JP6233048B2 - ラックハウジングの製造方法、およびラックハウジング - Google Patents
ラックハウジングの製造方法、およびラックハウジング Download PDFInfo
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- JP6233048B2 JP6233048B2 JP2014009684A JP2014009684A JP6233048B2 JP 6233048 B2 JP6233048 B2 JP 6233048B2 JP 2014009684 A JP2014009684 A JP 2014009684A JP 2014009684 A JP2014009684 A JP 2014009684A JP 6233048 B2 JP6233048 B2 JP 6233048B2
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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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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- 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
- B29C45/14336—Coating a portion of the article, e.g. the edge of the article
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- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
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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
- B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
- B29C70/021—Combinations of fibrous reinforcement and non-fibrous material
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- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B62D—MOTOR VEHICLES; TRAILERS
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
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- B29C2045/14483—Joining juxtaposed parts of a single article, e.g. edges of a folded container blank overlapping edges of the juxtaposed parts
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- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
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- B29C45/1418—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 inserts being deformed or preformed, e.g. by the injection pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
- B29C65/40—Applying molten plastics, e.g. hot melt
- B29C65/42—Applying molten plastics, e.g. hot melt between pre-assembled parts
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C65/70—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by moulding
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16H—GEARING
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- F16H57/02—Gearboxes; Mounting gearing therein
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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- Y10T74/00—Machine element or mechanism
- Y10T74/21—Elements
- Y10T74/2186—Gear casings
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- Transportation (AREA)
- General Engineering & Computer Science (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
Description
