be connected by a simple operation, thereby improving operability and manufacturing efficiency.

[0065] (4) The rail component according to any one of claims (1) to (3), wherein the first component and the second component are integrally formed by vacuum forming or air pressure forming.

[0066] According to this rail member, for example, since the parts to be connected are formed in groups, workability and manufacturing efficiency are improved. In addition, since, for example, deviations between the first and second parts to be connected due to differences in mold positions or production lines can be reduced, product quality can be improved.

[0067] (5) The rail component according to any one of claims (1) to (4), wherein the depth of the undercut is 0.5 mm or more.

[0068] When the undercut depth is greater than 0.5 mm, if the upper and lower components are not separated and vacuum-formed or pneumatically formed as a single component, the undercut will collide with the mold during demolding. Forcible demolding in this state can cause product deformation, leading to defective products. However, the rail component disclosed herein, for example, can be formed by vacuum forming or pneumatically forming even if it has an undercut of this depth.

[0069] (6) The rail component according to any one of claims (1) to (5), wherein the first opposing surface of the first component opposite to the second component, or the second opposing surface of the second component opposite to the first component has at least one or more ribs rising from the first opposing surface or the second opposing surface.

[0070] According to this rail member, for example, the strength of the rail member can be improved.

[0071] (7) A method for manufacturing a rail member for holding a slider of a linear guide device, the method comprising:

[0072] a molding step of forming a first member made of thermoplastic resin forming an upper portion of the rail member and a second member made of thermoplastic resin forming a lower portion of the rail member by vacuum molding or air pressure molding;

[0073] a connecting step of connecting the first component to the second component;

[0074] Wherein, through the connection process, a tool retreat groove extending along the longitudinal direction of the track component is formed on both side surfaces of the track component, the upper edge of the tool retreat groove is part of the first component, and the lower edge of the tool retreat groove is part of the second component.

[0075] According to this rail component, even if a side surface of a rail component for holding a slider of a linear guide device is provided with an undercut, it can be manufactured by vacuum forming or gas pressure forming. Specifically, this rail component is formed by connecting a first component including an upper edge of the undercut and a second component including a lower edge of the undercut. Therefore, for example, even if a rail component has an undercut perpendicular to the demolding direction when demolding from a mold or the like, it can be manufactured by vacuum forming or gas pressure forming.

Claims

1. A rail component for holding a slider of a linear guide device, wherein: The rail member is formed by connecting a first member made of thermoplastic resin forming an upper portion of the rail member and a second member made of thermoplastic resin forming a lower portion of the rail member; Both sides of the track component are provided with a tool-relief groove extending along the longitudinal direction of the track component; The undercut is formed by connecting the first member and the second member. An upper edge of the undercut is a portion of the first member, and a lower edge of the undercut is a portion of the second member.

2. The rail component according to claim 1, wherein The width of the central portion of the rail member in the longitudinal direction is greater than the width of both end portions of the rail member in the longitudinal direction.

3. The rail component according to claim 1 or 2, wherein: The first member has a first fitting portion, and the second member has a second fitting portion. The first member and the second member are connected by fitting the first fitting portion and the second fitting portion.

4. The rail component according to claim 1 or 2, wherein: The first member and the second member are integrally formed by vacuum forming or air pressure forming.

5. The rail component according to claim 1 or 2, wherein: The depth of the undercut is greater than 0.5 mm.

6. The rail component according to claim 1 or 2, wherein: The first opposing surface of the first member that faces the second member, or the second opposing surface of the second member that faces the first member, has at least one or more ribs rising from the first opposing surface or the second opposing surface.

7. A method for manufacturing a rail member for holding a slider of a linear guide device, the method comprising: a molding step of forming a first member made of thermoplastic resin forming an upper portion of the rail member and a second member made of thermoplastic resin forming a lower portion of the rail member by vacuum molding or air pressure molding; a connecting step of connecting the first component to the second component; Wherein, through the connection process, a tool retreat groove extending along the longitudinal direction of the track component is formed on both side surfaces of the track component, the upper edge of the tool retreat groove is part of the first component, and the lower edge of the tool retreat groove is part of the second component.

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