Composite structure rotor and resin molding

Abstract

To provide a composite structure rotor and a resin molding in which strength is improved by providing reinforcing fibers in a well-balanced manner.SOLUTION: A composite structure gear 1 comprises: an annular resin molding 5 including reinforcing fibers and resin, and having a tooth profile formed on an outer peripheral part 51; an annular metal bushing 3; and a bonding resin member 7 connecting the resin molding 5 and the metal bushing 3. The resin molding 5 has a plurality of recessed regions 531 formed at predetermined intervals in a circumferential direction, and the recessed region 531 has a thin-walled part 531x in which recess parts 531y are formed on both sides in a thickness direction of the resin molding 5. As shown in Fig.2(b), in the recessed region 531, the sum of a depths D1 of the recess parts 531y on both sides is smaller than a thickness T1 of the thin-walled part 531x.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] One aspect of the present invention relates to a composite structure rotating body and a resin molded body.

Background Art

[0002] Patent Document 1 describes a resin composite structure rotating body in which a tooth portion is formed by impregnating a reinforcing fiber base material with resin.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Here, in the above-described resin composite structure rotating body, during molding, in some regions of the resin molded body (a molded body containing reinforcing fibers and resin), for example, in the convex region of adjacent uneven shapes (the region sandwiched between two concave regions), the reinforcing fibers may be difficult to follow.

[0005] One aspect of the present invention has been made in view of the above circumstances, and an object thereof is to provide a composite structure rotating body and a resin molded body in which reinforcing fibers are provided in a well-balanced manner to improve strength.

Means for Solving the Problems

[0006] A composite structure rotating body according to one aspect of the present invention includes an annular resin molded body that contains reinforcing fibers and resin and has a tooth shape formed on an outer peripheral portion, an annular metal bush, and a bonding resin member that connects the resin molded body and the metal bush. A plurality of concave regions are formed in the resin molded body at predetermined intervals in the circumferential direction, and in the concave regions, a thin portion having concave portions formed on both surfaces in the thickness direction of the resin molded body is provided. In the concave regions, the total value of the depths of the concave portions on both surfaces is smaller than the thickness of the thin portion.

[0007] In the composite structure rotating body according to one aspect of the present invention, a plurality of concave regions are formed along the circumferential direction in the annular resin molded body, and in each concave region, a thin portion having concave portions formed on both surfaces in the thickness direction of the resin molded body is provided. And in each concave region, the total value of the depths of the concave portions on both surfaces is smaller than the thickness of the thin portion. In this way, by forming the concave portions shallowly, when molding the resin molded body, the reinforcing fibers can be appropriately provided so as to follow the region between the adjacent concave regions. That is, when the concave portions are formed deeply, it is difficult to make the reinforcing fibers follow the region adjacent to the concave region, whereas by making the concave portions shallow to such an extent that the total value of the depths of the concave portions on both surfaces is smaller than the thickness of the thin portion, the reinforcing fibers can be appropriately provided also in the region adjacent to the concave region. By this, for example, even in a resin molded body in which continuous uneven portions are formed, the reinforcing fibers can be provided in a well-balanced manner. Note that when the concave portions become shallow, a problem may arise that the bonding property between the resin molded body and the bonding resin member decreases. However, since the reinforcing fibers are appropriately provided also in the region adjacent to the concave region as described above, the strength can be ensured by the reinforcing fibers, and the decrease in the bonding property can be appropriately suppressed. As described above, according to one aspect of the present invention, it is possible to provide a composite structure rotating body in which the reinforcing fibers are provided in a well-balanced manner and the strength is improved.

[0008] The reinforcing fibers may be organic fibers. According to such a configuration, the strength of the composite structure rotating body can be appropriately improved.

[0009] The reinforcing fibers may be aramid fibers. According to such a configuration, the strength of the composite structure rotating body can be appropriately improved.

[0010] The region sandwiched between two adjacent concave regions may have a length in the circumferential direction that is two times or more the height. According to such a configuration, when molding the resin molded body, the reinforcing fibers can be appropriately provided so as to follow the region sandwiched between the two concave regions described above.

[0011] The resin molded body according to one aspect of the present invention is an annular resin molded body that is connected to a metal bush by a bonding resin member to form a composite structure rotating body, and includes reinforcing fibers and a resin. A plurality of concave regions are formed at predetermined intervals in the circumferential direction. The concave regions are provided with a thin portion having concave portions formed on both surfaces in the thickness direction. In the concave region, the total value of the depths of the concave portions on both surfaces is smaller than the thickness of the thin portion. By configuring the resin molded body in this way, it is possible to provide a composite structure rotating body in which reinforcing fibers are provided in a well-balanced manner to improve the strength.

