CN104786517A - 齿条壳体的制造方法、以及齿条壳体 - Google Patents

齿条壳体的制造方法、以及齿条壳体 Download PDF

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Publication number
CN104786517A
CN104786517A CN201510028693.XA CN201510028693A CN104786517A CN 104786517 A CN104786517 A CN 104786517A CN 201510028693 A CN201510028693 A CN 201510028693A CN 104786517 A CN104786517 A CN 104786517A
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Prior art keywords
thermoplastic resin
cylinder portion
tooth bar
bar housing
linking part
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CN201510028693.XA
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CN104786517B (zh
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国岛武史
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JTEKT Corp
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JTEKT Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14467—Joining articles or parts of a single article
    • B29C45/14508—Joining juxtaposed sheet-like articles, e.g. for making trim panels
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F16H—GEARING
    • F16H57/00—General details of gearing
    • F16H57/02—Gearboxes; Mounting gearing therein
    • F16H57/032—Gearboxes; Mounting gearing therein characterised by the materials used
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14336—Coating a portion of the article, e.g. the edge of the article
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • General Engineering & Computer Science (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

本发明提供一种齿条壳体的制造方法，在将层叠使热塑性树脂浸入纤维片的纤维强化复合材料的预成型料冲压成型而形成齿条壳体的筒部之后，将包含填料的热塑性树脂注射成型而形成将金属圆环一体化的连结部。齿条壳体通过所述制造方法制造。

Description

齿条壳体的制造方法、以及齿条壳体
技术领域
本申请主张于2014年1月22日提出的日本专利申请第2014-009684号的优先权，并在此引用包括说明书，附图以及说明书摘要的全部内容。
本发明涉及齿条壳体的制造方法以及通过该方法制造出的齿条壳体。
