Resin member and method for manufacturing the same

Abstract

A resin member includes a first body portion made of resin and a mounting portion provided to the first body portion. The mounting portion includes a collar made of metal and a collar holding portion made of resin provided so as to cover an outer peripheral surface of the collar. The collar includes a second body portion in a cylindrical shape and a flange portion provided continuously to the second body portion at a first end portion of the second body portion and extending outward from the second body portion. The flange portion includes a first surface intersecting with an axial direction of the second body portion, a second surface opposite to the first surface in the axial direction and located on a side close to a second end portion of the second body portion, a third surface parallel to the axial direction and continuous to the first surface and the second surface, and a fourth surface formed obliquely to an outer peripheral edge of the first surface toward the second end portion of the second body portion. The collar holding portion covers the outer peripheral surface of the second body portion and a part of the third surface. In the collar holding portion, a seventh surface intersecting with the axial direction and located on a side close to the flange portion is provided at a position where the first surface is taken as a reference to approach the second end portion of the second body portion by a first distance.

Description

Technical Field

[0001] This disclosure relates to resin components and methods for manufacturing the same. In particular, this disclosure relates to a resin component having a mounting portion having an outer circumferential surface of a cylindrical metal collar covered with resin. Background Technology

[0002] When mounting and securing a resin housing that houses heavy objects such as motors to an external device, the following steps are performed: a cylindrical metal collar is installed on the housing, and bolts passing through the collar are tightened to mount the housing to the external device.

[0003] When assembling the collar into the housing, for example, as disclosed in Patent Document 1, a method for insert molding of resin in such a way as to cover the outer peripheral surface of the collar is proposed.

[0004] When a collar assembled into a housing serves as a through hole for a bolt, it is typically designed with an outwardly extending flange at one end, allowing the bolt head to abut against the flange. When a flange is provided on a cylindrical collar, cold forging is often used. Cold forging is a metalworking method that applies pressure to metal at room temperature while simultaneously deforming it.

[0005] When using the cold forging method, a cylindrical collar is prepared, and pressure is applied to one end of the collar at room temperature to push it outward, forming a flange on the collar.

[0006] However, in this case, a collapsed edge may occur at the outer periphery of the flange. If resin adheres to the collapsed area during resin insert molding, resin will remain on the contact surface between the bolt head and the flange when the bolt is inserted into the collar for tightening. If resin is present on this contact surface, there is a concern that foreign matter formed by resin peeling may occur during bolt tightening. Furthermore, there is a concern that if the resin volume decreases due to changes in resin volume over time or atmospheric temperature, a gap may form at the contact point between the bolt and the flange, leading to loosening of the bolt.

[0007] Although no flange is provided at the other end of the collar, there is a concern that the end face at that other end may also collapse in collars formed by cold forging. Therefore, there is a concern that during insert molding, resin may adhere to the end face at the other end, causing the collapse. Since the end face at the other end of the collar abuts against the housing mounting surface in the external device, there is a similar concern as with the case of resin adhesion at the flange: foreign matter may be generated, or gaps may form at the abutment between the end face and the housing mounting surface, preventing the housing from being stably installed and secured to the external device.

[0008] Existing technical documents

[0009] Patent documents

[0010] Patent Document 1: Japanese Patent Application Publication No. 2004-042561 Summary of the Invention

[0011] This disclosure was made in view of this. The object of this disclosure is to provide a resin component and a method thereof capable of preventing resin from adhering to the contact surface of the collar assembled with other components.

[0012] To achieve the above objectives, the resin component of this disclosure comprises: a first main body portion made of resin; and a mounting portion disposed on the first main body portion. The mounting portion includes: a metal collar; and a resin collar retaining portion disposed to cover the outer peripheral surface of the collar. The collar includes: a cylindrical second main body portion; and a flange portion continuously disposed at a first end of the second main body portion and extending outward from the second main body portion. The flange portion includes: a first surface intersecting the axial direction of the second main body portion, i.e., a third direction; a second surface opposite to the first surface in the third direction and located on a side near the second end of the second main body portion; and a third surface parallel to the third direction and continuous with respect to the first and second surfaces. A fourth surface inclined toward the second end of the second main body portion is provided at the outer peripheral edge of the first surface. The collar retaining portion partially covers the outer peripheral surface of the second main body portion and the third surface. In the collar retaining portion, the seventh surface, which intersects the third direction and is located on the side near the flange portion, is positioned at the second end of the second main body portion, with the first surface as a reference and a first distance away.