Effect of the Invention

[0012] According to one aspect of the present invention, it is possible to provide a composite structure rotating body and a resin molded body in which reinforcing fibers are provided in a well-balanced manner to improve the strength.

Brief Description of the Drawings

[0013]

Figure 1

Figure 2

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Figure 5

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Figure 7

Figure 8

Figure 9

Figure 10

Embodiments for Carrying Out the Invention

[0014] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the description of the drawings, the same or corresponding elements are denoted by the same reference numerals, and duplicate descriptions are omitted.

[0015] FIG. 1 is a front view (FIG. 1(a)) and a cross-sectional view (FIG. 1(b)) of a composite structure gear according to an embodiment. As shown in FIGS. 1(a) and 1(b), the composite structure gear 1 is a so-called hybrid gear made of resin and metal, and is used as a gear for vehicles, industries, etc., for example. The composite structure gear 1 may be a composite structure rotating body including a metal bush 3, a resin molded body 5, and a bonding resin member 7.

[0016] The metal bush 3 is a member attached to a rotating shaft (not shown), for example. As shown in FIGS. 1(a) and 1(b), the metal bush 3 is annular. The metal bush 3 is formed of a metal such as stainless steel, for example. A through hole 3h is provided in the metal bush 3. The through hole 3h penetrates the metal bush 3 in the axial direction. A rotating shaft is inserted into the through hole 3h. The metal bush 3 has a plurality of convex anti-rotation portions 31 formed at predetermined intervals in the circumferential direction on its outer peripheral surface. The anti-rotation portion 31 enters the bonding resin member 7. The anti-rotation portion 31 has a function of preventing the bonding resin member 7 from rotating and coming off with respect to the metal bush 3.

[0017] The resin molded body 5 is a member that meshes with other gears. FIG. 2 is a front view and a cross-sectional view of the resin molded body 5 included in the composite structure gear 1 of FIG. 1. As shown in FIGS. 1(a)(b) and 2(a)(b), the resin molded body 5 is annular and coaxial with the metal bush 3. The resin molded body 5 is provided around the metal bush 3 and thus around the bonding resin member 7. The resin molded body 5 includes an outer peripheral portion 51, an inner peripheral portion 52, and an intermediate portion 53.

[0018] The outer peripheral portion 51 is an annular portion provided on the outer periphery of the resin molded body 5. A tooth shape is formed on the outer peripheral portion 51. A plurality of tooth shapes are formed at predetermined intervals in the circumferential direction of the resin molded body 5. The inner peripheral portion 52 is an annular portion provided on the inner periphery of the resin molded body 5.

[0019] The intermediate portion 53 is the portion between the outer peripheral portion 51 and the inner peripheral portion 52. As shown in Fig. 2(a), a plurality of concave regions 531 are formed at predetermined intervals in the circumferential direction in the intermediate portion 53 of the resin molded body 5. Specifically, in the intermediate portion 53 of the resin molded body 5, the concave regions 531 and the regions 532 are alternately arranged in the circumferential direction. Such a region 532 is a region sandwiched between two adjacent concave regions 531.

[0020] Each concave region 531 is provided with a thin-walled portion 531x in which concave portions 531y, 531y are formed on both surfaces in the thickness direction of the resin molded body 5 as shown in Fig. 2(b). In the concave region 531, the total value of the depths D1, D1 of the concave portions 531y, 531y on both surfaces is smaller than the thickness T1 of the thin-walled portion 531x. In other words, in the region 532 between each concave region 531, the total value of the heights of the inclined surface portions 532y, 532y (described later), which are convex portions on both surfaces (i.e., D1 + D1), is smaller than the thickness T1 of the thin-walled portion 531x. Hereinafter, the depth D1 of the concave portion 531y may be referred to as the height D1 of the region 532 (specifically, the inclined surface portion 532y). Also, the width W1 (see Fig. 5), which is the length in the circumferential direction of the region 532, is larger than the height D1 of the inclined surface portion 532y of the region 532, for example, 2 times or more. The thickness T1 of the thin-walled portion 531x may be, for example, about 5 to 10 mm. The height D1 (depth D1 of the concave portion 531y) of the inclined surface portion 532y of the region 532 may be, for example, about 2 to 5 mm. The width W1 (see Fig. 5) of the inclined surface portion 532y of the region 532 may be, for example, about 4 to 10 mm. Also, the radial length R1 (see Fig. 2(a)) from the inner peripheral surface of the inner peripheral portion 52 to the outer peripheral surface of the outer peripheral portion 51 in the resin molded body 5 may be about 40 to 50% of the radius of the resin molded body 5, and specifically, may be about 15 to 20 mm.