背景技术
在汽车等的转向装置中，使用齿条壳体以用于将齿条轴支承为能够自由地进行直线往复移动、并且固定于车身框架。齿条壳体沿齿条轴的轴向较长地形成，并接受在转向操作时从车轮传递而来的操舵反作用力。因此，一般将整体由强度和刚性优越的铝压铸件等而形成为一体。
但是，根据近年节能的要求，对于汽车部件也逐渐要求其轻量化。因此，对于在转向装置的总重量中所占据的重量比大的齿条壳体来说，也要在确保必要的强度和刚性的基础上，研究其轻量化。例如，将齿条壳体分为供齿条轴插通的筒部、和设置于该筒部两端的与其他部件连结的连结部。其中，可以考虑通过使热固化性树脂浸入碳纤维的CFRP(Carbon Fiber Reinforced Plastics)等纤维强化复合材料来形成筒部并使该筒部轻量化。
对于具备插通小齿轮轴、插通齿条引导件(支持轭部)、或者安装于车身的部分的连结部而言，与以往一样由铝压铸件等形成，该连结部与筒部可以通过螺纹紧固、螺旋镶套(helisert)***、金属螺纹一体成型等方式连结。另外，在日本特开2013-208927号公报中记载的发明中，将所述插通小齿轮轴、插通齿条引导件、或安装于车身的部分中的、至少构成开口的金属圆环，与由纤维强化复合材料形成的筒部一同配置于模具，将热塑性树脂注射成型而形成齿条壳体。由此，能够使齿条壳体进一步轻量化。
然而，使用CFRP等包含热固化性树脂的纤维强化复合材料来形成筒部需要较长时间。即，包含为了将纤维强化复合材料的片状的预成型料成型为筒状而加热软化的流动化时间、和成型为筒状后使之进一步升温至热固化性树脂的固化温度的升温时间，从加热开始至通过热固化性树脂的完全固化而完成筒部为止，大约需要五个小时以上的时间。
若考虑汽车部件的制造所需要的周期时间为一分钟左右，则这个时间非常长，而且在这期间持续加热所消耗掉的能量也很多，所以这些成为成本增大的重要因素。
发明内容
本发明的目的之一，是提供一种与整体由铝压铸件等形成的以往的结构相比，能够尽可能以短的时间和少的能量来高效地制造出轻量化的齿条壳体的制造方法，以及通过这样的制造方法制造出的齿条壳体。
本发明涉及齿条壳体的制造方法，包含：对于与具备覆盖齿条轴的筒部和与该筒部的两端相连的与其他部件连结的连结部的齿条壳体的立体形状对应的模具而言，在该模具的与所述连结部对应的区域，配置用于与其他部件连结或者插通的金属圆环，并且在该模具的与所述筒部对应的区域，配置将使热塑性树脂浸入于纤维片的至少两层的纤维强化复合材料层叠而成的、被加热的两个预成型料的工序；对所述模具进行合模，并将两个预成型料冲压成型为分别具有与筒部的半周对应的半筒体、和从该半筒体的周向的两端在筒部的轴向全长上向外侧延伸的平板状的连接部的形状，并且使两半筒体用各自的连接部的侧面彼此进行结合而形成筒部的工序；以及在与所述连结部及筒部对应的整个区域，将包含填料的热塑性树脂进行注射成型，从而形成将金属圆环一体化的连结部，并且将该连结部与筒部进行一体化的工序。
附图说明
根据以下参照附图对实施方式进行的详细说明，本发明的所述以及更多的特点和优点会变得更加清楚，其中对相同的元素标注相同的附图标记，其中，
图1是能够装入本发明的齿条壳体的转向装置的一个例子的示意图。
图2是表示本发明的齿条壳体的实施方式的一个例子的立体图。
图3(a)是图2例子的齿条壳体中的筒部的剖视图，图3(b)是对图3(a)的局部进行放大的剖视图。
图4(a)、图4(b)分别是对通过本发明的制造方法来制造图2的齿条壳体的一个工序进行说明的剖视图。
具体实施方式
图1是能够装入本发明的齿条壳体的、转向装置的一个例子的示意图。参照图1，转向装置1具备转向轴3、中间轴5、小齿轮轴7、以及齿条轴8。转向轴3与方向盘2连结为能够一体地旋转。中间轴5经由万向接头4与转向轴3连结。小齿轮轴7经由万向接头6与中间轴5连结。齿条轴8是具有与设于小齿轮轴7的小齿轮齿7a啮合的齿条齿8a、并沿汽车的左右方向延伸的转舵轴。
通过小齿轮轴7以及齿条轴8，构成了由齿轮齿条机构构成的转向操作机构9。齿条轴8经由未图示的多个轴承在固定于车身的齿条壳体10内被支承为能够自由地进行直线往复移动。齿条轴8的两端部向齿条壳体10的两侧突出，并在各端部分别与横拉杆11结合。