[0013] Preferably, a sixth surface is provided on the outer periphery of the fifth surface of the second main body located at the second end, which is inclined toward the first end of the second main body. The collar retaining portion partially covers the outer periphery of the second main body. In the collar retaining portion, an eighth surface that intersects the third direction and is located on the side close to the second end is provided at a position that is close to the first end of the second main body with the fifth surface as a reference and a second distance.

[0014] Preferably, the collar retaining portion is provided in a manner that does not cover the fourth surface.

[0015] Alternatively, the collar retaining part may be configured in a manner that does not cover the sixth surface.

[0016] Preferably, the collar retaining portion is formed of thermosetting resin.

[0017] Preferably, the collar is formed by cold forging.

[0018] Alternatively, the first main body part may be a hollow component.

[0019] Alternatively, the first main body may have a fixing leg for mounting on an external device.

[0020] The method for manufacturing a resin component disclosed herein includes: a first step of preparing the collar; a second step of positioning the collar at a predetermined position in a mold having a cavity; and a third step of injecting resin into the mold cavity to insert-form the collar retaining portion such that it covers the outer peripheral surface of the second main body portion of the collar. The mold comprises a first mold and a second mold, the first mold having a support pin for mounting the collar, and the second mold being disposed opposite to the first mold. The space formed when the first mold and the second mold abut together is the mold cavity. In cross-sectional view, a first step is provided on the abutment surface of the first mold that abuts the flange portion, and the height of the side surface of the first step is the first distance. In the second step, the first surface of the flange portion abuts against the bottom surface of the first step.

[0021] Preferably, in cross-sectional view, a second step is provided on the abutment surface of the second mold that abuts against the fifth surface of the second main body, the height of the side of the second step is the second distance, the fifth surface is the end face of the second end of the second main body, and in the second step, the fifth surface abuts against the bottom surface of the second step.

[0022] Preferably, the resin is a thermosetting resin.

[0023] According to this disclosure, it is possible to prevent resin from adhering to the contact surface of the collar assembled in the mounting part that abuts against other components. This suppresses the generation of foreign matter and prevents loosening of the fastening members secured to the mounting part. Attached Figure Description

[0024] Figure 1 This is a diagram obtained by viewing the blower housing of the embodiment from above.

[0025] Figure 2 yes Figure 1 A sectional view at line II-II.

[0026] Figure 3A Therefore Figure 2 An enlarged view of the area enclosed by the dashed line IIIA.

[0027] Figure 3B Therefore Figure 2 An enlarged view of the portion enclosed by the dashed line IIIB.

[0028] Figure 4 This is a diagram illustrating the manufacturing method of the mounting part of the blower housing.

[0029] Figure 5 This is a magnified view of a portion of the first mold.

[0030] Figure 6 This is a magnified view of a portion of the second mold. Detailed Implementation

[0031] Hereinafter, embodiments of the present disclosure will be described with reference to the accompanying drawings. The following description of preferred embodiments is merely illustrative in nature and is not intended to limit the present disclosure, its applications, or its uses.

[0032] (Implementation Method)

[0033] [Structure of the blower casing]

[0034] Figure 1 This is a diagram obtained from above, showing the resin component of the embodiment, namely the blower housing 10. Figure 2 yes Figure 1 A cross-sectional view at line II-II. In the following description, the direction perpendicular to the paper will be referred to as the Z direction or the third direction. The direction orthogonal to the Z direction will be referred to as the X direction or the first direction. The direction orthogonal to both the X and Z directions will be referred to as the Y direction or the second direction. The Z direction is also the axial direction of the second main body 41 of the collar 40 (see reference). Figure 2 In the Z direction, the side of the collar 40 with the flange portion 42 is referred to as the upper side or upper, and the side with the fifth surface 41a is referred to as the lower side or lower (see reference). Figure 2 ).