[0021] Further, as shown in FIG. 2(a), R may be provided at the corner on the outer peripheral side in the concave portion 531y in order to improve the mold release property from the mold.

[0022] Each region 532 is provided with a base portion 532x and an inclined surface portion 532y. The base portion 532x is a portion provided at a position continuous with the outer peripheral portion 51. The inclined surface portion 532y is a portion that is continuous with the base portion 532x and extends inclined so as to become thinner as it goes toward the inner peripheral portion 52 along the radial direction (see FIG. 2(b)). The inclined surface portion 532y is formed on both surfaces in the thickness direction of the resin molded body 5.

[0023] The resin molded body 5 is configured to include reinforcing fibers (strengthening fibers) and a resin. The reinforcing fibers included in the resin molded body 5 are, for example, organic fibers. The reinforcing fibers may be, for example, aramid fibers, or may be PBO (Poly-p-phenylenebenzobisoxazole) fibers, carbon fibers, glass fibers, or metal fibers, etc. The resin included in the resin molded body 5 may be, for example, a polyaminoamide resin, a phenol resin, an unsaturated polyester resin, etc. Note that the aramid fibers employed as the reinforcing fibers may be para-aramid fibers, may be meta-aramid fibers, or may be para-aramid fiber pulp. When para-aramid fibers are employed, the length thereof may be 3 mm or more. When meta-aramid fibers are employed, the length thereof may be 3 mm or more, or may be 6 mm or more. The total fiber amount (volume) of the reinforcing fibers included in the resin molded body 5 may be 40% or more, or may be 40% or more and 60% or less.

[0024] The bonding resin member 7 is a member that connects the resin molded body 5 and the metal bush 3. The bonding resin member 7 is provided, for example, to cover the surfaces of the intermediate portion 53 and the inner peripheral portion 52 in the resin molded body 5 and up to the position in contact with the outer peripheral surface of the metal bush 3. The resin contained in the bonding resin member 7 may be, for example, PPS (Polyphenylene sulfide), PEEK (Poly Ether Ether Ketone), PI (Polyimide), LCP (Liquid Crystal Polymer), PA (Polyamide), POM (Polyoxymethylene), PPE (Polyphenylene ether), or PBT (Poly Butylene Terephtalate), etc., and may be reinforced with glass fibers. Note that the resin contained in the bonding resin member 7 may be less expensive than the resin contained in the resin molded body 5.

[0025] Next, a manufacturing method of the composite structure gear 1 will be described. The manufacturing method of the composite structure gear 1 includes a step of forming a fiber assembly, a step of forming a resin rotating body, a molding step, and a step of forming the resin molded body 5.

[0026] The step of forming the fiber assembly will be described. In this step, short fibers are accumulated in an annular mold by a papermaking method, and a compression operation is performed using a papermaking compression device (not shown) to form a fiber assembly surrounding the outer peripheral portion of the metal bush 3. The short fibers are supplied as a slurry formed by being mixed with water to the mold of the papermaking compression device. Then, by performing vacuum suction and discharging moisture, an annular fiber assembly is formed.

[0027] Next, the step of forming the resin rotating body 556 will be described. In this step, an annular fiber aggregate is clamped and compressed, impregnated with resin, and the resin is cured to form the resin rotating body 556. As shown in Fig. 3(a), the fiber base material 555 is disposed within the mold 101. The mold 101 includes a lower mold 109 and an upper mold 110 that are paired in the vertical direction and sandwich a metal bush 3 or the like. As shown in Fig. 3(b), the lower mold 109 and the upper mold 110 perform clamping to forcibly compress the fiber base material 555 into a shape along the unevenness of the lower mold 109 and the upper mold 110. Liquid resin is injected into the mold 101 and the resin is cured, thereby forming the resin rotating body 556 including reinforcing fibers and resin.

[0028] Next, the molding step will be described. In this step, a molded product is formed by connecting the resin rotating body 556 and the metal bush 3 with a bonding resin member 7. Specifically, as shown in Fig. 4(a), the resin rotating body 556 and the metal bush 3 are set in another mold, and as shown in Fig. 4(b), after clamping, the bonding resin member 7 is injected and integrated to create a molded product.