各横拉杆11经由未图示的转向臂与对应的转向轮12连结。若操作方向盘2而旋转转向轴3，则其旋转通过小齿轮齿7a以及齿条齿8a，转换为沿着汽车左右方向的齿条轴8的直线运动，从而将转向轮12转舵。
图2是表示本发明的齿条壳体的实施方式的一个例子的立体图。另外，图3(a)是图2例子的齿条壳体中的筒部的剖视图。图3(b)是对图3(a)的局部进行放大的剖视图。参照图2，该例的齿条壳体10具备覆盖齿条轴的筒部13、和与该筒部13的两端连接为一体的与其他部件连结的连结部14、15。
参照图2、图3(a)、图3(b)，筒部13使两个半筒体17在其连接部16的侧面彼此结合而形成。两个半筒体17具有与其半周对应的剖面形状，并且具有使其周向的两端在该筒部13的轴向全长上向外侧折弯而形成为平板状的连接部16的剖面形状。包含这样的连接部16的半筒体17整体，由层叠有使热塑性树脂浸入纤维片而成的多个层，并经由热塑性树脂而一体化的纤维强化复合材料18构成。
另外，层叠而成的多层纤维强化复合材料18，通过随机地贯通其中的至少两层的纤维强化复合材料18的填料19，而加强层间的结合。由此，能够防止该层间的剥离和由此引起的强度、耐冲击性、以及热冲击性等的降低。
另外，为了构成连接部16的侧面、并使该连接部16彼此结合，相互层叠的两层纤维强化复合材料18也经由热塑性树脂而一体化。并且，通过随机地贯通这样的包含两层的纤维强化复合材料18的填料19，加强层间的结合。由此，也防止了半筒体17彼此的剥离。
在结合的状态下，向筒部13的径向外侧突出的连接部16被肋材20覆盖。肋材20在筒部13的轴向全长上一体地设置。由此，进一步加强连接部16彼此的结合，从而能够更可靠地防止剥离。在筒部13的外周的、两个肋材20的周向的中间位置，在该筒部13的轴向全长上与肋材20平行地设置有肋材21。另外，在筒部13的外周的、轴向的两处的中间位置，设有与肋材20、21正交且在筒部13的整周形成的圆环状的肋材22。
另外，筒部13的内周包含将连接部16向径向外侧折弯而产生的凹部23，并以填埋该凹部23的方式通过被覆物24覆盖该凹部23。由此，能够使筒部13的内周平滑化，提高与齿条轴8的滑动特性等。肋材20～22、以及被覆物24，均与接下来说明的连结部14、15一同，通过包含填料19的热塑性树脂而形成为一体。
参照图1、图2，连结部14整体通过包含填料19的热塑性树脂，形成为从筒部13的一端连续的大致筒状。连结部14的与该筒部13侧相反的一侧，具有用于使齿条轴8的一端部向齿条壳体10的外部突出的开口25。
在开口25将金属圆环26实施一体化，该金属圆环26用于加强该开口25，并且供允许齿条轴8的直线运动以及关闭开口25的未图示的护罩安装。
另外，在连结部14的侧面，形成有供小齿轮轴7插通的开口27、以及供未图示的齿条引导件***的开口28，并且突出设置有用于将齿条壳体10固定于车身的安装部29。在开口27将金属圆环30实施一体化，该金属圆环30加强该开口27，并且用于安装未图示的小齿轮轴的罩。
另外，在开口28将金属圆环31实施一体化，该金属圆环31加强该开口28，并且用于安装***未图示的齿条引导件之后关闭开口28的、未图示的密封部件。而且，安装部29通过包含填料19的热塑性树脂而与连结部14形成为一体，并且将具备供用于安装的螺栓等插通的通孔的金属圆环32一体化。
连结部15整体通过包含填料19的热塑性树脂，而形成为从筒部13的另一端连续的大致筒状。连结部15的与该筒部13侧相反的一侧具有用于使齿条轴8的另一端部向齿条壳体10的外部突出的开口33。在开口33将金属圆环34实施一体化，该金属圆环34加强该开口33，并且用于安装允许齿条轴8的直线运动并且关闭开口33的未图示的护罩。
另外，在连结部15的侧面，突出设置有用于将齿条壳体10固定于车身的安装部29。安装部35通过包含填料19的热塑性树脂而与连结部15形成为一体，并且将具备供用于安装的螺栓等插通的通孔的金属圆环36一体化。
