GB1585508A - Machine elements - Google Patents

Description

(54) MACHINE ELEMENTS (71) We, POLYPLASTICS CO., LTD. a Japanese body corporate, of 30, 2-chome, Azuchimachi, Higashi-ku, Osaka-shi, Japan, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: This invention relates to machine elements which can be easily manufactured according to the so-called outsert molding method (see below).

Elements comprising a metal substrate or base and a cylindrical, columnar, prismatic, hooked or otherwise shaped upstanding member are very useful as mechanical elements for bearings, shafts, supports, etc., and widely utilized as functional or operating elements in clocks, recorders and the like.

Heretofore, these elements have been manufactured through the complicated metal working steps such as sheet working, caulking, screwing, welding and such, so that manufacture of such elements has involved many problems to be solved, such as high manufacturing cost and an high percentage of defective elements.

Recently, however, there has been rapid progress in applying the techniques of the so-called engineering plastics such as for example polyacetal resins which, because of their many excellent properties and balanced quality, are popularly used for various types of functional elements by superseding metal, and now techniques are being developed for manufacturing such elements by using metal for the substrate portion alone while using synthetic resin for forming the upstanding portion or portions.

This method is generally called the "outsert" molding method as the resin portion is inserted in the metal substrate in contrast to the insert molding method in which a metal element is inserted in a resin substrate.

Usually, these shaped elements, when for instance applied in a clock or such, are used in many combinations, and according to said outsert molding method, the parts consisting of combinations of such elements are manufactured by a single molding operation. This method is therefore very advantageous economically.

The invention will be further described with reference to the accompanying drawing in which: Figs. 1 and 2 are diagrammatic drawings showing machine elements produced according to a known outsert molding system: Fig. 3(a), (b) and (c) are diagrammatic drawings showing examples of machine elements according to the present invention; and Fig. 4 is a diagrammatic drawing showing a modified form of substrate used in the present device.

Fig. 1 shows an example of a shaped element produced according to an outsert molding method. Fig. l(a) is a perspective view of the element and Fig. l(b) is a sectional view thereof, and in these drawings, numeral 1 indicates the metal substrate or base, 2 a resin member, and 3 a cutout hole provided in the substrate.

These shaped elements are being widely utilized in many fields of industry as they are easily manufactured by said outsert molding method, but they are still subject to certain limitations in their use because of the low strength of the resin as compared with metal. Particularly, problems may arise in applications where a strong force is applied sidewise to the resin member or a strong impact force is given to the elemenf.

As these elements, when used as mechanical elements, are destined to be placed under such force, there has been a strong request for development of elements which have said excellent properties and functions and can also withstand the strict conditions of use.

As an answer to such request, there were devised the elements such as shown in Fig.

2 which feature provision of detents around the columnar shaped portion. These ele ments, however, are still unsatisfactory in strength, and as easily understood, their use is limited because of their specific configuration.

The present deviser has attempted to provide a satisfactory answer to such a request and has succeeded in devising machine elements which are easy to manufacture and which can be used as various types of machine elements under strict conditions of use.

The functional machine element according to this invention comprises (a) a metal substrate, said substrate being a metal sheet, (b) a metal projection formed integrally with and extending outwardly from the substrate, the projection being a strip or strips projecting from the sheet and the or each strip having been cut~from a part of the sheet so as to leave one end of the strip attached to the sheet and the strip having been bent outwardly from the sheet to form the projection while leaving a cutout hole in the sheet and (c) at least one member made from a synthetic resin and secured to and in contact with the substrate, the projection being located within and serving as a core for the synthetic resin member.

Fig. 3 shows an example of the configuration and structure of a functional element according to the present invention.

Fig. 3(a) is a perspective view of the element and Fig. 3(b) is a sectional view thereof.

This element can be easily manufactured, as shown in Fig. 3(c), by cutting a strip from a part of a metal sheet 1 while leaving an end of the strip attached to the sheet, bending the strip outwardly from the sheet to form a core 5 while leaving a cutout hole 5' in the sheet, and then, by using this core 5, shaping a member or members 2 (and 2') from a synthetic resin according to a normal outsert molding method (Figs. 3(a) and 3(b). The substrate of such configuration can be manufactured by substantially the same process as that generally used in producing the substrates for ordinary outsert molding.

The elements of this configuration can be used as various types of machine elements such as shafts as well as for other purposes, for example, as lugs for connection with other parts or as detents for springs or such. Also, as it has a metal core integral with the metal substrate, it can be used even under strict conditions of use Although it is desirable that the core 5 is positioned centrally of the substrate, such is not an absolute requirement. Also, the core may be one which extends to the top of the resin member or extends along half of the length of the resin member.

After the core 5 has been cut out from the substrate, the hole 5' may be filled with resin 2' as shown in Fig. 3(a), but if desired, all or a part of such space may be left vacant. It is also possible to provide two or more cores in the substrate. An example of such substrate is shown in Fig.

4. In the case where the core portion is short, the hole left after cutting and bending out the core may be contained within the span of the resin member and therefore may not be seen from the outside.

In the case where the resin members are provided on both sides of the substrate, the core may be formed so as to project from both sides of the substrate. It is also desirable to provide a deformation such as a kink to the core so as to enhance its resistance to bending.