[0035] In this application specification, "parallel," "identical," or "orthogonal" refers to the fact that the assembly tolerances or machining tolerances of the blower housing 10 or its component mounting portion 30 or collar 40 result in parallelness, identicalness, or orthogonality. "Parallel," "identical," or "orthogonal" does not mean that the compared objects are strictly parallel, identical, or orthogonal to each other. That is, it can be said that the X, Y, and Z directions intersect each other.

[0036] like Figure 1As shown, the blower housing 10 has: a first main body portion 20 having an opening 21; and an airflow outlet 22, which opens continuously in the Y direction from the first main body portion 20. The first main body portion 20 is annular when viewed from above. The first main body portion 20 is a hollow component. Although not shown, a centrifugal fan and a motor (both not shown) connected to the centrifugal fan are arranged in the opening 21. By operating the motor, the centrifugal fan rotates, and airflow is discharged from the airflow outlet 22. Heat-generating components, such as batteries, arranged in the airflow discharge direction are cooled by the airflow discharged from the airflow outlet 22.

[0037] On the outer peripheral surface of the first main body 20, three mounting portions 30 are provided at intervals. Each mounting portion 30 has a collar 40 and a collar retaining portion 31 (see reference). Figure 2 The first main body 20 and the air outlet 22 are integrally molded from resin. The collar retaining part 31 is also a resin component. Alternatively, the collar retaining part 31 may be integrally molded with the first main body 20 and the air outlet 22. However, it is also possible that after the collar 40 is assembled to the collar retaining part 31 and the mounting part 30 is completed, the mounting part 30 is mounted to the first main body 20 by means of welding or the like.

[0038] [Structure of the mounting section]

[0039] Figure 3A Therefore Figure 2 An enlarged view of the area enclosed by the dashed line IIIA. Figure 3B Therefore Figure 2 An enlarged view of the portion enclosed by the dashed line IIIB.

[0040] like Figure 2 As shown, the mounting portion 30 includes a collar 40 and a collar retaining portion 31. The collar 40 is a cylindrical member made of metal, such as low-carbon steel. The collar 40 has a second main body portion 41 and a flange portion 42 integrally formed with the second main body portion 41. The second main body portion 41 is a straight cylindrical member. The flange portion 42 extends outward from the upper end portion 41A of the second main body portion 41 along an XY plane orthogonal to the Z direction towards the outside of the second main body portion 41. The XY plane refers to an imaginary plane that includes imaginary lines along the X direction and imaginary lines along the Y direction within a plane.

[0041] like Figure 3A As shown, the flange portion 42 has a first surface (upper surface) 42a, a second surface (lower surface) 42b opposite to the first surface 42a in the Z direction, and a third surface (side surface) 42c parallel to the Z direction and continuous with respect to the first surface 42a and the second surface 42b. A fourth surface (first inclined surface) 42d inclined in the Z direction is formed on the outer periphery of the first surface 42a. Figure 2The example shown is a fourth surface 42d that is an upwardly convex inclined surface. However, it is not particularly limited to this. It is also possible that the fourth surface 42d is an downwardly convex inclined surface. It is also possible that the fourth surface 42d has concavity and convexity in the Z direction.

[0042] The collar 40 is formed by cold forging. Although not shown, the flange 42 is formed by pressing and deforming a straight cylindrical member made of low-carbon steel from above. By pressing the cylindrical member, a so-called collapsed edge is created at the outer periphery of the flange 42, forming a fourth surface 42d that is inclined from the first surface 42a in the Z direction.

[0043] like Figure 3B As shown, at the lower end of the second main body 41, i.e., the second end 41B, on the fifth surface (end surface) 41a, a sixth surface (second inclined surface) 41b inclined in the Z direction is also formed for the same reason. End surface 41a is a surface parallel to the XY plane. Figure 2 The diagram shows an example where the sixth surface 41b is a downward-convex inclined surface. However, it is not particularly limited to this. Alternatively, the sixth surface 41b could be an upward-convex inclined surface. It could also be that the sixth surface 41b has irregularities in the Z direction.