图4(a)、图4(b)分别是对通过本发明的制造方法来制造图2的齿条壳体的一个工序进行说明的剖视图。参照图4(a)，在该例中，为了实施冲压成型的工序和注射成型的工序，使用注射成型用的模具38。冲压成型的工序将作为半筒体17的基础的两个平板状的预成型料37冲压成型为该半筒体17的形状并且使之结合，从而形成筒部13。注射成型的工序将包含填料19的热塑性树脂注射成型，从而形成与筒部13的两端连结的连结部14、15。
模具38具备柱状的内模39和两组外模40。内模39在与筒部13对应的区域具有与该筒部13的内径对应的外径。在外模40还分别设置有在合模时相互抵接的对接面41。在外模40，形成有从该对接面41凹陷、并具有与筒部13的外径对应的内径和与筒部13的轴向全长对应的长度的、半周大小的凹部42。
另外，在外模40，还形成有与凹部42连通、并与肋材20～22对应的凹槽43～45。即、在凹部42的对接面41处的开口部，形成有具有肋材20一半厚度的深度、并且遍及凹部42全长的凹槽43。另外，在凹部42的最深处，形成有与肋材21对应并遍及凹部42全长的凹槽44。而且，在凹部42的、筒部13的轴向的两处，形成有与肋材22对应的圆弧状的凹槽45。
另外，在图中，右侧的外模40中，设置有用于与未图示的注射成型机的喷嘴的前端连接、并向模具38内注入包含填料19的热塑性树脂的浇口46。
另外，虽然未图示，但是在模具38的与所述筒部13对应的区域的轴向的两侧(纸面近前侧与里侧)，连接有与图2所示的连结部14、15的立体形状对应、并且具备在其规定的位置配置之前说明的金属圆环26、30、31、32、36的保持部的区域。
为了使用这样的模具38来制造图2的齿条壳体10，首先准备作为半筒体17的基础的两个平板状的预成型料37。平板状的预成型料37通过如下方式来形成，即，将例如使热塑性树脂浸入纤维片而成的纤维强化复合材料18多层重叠的状态下，使用热冲压在加压下加热至热塑性树脂的熔点附近而使各纤维强化复合材料18中的热塑性树脂熔融一体化。
接下来，将这两个平板状的预成型料37，例如使用烤炉或红外线加热器加热至热塑性树脂的熔点附近而使其软化或熔融的状态下，分别***内模39与两组外模40之间(图4(a))。另外，虽然未图示，但是模具38的、与连结部14、15对应的区域的保持部，配置各金属圆环26、30、31、32、36。
接下来，参照图4(b)，在两组外模40之间夹入内模39、并且在各自的对接面41彼此对接合模，从而将各自的预成型料37冲压成型为半筒体17的形状，并且在连接部16相互结合。而且如图中白色箭头所指示的那样，在模具38内，通过浇口46注入包含填料19的热塑性树脂。
由此，除了通过各自的纤维强化复合材料18中包含的热塑性树脂之外，还通过由注射成型而浸透于纤维强化复合材料18之间以及纤维强化复合材料18中的热塑性树脂、以及贯通层叠的至少两层的纤维强化复合材料18的填料19，使多层的纤维强化复合材料18更加稳固地结合，从而形成作为筒部13的基础的半筒体17。
另外，为了构成连接部16的侧面、并使该连接部16彼此结合，使层叠的两层纤维强化复合材料18经由热塑性树脂而结合，并且，通过贯通这样的包含两层的纤维强化复合材料18的填料19而加强结合，从而使半筒体17彼此一体化并形成筒部13。另外，通过浇口46注入包含填料19的热塑性树脂，由此在形成的筒部13的外周一体地形成有各肋材20～22，并且所述筒部的内周通过被覆物24覆盖。
并且，在筒部13的一端侧一体地形成有将金属圆环26、30、31、32一体化的连结部14、在所述筒部13的另一端侧一体地形成有将金属圆环36一体化的连结部15。之后，通过将模具38打开并取出，而制造出图2所示的齿条壳体10。
通过这样的制造方法，使用相同的模具38能够连续地实施以下两个工序，即，使用由使用了热塑性树脂的CFRTP等纤维强化复合材料构成的两个预成型料37、并通过冲压成型而形成筒部13的工序，以及使用包含填料的热塑性树脂、通过注射成型形成连结部14、15、并且使各部分一体化的工序。另外，形成筒部13的工序不需要如使用热固化性树脂那样，升温时间和固化时间、以及其间持续加热的能量，而仅在注射成型后从模具38中取出，就能够制造齿条壳体10。因此，能够大幅度减少其制造所需要的时间和能量。