ラックハウジングはラック軸の軸方向に長く形成され、操舵時に車輪から伝達される操舵反力を受けるため、全体を強度や剛性に優れたアルミダイキャスト等によって一体に形成するのが一般的である。
例えばラックハウジングをラック軸が挿通される筒部とその両端に設けられた他部材との連結部に分け、このうち筒部を炭素繊維に熱硬化性樹脂を含浸させたCFRP(Carbon Fiber Reinforced Plastics)等の繊維強化複合材によって形成して軽量化することが考えられる。
また特許文献1に記載の発明では、上記ピニオンシャフトを挿通したりラックガイドを挿入したり車体に取り付けたりする部分の少なくとも開口を構成する金属円環を、繊維強化複合材によって形成した筒部とともに金型にセットし、熱可塑性樹脂を射出成形してラックハウジングを形成している。これによりラックハウジングのさらなる軽量化が可能となる。
すなわち繊維強化複合材のシート状のプリプレグを筒状に成形するために加熱して軟化させる流動化時間や、筒状に成形後さらに熱硬化性樹脂の硬化温度まで昇温させる昇温時間も含めて、加熱開始から熱硬化性樹脂の完全硬化による筒部の完成までにおよそ5時間以上の時間が必要となる。
本発明の目的は、全体がアルミダイキャスト等によって形成された従来のものに比べて軽量化されたラックハウジングをできるだけ短時間かつ少ないエネルギーにより効率よく製造するための製造方法と、かかる製造方法によって製造されたラックハウジングを提供することにある。
前記金型を型締めして、2枚のプリプレグを、それぞれ筒部の半周分の半筒体(17)と、当該半筒体の周方向の両端から筒部の軸方向の全長に亘って外方へ延設された平板状の接続部(16)とを有する形状にプレス成形するとともに、両半筒体をそれぞれの接続部の側面同士で結合させて筒部を形成する工程、および
前記連結部および筒部に対応する領域の全体にフィラー(19)を含む熱可塑性樹脂を射出成形して、金属円環が一体化された連結部を形成するとともに、当該連結部と筒部とを一体化する工程、
を含むラックハウジングの製造方法である。
請求項3記載の発明は、前記射出成形の工程で、繊維シートに含浸させた熱可塑性樹脂よりもメルトフローレートの大きい熱可塑性樹脂を射出成形する請求項1または2に記載のラックハウジングの製造方法である。
しかも請求項1記載の発明によれば、半筒体を構成する隣り合う少なくとも2層の強化複合材の層間や、当該半筒体同士の接合部の側面を構成し互いに接触する2層の強化複合材の層間を、それぞれの繊維強化複合材に含まれていた熱可塑性樹脂に加えて、射出成形によって繊維強化複合材間および繊維強化複合材中に浸透させた熱可塑性樹脂、ならびに少なくとも2層の繊維強化複合材間を貫通させたフィラーによって強固に結合できる。したがって筒部の強度を、従来の熱硬化性樹脂からなるものと同等またはそれ以上とすることもできる。
請求項2記載の発明によれば、半筒体同士の結合させた接続部を覆うように形成したリブによって上記接続部の接続を補強でき、筒部の強度をさらに向上できる。
請求項4記載の発明によれば、上記の製造方法によって効率よくコスト安価に製造され、軽量でしかも必要な強度と剛性を有するラックハウジングを提供でき、自動車等の車両の軽量化、省エネルギー化に貢献できる。
図1を参照して、ステアリング装置1は、ハンドル2と一体回転可能に連結されたステアリングシャフト3、ステアリングシャフト3に自在継手4を介して連結されたインターミディエートシャフト5、インターミディエートシャフト5に自在継手6を介して連結されたピニオンシャフト7、およびピニオンシャフト7に設けられたピニオン歯7aに噛み合うラック歯8aを有して、自動車の左右方向に延びる転舵軸としてのラック軸8を備えている。
ラック軸8は、車体に固定されるラックハウジング10内に図示しない複数の軸受を介して直線往復動自在に支持されている。ラック軸8の両端部はラックハウジング10の両側へ突出し、各端部にはそれぞれタイロッド11が結合されている。
ハンドル2が操作されてステアリングシャフト3が回転されると、その回転がピニオン歯7aおよびラック歯8aによって自動車の左右方向に沿うラック軸8の直線運動に変換されて操向輪12が転舵される。
図2を参照して、この例のラックハウジング10は、ラック軸を覆う筒部13と、当該筒部13の両端に一体に連なる他部材との連結部14、15とを備えている。
かかる接続部16を含む半筒体17の全体は、繊維シートに熱可塑性樹脂を含浸させてなる複数層が積層され、熱可塑性樹脂を介して一体化された繊維強化複合材18からなる。
また接続部16の側面を構成し、当該接続部16同士を結合させるべく互いに積層された2層の繊維強化複合材18も熱可塑性樹脂を介して一体化されているとともに、かかる2層を含む繊維強化複合材18をランダムに貫通させたフィラー19によって結合が補強されており、これによって半筒体17同士のはく離も防止されている。
筒部13の外周の、2つのリブ20の周方向の中間位置には、当該筒部13の軸方向の全長に亘ってリブ21がリブ20と平行に設けられている。また筒部13の外周の、軸方向の2箇所の中間位置には、リブ20、21と直交させて筒部13の全周に亘る円環状のリブ22が設けられている。
リブ20〜22、ならびに被覆24は、いずれも次に説明する連結部14、15とともにフィラー19を含む熱可塑性樹脂によって一体に形成されている。
開口25には、当該開口25を補強するとともに、ラック軸8の直線運動を許容しつつ開口25を閉じる図示しないブーツを取り付けるための金属円環26が一体化されている。
開口27には、当該開口27を補強するとともに図示しないピニオンシャフトのカバーを取り付けるための金属円環30が一体化されている。
さらに取付部29はフィラー19を含む熱可塑性樹脂によって連結部14と一体に形成されているとともに、取り付けのためのボルト等が挿通される通孔を備えた金属円環32が一体化されている。