[0044] like Figure 2 As shown, the collar retaining portion 31 has a seventh surface (upper surface) 31a and an eighth surface (lower surface) 31b. The collar retaining portion 31 is a component formed of thermosetting resin. The collar retaining portion 31 is provided in such a way that it covers the outer peripheral surface of the collar 40. Figure 3A As shown, the seventh surface 31a of the collar retaining portion 31 is located at a first distance D1 from the first surface 42a of the flange portion 42 along the Z direction. The first distance D1 is set to be longer than the distance d1 along the Z direction from the first surface 42a to the lower end of the fourth surface 42d. That is, the collar retaining portion 31 partially covers the outer peripheral surface of the second body portion 41 of the collar 40, the second surface 42b of the flange portion 42, and the third surface 42c. On the other hand, the collar retaining portion 31 is formed not to partially cover the first surface 42a, the fourth surface 42d, and the third surface 42c of the flange portion 42. The first distance D1 may also be the same as the distance d1. In this case, the collar retaining portion 31 is formed to completely cover the second surface 42b and the third surface 42c of the flange portion 42.

[0045] like Figure 3BAs shown, the eighth surface 31b of the collar retaining portion 31 is located at a second distance D2 from the fifth surface 41a of the second main body portion 41 along the Z direction. The second distance D2 is set to be longer than the distance d2 along the Z direction from the fifth surface 41a to the upper end of the sixth surface 41b. In other words, the collar retaining portion 31 is formed to cover the outer peripheral surface of the second main body portion 41 without covering the fifth surface 41a and the sixth surface 41b. The second distance D2 can also be the same as the distance d2.

[0046] like Figure 1 and Figure 2 As shown, when the blower housing 10 is mounted on an external device, the mounting portion 30 is provided on the support portion 60 of the external device. In this case, the mounting portion 30 is provided on the support portion 60 such that the eighth surface 31b of the collar retaining portion 31 abuts against the mounting surface 60a. The mounting portion 30 is aligned relative to the support portion 60 such that the through hole 43 of the collar 40 overlaps with the mounting hole 60b provided in the support portion 60 when viewed from above, and based on this, the mounting portion 30 is provided on the support portion 60.

[0047] After the bolt (fastening member) 50 is passed through the through hole 43 and the mounting hole 60b, the bolt 50 is tightened, and the mounting part 30 is installed and fixed to the support part 60. With this arrangement, the blower housing 10 is installed and fixed to the external equipment.

[0048] Actual measurements show that the actual values ​​of the aforementioned distances d1 and d2 are approximately less than 0.1 mm. Therefore, it is preferable that both the first distance D1 and the second distance D2 are set to be greater than 0.1 mm. In practice, the thermal shrinkage of the resin and the mold 100 (refer to...) need to be considered. Figure 4 The first distance D1 and the second distance D2 are set respectively by the machining tolerance of the collar 40 or the machining tolerance of the flange portion 42.

[0049] [Manufacturing method for the installation section]

[0050] Figure 4 This is a diagram illustrating the manufacturing method of the mounting part 30 of the blower housing 10. Figure 5 This is a magnified view of a portion of mold 110. Figure 6 This is a magnified view of a portion of mold 120, part 2. For clarity, [the view is shown here]. Figures 4-6 The resin inlet diagram is omitted in the text.

[0051] The mounting section 30 is formed by insert molding. Hereinafter, it will be used... Figures 4-6 Further explanation is needed. For example... Figure 4As shown, the mold 100 for insert molding is composed of a first mold 110 and a second mold 120. The first mold 110 has a support pin 112, and the second mold 120 is arranged opposite to the first mold 110 at a distance from the long side of the support pin 112.

[0052] like Figure 4 As shown, a support pin 112 provided in the first mold 110 passes through the through hole 43 of the collar 40, and the collar 40 is installed in the first mold 110. Next, the first mold 110 is moved toward the second mold 120 such that the first abutting surface 110a of the first mold 110 abuts against the second abutting surface 120a of the second mold 120. With this arrangement, the front end of the support pin 112 is embedded in the recess 122 provided in the second mold 120, and a mold cavity 101 is provided between the first mold 110 and the second mold 120. The support pin 112 and the collar 40 are disposed inside the mold cavity 101.