[0029] Finally, the step of forming the resin molded body 5 will be described. In this step, machining is performed on the outer peripheral portion of the resin rotating body 556 to form a tooth shape, thereby forming the resin molded body 5. In this way, the composite structure gear 1 in which the metal bush 3 and the resin molded body 5 are connected by the bonding resin member 7 is manufactured.

[0030] Next, the operation and effects of the composite structure gear 1 (and the resin molded body 5) according to the present embodiment will be described.

[0031] First, referring to FIGS. 6 and 7, the composite structure gear 301 according to the comparative example will be described. As shown in FIG. 6, the basic configuration of the composite structure gear 301 is the same as that of the composite structure gear 1 according to the present embodiment, and includes a resin molded body 305, a metal bush 303, and a bonding resin member 307. A through hole 303h is provided in the metal bush 303. The metal bush 303 has a plurality of convex anti-rotation portions 331 formed at predetermined intervals in the circumferential direction on its outer peripheral surface. As shown in FIG. 7, in the concave region 3531 of the resin molded body 305, a thin portion 3531x having recesses 3531y, 3531y formed on both surfaces in the thickness direction of the resin molded body 305 is provided. In each concave region 3531, the total value (D2 + D2) of the depths D2, D2 of the recesses 3531y, 3531y on both surfaces is larger than the thickness T2 of the thin portion 3531x. In the example shown in FIG. 7, the depth D2 of the recess 3531y is approximately the same as the thickness T2 of the thin portion 3531x, and the total value (D2 + D2) of the depths D2, D2 of the recesses 3531y, 3531y on both surfaces is approximately twice the thickness T2 of the thin portion 3531x.

[0032] Regarding such a resin molded body 305 with a deep depth D2 of the recess 3531y, it is not possible to appropriately adhere the reinforcing fibers to the region adjacent to the recess 3531y (for example, the convex portion) during molding, and there is a risk of weakening the strength. FIG. 8 is a diagram showing the state of the fiber base material 555 (reinforcing fiber) during mold clamping compression with respect to the resin molded body 305. As shown in FIG. 8, when the depth of the recess 3531y after molding is increased, the fiber base material 555 (reinforcing fiber) does not appropriately follow the upper mold 110, and it is not possible to appropriately provide reinforcing fibers in the region adjacent to the recess 3531y.

[0033] In contrast, the composite structure gear 1 according to the present embodiment includes reinforcing fibers and resin, and includes an annular resin molded body 5 having a tooth shape formed on the outer peripheral portion 51, an annular metal bush 3, and a bonding resin member 7 that connects the resin molded body 5 and the metal bush 3. In the resin molded body 5, a plurality of concave regions 531 are formed at predetermined intervals in the circumferential direction, and a region 532 is formed between the adjacent concave regions 531. In the concave region 531, a thin portion 531x having concave portions 531y formed on both surfaces in the thickness direction of the resin molded body 5 is provided. Then, as shown in FIG. 2(b), in the concave region 531, the total value of the depths D1 of the concave portions 531y on both surfaces is smaller than the thickness T1 of the thin portion 531x.

[0034] In such a composite structure gear 1, a plurality of concave regions 531 are formed along the circumferential direction in the annular resin molded body 5. In each concave region 531, a thin-walled portion 531x is provided with recesses 531y, 531y formed on both surfaces in the thickness direction of the resin molded body 5. And in each concave region 531, the total value of the depths D1, D1 of the recesses 531y, 531y on both surfaces is smaller than the thickness T1 of the thin-walled portion 531x. In this way, by forming the recesses shallowly, the reinforcing fibers can be appropriately made to follow and provided in the region 532 between the adjacent concave regions 531 when the resin molded body 5 is molded. That is, when the recess 3531y is formed deeply as in the configuration according to the comparative example, it is difficult to make the reinforcing fibers follow the region 532 between the concave regions 531. On the other hand, by making the recess 531y shallow to such an extent that the total value of the depths of the recesses 531y, 531y on both surfaces is smaller than the thickness of the thin-walled portion 531x, the reinforcing fibers can also be appropriately provided in the region 532 adjacent to the concave region 531. By this, even in the resin molded body 5 in which continuous uneven portions are formed, the reinforcing fibers can be provided in a well-balanced manner. Note that when the recesses become shallow, the problem may arise that the bonding property between the resin molded body 5 and the bonding resin member 7 decreases. However, as described above, since the reinforcing fibers are also appropriately provided in the region 532, the strength is ensured by the reinforcing fibers, and the decrease in the bonding property can be appropriately suppressed. As described above, according to the configuration according to the present embodiment, it is possible to provide the composite structure gear 1 in which the reinforcing fibers are provided in a well-balanced manner to improve the strength.