The resin members used in this invention are not restricted to such configuration but may be embodied in various other forms suitable for meeting the requirements for use as individual machine elements. For instance, they may be cylindrical, tubular with different external sections, tubular with different internal sections, screw-shaped, hooked, prismmatic or otherwise configured.

In either case, however, the resin member or members 2 is or are firmly attached to the substrate and one or more metal cores are incorporated therein. In the case of elements where symmetry is required, it is desirable that a plurality of cores is provided in symmetrical relation to each other.

WHAT WE CLAIM IS: 1. A machine element comprising (a) a metal substrate, said substrate being a metal sheet, (b) a metal projection formed integrally with and extending outwardly from the substrate, the projection being a strip or strips projecting from the sheet and the or each strip having been cut from a part of the sheet so as to leave one end of the strip attached to the sheet and the strip having been bent outwardly from the sheet to form the projection while leaving a cutout hole in the sheet and (c) at least one member made from a synthetic resin and secured to and in contact with the substrate, the projection being located within and serving as a core for the synthetic resin member.

2. An element as claimed in claim 1 in which the cutout hole has been at least partly filled with synthetic resin.

3. An element as claimed in claim 1 or 2 in which the projection or core extends through at least half of the length of the synthetic resin member.

4. An element as claimed in claim 1 and substantially as hereinbefore described

**WARNING** end of DESC field may overlap start of CLMS **.

Claims (5)

**WARNING** start of CLMS field may overlap end of DESC **. ments, however, are still unsatisfactory in strength, and as easily understood, their use is limited because of their specific configuration. The present deviser has attempted to provide a satisfactory answer to such a request and has succeeded in devising machine elements which are easy to manufacture and which can be used as various types of machine elements under strict conditions of use. The functional machine element according to this invention comprises (a) a metal substrate, said substrate being a metal sheet, (b) a metal projection formed integrally with and extending outwardly from the substrate, the projection being a strip or strips projecting from the sheet and the or each strip having been cut~from a part of the sheet so as to leave one end of the strip attached to the sheet and the strip having been bent outwardly from the sheet to form the projection while leaving a cutout hole in the sheet and (c) at least one member made from a synthetic resin and secured to and in contact with the substrate, the projection being located within and serving as a core for the synthetic resin member. Fig. 3 shows an example of the configuration and structure of a functional element according to the present invention. Fig. 3(a) is a perspective view of the element and Fig. 3(b) is a sectional view thereof. This element can be easily manufactured, as shown in Fig. 3(c), by cutting a strip from a part of a metal sheet 1 while leaving an end of the strip attached to the sheet, bending the strip outwardly from the sheet to form a core 5 while leaving a cutout hole 5' in the sheet, and then, by using this core 5, shaping a member or members 2 (and 2') from a synthetic resin according to a normal outsert molding method (Figs. 3(a) and 3(b). The substrate of such configuration can be manufactured by substantially the same process as that generally used in producing the substrates for ordinary outsert molding. The elements of this configuration can be used as various types of machine elements such as shafts as well as for other purposes, for example, as lugs for connection with other parts or as detents for springs or such. Also, as it has a metal core integral with the metal substrate, it can be used even under strict conditions of use Although it is desirable that the core 5 is positioned centrally of the substrate, such is not an absolute requirement. Also, the core may be one which extends to the top of the resin member or extends along half of the length of the resin member. After the core 5 has been cut out from the substrate, the hole 5' may be filled with resin 2' as shown in Fig. 3(a), but if desired, all or a part of such space may be left vacant. It is also possible to provide two or more cores in the substrate. An example of such substrate is shown in Fig. 4. In the case where the core portion is short, the hole left after cutting and bending out the core may be contained within the span of the resin member and therefore may not be seen from the outside. In the case where the resin members are provided on both sides of the substrate, the core may be formed so as to project from both sides of the substrate. It is also desirable to provide a deformation such as a kink to the core so as to enhance its resistance to bending. The resin members used in this invention are not restricted to such configuration but may be embodied in various other forms suitable for meeting the requirements for use as individual machine elements. For instance, they may be cylindrical, tubular with different external sections, tubular with different internal sections, screw-shaped, hooked, prismmatic or otherwise configured. In either case, however, the resin member or members 2 is or are firmly attached to the substrate and one or more metal cores are incorporated therein. In the case of elements where symmetry is required, it is desirable that a plurality of cores is provided in symmetrical relation to each other. WHAT WE CLAIM IS:

1. A machine element comprising (a) a metal substrate, said substrate being a metal sheet, (b) a metal projection formed integrally with and extending outwardly from the substrate, the projection being a strip or strips projecting from the sheet and the or each strip having been cut from a part of the sheet so as to leave one end of the strip attached to the sheet and the strip having been bent outwardly from the sheet to form the projection while leaving a cutout hole in the sheet and (c) at least one member made from a synthetic resin and secured to and in contact with the substrate, the projection being located within and serving as a core for the synthetic resin member.

2. An element as claimed in claim 1 in which the cutout hole has been at least partly filled with synthetic resin.

3. An element as claimed in claim 1 or 2 in which the projection or core extends through at least half of the length of the synthetic resin member.

4. An element as claimed in claim 1 and substantially as hereinbefore described

with reference to Fig. 3(a), Fig. 3(b) and Fig. 3(c) of the accompanying drawings.

5. An element as claimed in claim 4, modified substantially as hereinbefore described with reference tb Fig. 4 of the accompanying drawings.