[0053] In this state, resin is injected into the mold cavity 101 through a resin injection port (not shown) provided in the second mold 120. This resin is a thermosetting resin. To ensure flowability, the resin is heated to a temperature of several tens of degrees Celsius at the moment of injection. The mold 100 is heated to approximately the thermosetting temperature of the resin, for example, around 100-230 degrees Celsius. Therefore, the resin flowing into the mold cavity 101 solidifies, forming a collar retaining portion 31 that covers the outer peripheral surface of the collar 40. After the formation of the collar retaining portion 31 is completed, the first mold 110 and the second mold 120 are separated, and the mounting portion 30 is removed from the mold 100.

[0054] like Figure 3A as well as Figure 5 As shown, a first annular step 111 is provided around the support pin 112 on the mounting surface of the support pin 112 in the first mold 110. With the collar 40 mounted on the support pin 112, the first surface 42a of the flange 42 abuts against the bottom surface 111a of the first step 111. Conversely, a portion of the third surface 42c of the flange 42 abuts against the side surface 111b of the first step 111. The height of the first step 111, based on the bottom surface 111a, is equal to the aforementioned first distance D1.

[0055] like Figure 3B as well as Figure 6As shown, a second annular step 121 surrounds the recess 122 on the forming surface of the second mold 120. With the front end of the support pin 112 inserted into the recess 122, the fifth surface 41a of the second main body 41 abuts against the bottom surface 121a of the second step 121. On the other hand, a portion of the outer peripheral surface of the second main body 41 abuts against the side surface 121b of the second step 121. The height of the second step 121, based on the bottom surface 121a, is equal to the aforementioned second distance D2.

[0056] Figure 4 The first mold 110 and the second mold 120 shown only illustrate the parts related to the mounting portion 30. When the mounting portion 30 is integrally formed with the first main body 20 or the air outlet 22 of the blower housing 10, the shapes of the first mold 110 and the second mold 120 respectively reflect the shapes of the first main body 20 or the air outlet 22, resulting in complex shapes. Furthermore, in the following description, the blower housing 10 with the mounting portion 30 may be referred to as a resin component.

[0057] [Effects, etc.]

[0058] As described above, the blower housing (resin component) 10 of this embodiment includes: a first main body portion 20, which is made of resin and is hollow; and a mounting portion 30 provided on the first main body portion 20. The mounting portion 30 includes: a metal collar 40; and a resin collar retaining portion 31, which covers the outer peripheral surface of the collar 40.

[0059] The collar 40 has: a cylindrical second main body portion 41; and a flange portion 42, which is continuously disposed at the first end 41A of the second main body portion 41 and extends outward from the second main body portion 41.

[0060] The flange portion 42 has: a first surface (upper surface) 42a, which is orthogonal to the axial direction of the second main body portion 41, i.e., the Z direction (third direction); and a second surface (lower surface) 42b, which is opposite to the first surface 42a in the Z direction and is located on the side close to the second end portion 41B of the second main body portion 41. Additionally, the flange portion 42 has a third surface (side surface) 42c, which is parallel to the Z direction and continuous with respect to the first surface 42a and the second surface 42b. A fourth surface (first inclined surface) 42d is provided on the outer periphery of the first surface 42a, inclined toward the second end portion 41B of the second main body portion 41.

[0061] The collar retaining portion 31 partially covers the outer peripheral surface of the second main body portion 41 and the third surface 42c of the flange portion 42. In the collar retaining portion 31, the seventh surface (upper surface) 31a, which is orthogonal to the Z direction and located on the side close to the flange portion 42, is provided at a position close to the second end portion 41B of the second main body portion 41 with the first surface 42a as a reference and a first distance D1.

[0062] By constructing the blower housing 10 in this way, it is possible to prevent the following situation: during the molding of the insert in the mounting part 30, a collapsed portion, namely the fourth surface 42d, of the flange portion 42 of the collar 40, from resin adhesion, can be formed. Therefore, it is possible to suppress the situation where, when the bolt 50 is inserted into the collar 40 and tightened, the resin adhering to the fourth surface 42d peels off, creating foreign matter. Furthermore, it is possible to suppress the situation where the resin volume decreases due to changes in resin over time or changes in ambient temperature, creating a gap at the contact point between the bolt 50 and the flange portion 42, leading to loosening of the bolt 50.