開口33には、当該開口33を補強するとともに、ラック軸8の直線運動を許容しつつ開口33を閉じる図示しないブーツを取り付けるための金属円環34が一体化されている。
取付部35はフィラー19を含む熱可塑性樹脂によって連結部15と一体に形成されているとともに、取り付けのためのボルト等が挿通される通孔を備えた金属円環36が一体化されている。
図4(a)を参照して、この例では半筒体17のもとになる2枚の平板状のプリプレグ37を当該半筒体17の形状にプレス成形するとともに結合させて筒部13を形成するプレス成形の工程と、フィラー19を含む熱可塑性樹脂を射出成形して筒部13の両端に連なる連結部14、15を形成する射出成形の工程を実施するために、射出成形用の金型38を用いる。
また外型40には、それぞれ型締めの際に互いに当接させる合わせ面41が設けられているとともに、当該合わせ面41から凹入させて、筒部13の外径に対応する内径と筒部13の軸方向の全長に対応する長さを有する半周分の凹部42が形成されている。
また凹部42の最奥部には、リブ21に対応し凹部42の全長に亘る凹溝44が形成されている。さらに凹部42の、筒部13の軸方向の2箇所にはリブ22に対応する円弧状の凹溝45が形成されている。
また図示していないが、金型38の上記筒部13に対応する領域の軸方向の両側(紙面手前側と奥側)には、図2に示す連結部14、15の立体形状に対応しかつその所定の箇所に先に説明した金属円環26、30、31、32、36をセットする保持部を備えた領域が連成されている。
平板状のプリプレグ37は、例えば繊維シートに熱可塑性樹脂を含浸させてなる繊維強化複合材18を複数層、重ね合わせた状態で熱プレスを用いて加圧下で熱可塑性樹脂の融点付近まで加熱して各繊維強化複合材18中の熱可塑性樹脂を溶融一体化させることで形成される。
また図示していないが金型38の、連結部14、15に対応する領域の保持部に各金属円環26、30、31、32、36をセットする。
そして図中に白矢印で示すように金型38内に、ゲート46を通してフィラー19を含む熱可塑性樹脂を注入する。
またゲート46を通してフィラー19を含む熱可塑性樹脂を注入することにより、形成した筒部13の外周には各リブ20〜22が一体に形成され、上記筒部の内周は被覆24によって被覆される。
このあと、金型38を開いて取り出すことで図2に示すラックハウジング10が製造される。
また筒部13を形成する工程は、熱硬化性樹脂を用いるもののように昇温時間や硬化時間、ならびにその間加熱し続けるエネルギーが不要であり、続く射出成形後に金型38から取り出すだけでラックハウジング10を製造できるため、その製造に要する時間とエネルギーを大幅に削減できる。
しかも製造されたラックハウジング10は、筒部13を構成する隣り合う少なくとも2層の繊維強化複合材18の結合がフィラー19の貫通によって補強されているとともに、かかる筒部13と連結部14、15が、フィラーを含む熱可塑性樹脂によって一体に形成されているため、軽量でしかも必要な強度と剛性を有しており、自動車等の車両の軽量化、省エネルギー化に貢献できる。
また繊維シートに含浸させる熱可塑性樹脂としては、ポリアミド66、ポリフェニレンサルファイド(PPS)、熱可塑性ポリウレタン(TPU)、ポリエーテルエーテルケトン(PEEK)等の、一般的な熱可塑性樹脂が挙げられる。熱可塑性樹脂の種類は適宜変更できる。
また射出成形する熱可塑性樹脂としては、繊維シートに含浸させる熱可塑性樹脂よりもメルトフローレートが大きいものを選択して用いるのが好ましい。
かかる効果の点で、射出成形する熱可塑性樹脂としては、メルトフローレートが30g/10min以上、特に50g/10min以上であるものを用いるのが好ましい。メルトフローレートがこの範囲未満では、熱可塑性樹脂とフィラー19とを、繊維強化複合材の層間、および繊維強化複合材中に良好に浸透させて、層間でのはく離を防止する効果が得られないおそれがある。
特に長繊維状の炭素繊維が好ましい。炭素繊維はそれ自体が高強度である上、長繊維とすることで2層以上の積層された繊維強化複合材18を貫通できるため、結合の補強効果に優れている。
本発明の構成は、以上で説明した各図の例には限定されず、種々の形状、構造を有するラックハウジングの製造に適用可能である。
Claims (4)
- ラック軸を覆う筒部と、この筒部の両端に連なる他部材との連結部とを備えたラックハウジングの立体形状に対応した金型の、前記連結部に対応する領域に他部材との連結用または挿通用の金属円環をセットするとともに、前記筒部に対応する領域に、繊維シートに熱可塑性樹脂を含浸させた少なくとも2層の繊維強化複合材を積層してなる、加熱された2枚のプリプレグをセットする工程、
前記金型を型締めして、2枚のプリプレグを、それぞれ筒部の半周分の半筒体と、当該半筒体の周方向の両端から筒部の軸方向の全長に亘って外方へ延設された平板状の接続部とを有する形状にプレス成形するとともに、両半筒体をそれぞれの接続部の側面同士で結合させて筒部を形成する工程、および
前記連結部および筒部に対応する領域の全体にフィラーを含む熱可塑性樹脂を射出成形して、金属円環が一体化された連結部を形成するとともに、当該連結部を筒部と一体化する工程、
を含むラックハウジングの製造方法。 - 前記射出成形の工程で、フィラーを含む熱可塑性樹脂により、結合させた接続部を覆うリブを形成する請求項1に記載のラックハウジングの製造方法。
- 前記射出成形の工程で、繊維シートに含浸させた熱可塑性樹脂よりもメルトフローレートの大きい熱可塑性樹脂を射出成形する請求項1または2に記載のラックハウジングの製造方法。
- 前記請求項1ないし3のいずれか1項に記載の製造方法によって製造され、前記筒部を構成する隣り合う少なくとも2層の繊維強化複合材の結合がフィラーの貫通によって補強されているとともに、前記筒部と、この筒部の両端に連なる前記連結部が、フィラーを含む熱可塑性樹脂によって一体に形成されているラックハウジング。
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