[0035] The reinforcing fibers may be organic fibers, or further, aramid fibers. According to such a configuration, the strength of the composite structure gear 1 can be appropriately ensured.

[0036] As shown in FIG. 5, in the region 532, the width W1, which is the length in the circumferential direction, may be twice or more the height D1. By making the width wide and the depth shallow in this way, the reinforcing fibers can be appropriately made to follow the region 532 during mold clamping compression.

[0037] The above describes one embodiment of the present invention, but the present invention is not limited to the above. For example, as the composite structure gear, the composite structure gear 1A shown in FIGS. 9 and 10 may be adopted. As shown in FIG. 9, the basic configuration of the composite structure gear 1A is the same as that of the composite structure gear 1 according to the above-described embodiment, and includes a resin molded body 5A, a metal bush 3, and a bonding resin member 7. Here, the resin molded body 5A, which is a point where the configuration of the composite structure gear 1A is different from that of the composite structure gear 1, will be described in detail.

[0038] FIG. 10 is a front view (FIG. 10(a)) and a cross-sectional view (FIG. 10(b)) of the resin molded body 5A included in the composite structure gear 1A of FIG. 9. As shown in FIG. 10, a plurality of concave regions 531A are formed in the central portion 53A of the resin molded body 5A at predetermined intervals in the circumferential direction. In the concave region 531A, a thin portion 531Ax having concave portions 531Ay, 531Ay formed on both surfaces in the thickness direction of the resin molded body 5A is provided. And as shown in FIG. 10(b), in the concave region 531A, the total value of the depths of the concave portions 531Ay, 531Ay on both surfaces is smaller than the thickness of the thin portion 531Ax.

[0039] Then, as is clear from comparing FIGS. 10(a) and 2(a), the radial length R2 (see FIG. 10(a)) from the inner peripheral surface of the inner peripheral portion 52A to the outer peripheral surface of the outer peripheral portion 51A in the resin molded body 5A is smaller than the radial length R1 (see FIG. 2(a)) from the inner peripheral surface of the inner peripheral portion 52 to the outer peripheral surface of the outer peripheral portion 51 in the resin molded body 5. Specifically, the radial length R2 from the inner peripheral surface of the inner peripheral portion 52A to the outer peripheral surface of the outer peripheral portion 51A in the resin molded body 5A may be about 30 to 40% of the radius of the resin molded body 5A, and the value may be about 10 to 15.

[0040] By reducing the radial length R2 in the resin molded body 5A in this way, the volume of the resin molded body 5A, which is more expensive than the bonding resin member 7, can be reduced, and the material cost can be reduced.

Explanation of reference numerals

[0041] 1, 1A... composite structure gear, 3... metal bush, 5, 5A... resin molded body, 7... bonding resin member, 531, 531A... concave region, 531x, 531Ax... thin-walled part, 531y, 531Ay... recess, D1... depth of recess (height of region between concave regions), W1... width (length in circumferential direction).

Claims

1. An annular resin molded body including reinforcing fibers and a resin, with a tooth shape formed on the outer peripheral portion, An annular metal bush, A bonding resin member that connects the resin molded body and the metal bush, and includes: In the resin molded body, a plurality of concave regions are formed at predetermined intervals in the circumferential direction, In the concave region, a thin-walled portion having concave portions formed on both surfaces in the thickness direction of the resin molded body is provided, In the concave region, a composite structure rotating body in which the total value of the depths of the concave portions on both surfaces is smaller than the thickness of the thin-walled portion.

2. The composite structure rotating body according to Claim 1, wherein the reinforcing fibers are organic fibers.

3. The composite structure rotating body according to Claim 2, wherein the reinforcing fibers are aramid fibers.

4. The composite structure rotating body according to any one of Claims 1 to 3, wherein the length in the circumferential direction of the region sandwiched between two adjacent concave regions is twice or more the height.

5. An annular resin molded body that is connected to a metal bush by a bonding resin member to form a composite structure rotating body, Comprising reinforcing fibers and a resin, A plurality of concave regions are formed at predetermined intervals in the circumferential direction, In the concave region, a thin-walled portion having concave portions formed on both surfaces in the thickness direction is provided, In the concave region, a resin molded body in which the total value of the depths of the concave portions on both surfaces is smaller than the thickness of the thin-walled portion.

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