[0063] Furthermore, it can prevent situations such as resin cracking and cracks forming in the collar retaining portion 31 during bolt 50 tightening. This prevents damage to the collar retaining portion 31 and even the mounting portion 30, thus preventing the blower housing 10 from falling off the support portion 60.

[0064] The first distance D1 is preferably set to be the same as or longer than the distance d1 along the Z direction from the first surface 42a to the lower end of the fourth surface 42d. In other words, it is preferable that the collar retaining portion 31 is provided in a manner that does not cover the fourth surface 42d. By providing this arrangement, it is possible to reliably prevent resin from adhering to the fourth surface 42d during the formation of the insert of the mounting portion 30.

[0065] The second main body portion 41 of the collar 40 has a sixth surface (second inclined surface) 41b on the outer periphery of the fifth surface (end surface) 41a located at the second end 41B, which is inclined toward the first end 41A.

[0066] The collar retaining part 31 partially covers the outer peripheral surface of the second main body part 41. In the collar retaining part 31, the eighth surface (lower surface) 31b, which is orthogonal to the Z direction and located near the second end 41B, is provided at a position close to the first end 41A of the second main body part 41 with the fifth surface 41a as a reference and a second distance D2.

[0067] As described above, in the second main body portion 41 of the collar 40, a portion with a collapsed edge, namely the sixth surface 41b, can also be formed on the outer periphery of the fifth surface 41a located at the lower end. Therefore, according to this embodiment, it is possible to prevent resin from adhering to the sixth surface 41b, and to suppress the situation where, when the bolt 50 is inserted into the collar 40 and tightened, the resin adhering to the fourth surface 42d peels off and generates foreign matter. In addition, it is possible to suppress the situation where the volume of resin decreases due to changes in resin over the years or changes in ambient temperature, resulting in a gap at the abutment portion between the bolt 50 and the flange portion 42, and causing loosening at the bolt 50.

[0068] Furthermore, it can prevent situations such as resin cracking and cracks forming in the collar retaining portion 31 during bolt 50 tightening. This prevents damage to the collar retaining portion 31 and even the mounting portion 30, thus preventing the blower housing 10 from falling off the support portion 60.

[0069] The second distance D2 is preferably set to be the same as or longer than the distance d2 along the Z direction from the fifth surface 41a to the upper end of the sixth surface 41b. In other words, it is preferable that the collar retaining portion 31 is provided in a manner that does not cover the sixth surface 41b. By providing this arrangement, it is possible to reliably prevent resin from adhering to the sixth surface 41b during the formation of the insert of the mounting portion 30.

[0070] In this embodiment, the collar retaining portion 31 and the first main body portion 20 are integrally formed. This arrangement reduces the mold or molding time required to form the blower housing 10, thus lowering the manufacturing cost of the blower housing 10. Alternatively, as described above, the mounting portion 30 can be formed separately from the first main body portion 20, and then mounted onto the first main body portion 20. This arrangement simplifies the shape of the mold used to form the blower housing 10.

[0071] Furthermore, in this embodiment, the resin portion of the blower housing 10 is a thermosetting resin. As described above, the motor is housed inside the blower housing 10. Since the motor generates heat during operation, there is a concern that the blower housing 10 might deform due to heat if it were made of thermoplastic resin. As shown in this embodiment, by using a thermosetting resin for the resin portion of the blower housing 10, deformation caused by the motor's heat can be prevented, and the operational reliability of the blower unit can be ensured.

[0072] Furthermore, the collar 40 in this embodiment is formed by cold forging. This arrangement allows for the simple and low-cost manufacture of the collar 40, thereby reducing the manufacturing cost of the blower housing 10.

[0073] The manufacturing method of the mounting portion 30 of the blower housing 10 in this embodiment includes the following steps 1 to 3.

[0074] In step 1, a collar 40 is prepared. In step 2, the collar 40 is positioned at a predetermined location on the mold 100 having the mold cavity 101. In this embodiment, the collar 40 is mounted on the support pin 112 of the first mold 110.

[0075] In step 3, resin is injected into the mold cavity 101 to insert the collar retaining portion 31 so as to cover the outer peripheral surface of the second main body portion 41 of the collar 40.