因此，筒部13和连结部14、15都是由包含热塑性树脂的复合材料构成，与整体由铝压铸件等形成的以往的产品相比，能够尽可能以短的时间和少的能量来高效地制造出轻量化的齿条壳体10。而且制造出的齿条壳体10，其构成筒部13的、邻接的至少两层纤维强化复合材料18的结合，通过填料19的贯通得到加强。并且，这样的筒部13和连结部14、15，通过包含填料的热塑性树脂而形成为一体。因此，轻量、并且具有必要的强度和刚性，从而能够为汽车等车辆的轻量化、节能做出贡献。
作为成为纤维强化复合材料18的基础的纤维片，例如，可举出由碳纤维、玻璃纤维、芳族聚酰胺纤维等各种纤维构成的织物、无纺布、绳线(strand)等。纤维片的种类能够适当地变更。另外，作为浸入纤维片的热塑性树脂，可举出聚酰胺66、聚苯硫醚(PPS)、热塑性聚氨基甲酸乙酯(TPU)、聚醚醚酮(PEEK)等一般的热塑性树脂。热塑性树脂的种类能够适当地变更。
作为注射成型的热塑性树脂，可举出与浸入纤维片的热塑性树脂具有良好的相溶性的同种或者不同种的热塑性树脂。特别优选同种的热塑性树脂。
另外，作为注射成型的热塑性树脂，优选使用熔体流动速率比浸入纤维片的热塑性树脂大的树脂。
通过注射成型熔体流动速率大、流动性优越的热塑性树脂，使该热塑性树脂及填料19良好地浸透于纤维强化复合材料18的层间、以及纤维强化复合材料18中，从而能够更好地防止层间的剥离。在这样的效果方面，作为注射成型的热塑性树脂，使用熔体流动速率在30g/10min以上、特别优选50g/10min以上。在熔体流动速率小于该范围的情况下，有可能得不到使热塑性树脂及填料19良好地浸透于纤维强化复合材料的层间、以及纤维强化复合材料中从而防止层间剥离的效果。
作为填料19，可举出能贯通层叠的至少两层纤维强化复合材料18并加强其结合的、纤维状或者板状的各种填料。特别优选长纤维状的碳纤维。碳纤维其本身为高强度，而且为长纤维，所以能够贯通两层以上的层叠的纤维强化复合材料18，因此结合的加强效果优越。
为了得到上述效果，优选碳纤维等长纤维状的纤维的纤维长度在纤维强化复合材料18的厚度以上、且在10mm以下。优选纤维长度在10mm以下是因为通过注射成型使纤维尽可能平滑并均匀地分散于纤维强化复合材料18中。本发明的构成不限于以上说明的各图的例子，而能够用于具有各种形状、构造的齿条壳体的制造。

Claims (5)

1.一种齿条壳体的制造方法，其特征在于，包含：
对于与具备覆盖齿条轴的筒部和与该筒部的两端相连的与其他部件连结的连结部的齿条壳体的立体形状对应的模具而言，在该模具的与所述连结部对应的区域，配置用于与其他部件连结或者插通的金属圆环，并且在该模具的与所述筒部对应的区域，配置将使热塑性树脂浸入于纤维片的至少两层的纤维强化复合材料层叠而成的、被加热的两个预成型料的工序；
对所述模具进行合模，并将两个预成型料冲压成型为分别具有与筒部的半周对应的半筒体、和从该半筒体的周向的两端在筒部的轴向全长上向外侧延伸的平板状的连接部的形状，并且使两半筒体用各自的连接部的侧面彼此进行结合而形成筒部的工序；以及
在与所述连结部及筒部对应的整个区域，将包含填料的热塑性树脂进行注射成型，从而形成将金属圆环一体化的连结部，并且将该连结部与筒部进行一体化的工序。
2.根据权利要求1所述的齿条壳体的制造方法，其特征在于，
在所述注射成型的工序，通过包含填料的热塑性树脂，来形成对结合在一起的连接部进行覆盖的肋材。
3.根据权利要求1所述的齿条壳体的制造方法，其特征在于，
在所述注射成型的工序，将熔体流动速率比浸入纤维片的热塑性树脂的熔体流动速率大的热塑性树脂进行注射成型。
4.根据权利要求2所述的齿条壳体的制造方法，其特征在于，
在所述注射成型的工序，将熔体流动速率比浸入纤维片的热塑性树脂的熔体流动速率大的热塑性树脂进行注射成型。
5.一种齿条壳体，其特征在于，
该齿条壳体通过权利要求1～4中任一项所述的制造方法来制造，构成所述筒部的、邻接的至少两层的纤维强化复合材料的结合，通过填料的贯通而得到加强，并且所述筒部和与该筒部的两端相连的所述连结部，通过包含填料的热塑性树脂而形成为一体。
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