[0076] The mold 100 is composed of a first mold 110 and a second mold 120. The first mold 110 has a support pin 112 for mounting a collar 40, and the second mold 120 is configured opposite to the first mold 110. The space formed when the first mold 110 and the second mold 120 abut together is a mold cavity 101.

[0077] In cross-sectional view, a first step 111 is provided on the abutment surface of the first mold 110 that abuts against the flange portion 42. The height of the side surface 111b of the first step 111 is a first distance D1. In the second step, the first surface 42a of the flange portion 42 abuts against the bottom surface 111a of the first step 111.

[0078] By using this configuration, the first step 111 of the first mold 110 can be used to prevent resin from adhering to the fourth surface 42d located at the outer periphery of the first surface 42a of the flange portion 42. This prevents the generation of foreign matter during bolt tightening, loosening of the bolt 50 due to resin volume reduction, or damage to the collar retainer 31.

[0079] Furthermore, in cross-sectional view, a second step 121 is provided on the abutment surface of the second mold 120 that abuts against the fifth surface 41a of the second main body 41. The height of the side surface 121b of the second step 121 is a second distance D2. The fifth surface 41a is the end face of the second end portion 41B of the second main body 41. In the second step, the fifth surface 41a is brought into contact with the bottom surface 121a of the second step 121.

[0080] The cross-sectional observation mentioned here refers to the following situations: such as Figures 4-6 As shown, in a cross-section of the mold 100 with the collar 40 cut through the axis of the support pin 112, the collar 40 and the mold 100 are observed.

[0081] By using this configuration, the second step 121 of the second mold 120 can be used to prevent resin from adhering to the sixth surface 41b located at the outer periphery of the fifth surface 41a on the second main body 41. This prevents situations such as foreign matter from being generated during bolt tightening, loosening of the bolt 50 due to resin volume reduction, or damage to the collar retainer 31.

[0082] Furthermore, it is preferable that the resin injected into the mold cavity 101 is a thermosetting resin. By using a thermosetting resin for the collar retaining portion 31, deformation caused by motor heat can be prevented, the strength of the mounting portion 30 can be ensured, and the blower housing 10 can be reliably mounted to the support portion 60 of the external equipment. Additionally, it prevents the blower housing 10 from falling off the support portion 60 when the motor is operating.

[0083] (Other implementation methods)

[0084] In the above embodiments, the blower housing 10 was described as an example. However, the resin component for which the mounting portion 30 is provided is not particularly limited to this. For example, the resin component may be a fixing leg for mounting on the support portion 60 of an external device. Alternatively, the mounting portion 30 may be a part of the fixing leg. As long as the resin component having the mounting portion 30 is mounted on the external device using fastening members such as bolts, it is sufficient to prevent the generation of foreign matter in the collar retaining portion 31 of the mounting portion 30 due to the loss of resin adhering to the first inclined surface 42d or the second inclined surface 41b. In addition, it is sufficient to prevent the bolt 50 from loosening or the collar retaining portion 31 from breaking due to the reduction in resin volume.

[0085] Furthermore, it is preferable that when the mounting portion 30 and the first main body portion 20 are formed separately, at least the collar retaining portion 31 is formed of thermosetting resin. This prevents situations such as foreign matter from being generated during bolt tightening, loosening of the bolt 50 due to resin volume reduction, or damage to the collar retaining portion 31.

[0086] Furthermore, this application specification shows an example using a collar 40 formed by cold forging. However, the manufacturing method of the collar 40 is not limited to this. When a downwardly inclined surface is formed at the outer periphery of the first surface (upper surface) 42a in the flange portion 42 of the collar 40 due to processing reasons, etc., the mounting portion 30 can be formed using the structure or method disclosed in this application specification, thereby achieving the same effect as shown in the embodiment. That is, it is possible to prevent resin from adhering to the inclined surface provided at the outer periphery of the first surface 42a. Therefore, it is possible to prevent the generation of foreign matter during bolt 50 tightening, loosening of the bolt 50 due to resin volume reduction, or damage to the collar retaining portion 31.

[0087] Industrial availability

[0088] The resin component disclosed herein is useful in preventing resin from adhering to the contact surface of the collar assembled in the mounting section where it contacts other components.

[0089] Explanation of reference numerals in the attached figures

[0090] 10. Blower housing (resin component); 20. First main body; 21. Opening; 22. Air outlet; 30. Mounting part; 31. Collar retaining part; 31a. 7th surface (upper surface); 31b. 8th surface (lower surface); 40. Collar; 41. Second main body; 41A. 1st end (upper end); 41B. 2nd end (lower end); 41a. 5th surface (end face); 41b. 6th surface (2nd inclined surface); 42. Flange; 42a. 1st surface (upper surface); 42b. 2nd surface (lower surface); 42 c. Third surface (side surface); 42d. Fourth surface (first inclined surface); 43. Through hole; 50. Bolt (fastening component); 60. Support part; 60a. Setting surface; 60b. Mounting hole; 100. Mold; 101. Mold cavity; 110. First mold; 110a. First abutment surface; 111. First step; 111a. Bottom surface; 111b. Side surface; 112. Support pin; 120. Second mold; 120a. Second abutment surface; 121. Second step; 121a. Bottom surface; 121b. Side surface; 122. Recess.

Claims

1. A resin component, wherein, The resin component has: The first main body part made of resin; and The mounting section is located in the first main body section. The mounting part has: Metal collar; and A resin-made collar retainer is provided such that it covers the outer peripheral surface of the collar. The collar has: The second main body part is cylindrical; and A flange portion is provided continuously with the second main body portion at its first end and extends outward from the second main body portion. The flange portion has: The first surface intersects with the axial direction of the second main body, i.e., the third direction; The second surface is opposite to the first surface in the third direction and is located on the side near the second end of the second main body. A third surface, which is parallel to the third direction and continuous with respect to the first surface and the second surface; and The fourth surface is formed obliquely on the outer periphery of the first surface, toward the second end of the second main body. The collar retaining portion partially covers the outer peripheral surface of the second main body and a portion of the third surface. In the collar retaining portion, the seventh surface, which intersects the third direction and is located on the side near the flange portion, is positioned at the second end of the second main body portion, with the first surface as a reference and a first distance away.

2. The resin component according to claim 1, wherein, A sixth surface is provided on the outer periphery of the fifth surface located at the second end of the second main body, which is inclined toward the first end of the second main body. The collar retaining portion partially covers the outer peripheral surface of the second main body portion. In the collar retaining portion, the eighth surface, which intersects the third direction and is located on the side near the second end, is positioned at a second distance from the first end of the second main body portion, with the fifth surface as a reference.

3. The resin component according to claim 1, wherein, The collar retaining part is configured in a manner that does not cover the fourth surface.

4. The resin component according to claim 2, wherein, The collar retaining part is configured such that it does not cover the sixth surface.

5. The resin component according to claim 1, wherein, The retaining part of the collar is formed of thermosetting resin.

6. The resin component according to any one of claims 1 to 5, wherein, The collar is formed by cold forging.

7. The resin component according to claim 6, wherein, The first main body is a hollow component.

8. The resin component according to claim 6, wherein, The first main body has a fixing leg for mounting to an external device.

9. A method for manufacturing a resin component, which is the method for manufacturing a resin component according to claim 6, wherein, The method for manufacturing the resin component includes: Step 1: In this first step, the collar is prepared; In the second step, the collar is positioned at a predetermined location in the mold having a cavity. as well as In the third step, resin is injected into the mold cavity to insert the collar retaining portion by covering the outer peripheral surface of the second main body of the collar. The mold consists of a first mold and a second mold. The first mold has a support pin for mounting the collar, and the second mold is configured opposite to the first mold. The space formed when the first mold and the second mold abut together is the mold cavity. In cross-sectional view, a first step is provided on the abutment surface of the first mold that abuts against the flange portion, and the height of the side of the first step is the first distance. In the second step, the first surface of the flange portion is brought into contact with the bottom surface of the first step.

10. The method for manufacturing a resin component according to claim 9, wherein, In cross-sectional view, a second step is provided on the abutment surface of the second mold that abuts against the fifth surface of the second main body. The height of the side of the second step is the second distance. The fifth surface is the end face of the second end portion of the second main body. In the second step, the fifth surface is brought into contact with the bottom surface of the second step.

11. The method for manufacturing a resin component according to claim 9, wherein, The resin is a thermosetting resin.

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